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Ultrasonic Machining

5/25/2015

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There are varying levels of complexity for machining tools. A magnet tool which is commonly used for holding down work pieces seems very archaic compared to an ultrasonic machining tool.

In ultrasonic machining, material is removed from the work piece with particles of abrasive that vibrate at a very high rate in a semi-liquid water mixture that circulates through a narrow space between a vibrating tool and the work piece. This non-traditional machining technique is mostly used for creating  a cavity in material. The process is also known as ultrasonic impact grinding as the moving abrasive particles performs a grinding action on the work piece.

The vibrating tool which has the shaped of cavity that is to be produced oscillates up and down about 0.013 to 0.062 millimeter at 19,000 to 25,000 cycles per second. The oscillation causes the abrasive particles to vibrate against the surface of the work piece which then removes the material.

The oscillating tool made of a softer material than the work piece. Nickel and soft steels are the materials commonly used for the tool. As the tool pulsates, it pushes down on the abrasive particles on the surface of work piece. Under the impact of the abrasive particles, the surface of the work piece of the work piece abrades due to its brittleness while the softer tool material simply deforms slightly.

This method of machining is mostly used for cutting and shaping of hard and brittle materials that may either be conductors of electricity or insulators. It is also used for machining hardened steels, carbides and semiconductors.

There are several advantages to ultrasonic machining compared to other methods. It can be used for machining any hard material and creates a very good surface finish. There is also very little heat produced while other techniques create so much heat that a downtimes are required after several operations.


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Diamond Turning

5/7/2015

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Machine tools are power-driven tools that are used to change the shape, size or finish of work pieces. In the past, work pieces were mostly metal objects. As such, machine tools were closely associated with metal working. Technological advancements has created new materials for work pieces and machining processes are now also used for non-metal materials. These new materials has brought up new challenges in machining processes which resulted to the development of new tools and machining processes. Diamond tools, laser cutting and electro chemical machining processes are just some examples of the many technological advancements in the industry.

Every machine tool performs several functions. It holds a work piece and a cutting tool and moves one or both of these objects. It must also provide a feeding process for the tool or the work piece. Turning operations produces a cutting action by rotating a work piece against a fixed tool. The cutting action produces a cylindrical surface. The lathe is the type of machine tool used for performing turning operations.

Diamond turning is used to describe any  turning operation that use machine tools that are equipped with diamond-tipped tool bits. This operation is used for the production optical elements. Optical elements created by the means of diamond turning are mostly used in optical assemblies in telescopes, video projectors, missile guidance systems, lasers, scientific research instruments, and many other systems and devices.

Diamond turning involves several stages of processing. Computer controlled lathes are used in the early stages with escalating accuracy. A diamond lathe tool is only used in the final stages of the process to achieve surface finishes with sub-nanometer accuracy. Controlling of the temperature is crucial for the diamond turning stages. A slight change in the temperature can have significant effect on the quality of the finish.

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