• It uses formed tools, vibrations of high frequency and a suitable abrasive slurry mix. Figs. Diagram shows some of the factors that affect the USM. Explained the effects of process parameters on material removal rate. Ultrasonic machining process is an abrasive process and material removal is purely mechanical. The surface finish in USM process is … The process was first developed in 1950s and was originally used for finishing EDM surfaces. This process is non-thermal, non-chemical, non-electrical and creates no change in the metallurgical, chemical or physical properties of the workpiece material. • Ultrasonic range is possible with the help of piezoelectric materials. he listed all the models of material removal mechanisms introduced since 1956 to 1999. •USM is able to effectively machine all materials harder than HRc40, whether or not material is an electrical conductor or an insulator. RavipudiVenkata Rao, P. J. Pawar& J. P. Davim (2010) Parameter Optimization of Ultrasonic Machining Process Using Nontraditional Optimization Algorithms, Materials and Manufacturing Processes… the development of ultrasonic machining and recent reports from researches in the areas of conventional ultrasonic machining processes. The following report gives an overview of these parameters and how this affects the different process characteristics of the Ultrasonic machining process. Rotary type ultrasonic machining is one of the cost-effective machining processes available for drilling holes in advanced ceramics. Now this process is used in many industries to remove metal due to its lower cost, no heat generation, and effective machining. It is employed to machine hard and brittle materials (both electrically conductive and non conductive material) having hardness usually greater than 40 HRC. traditional machining process. Ultrasonic Machining • It is a mechanical material removal process, used to erode material in the form of fine holes and cavities in hard or brittle workpiece. 1.PROCESS PRINCIPLES •Ultrasonic Machining (USM) is a mechanical material removal process used to erode holes and cavities in hard or brittle workpieces by using shaped tools, high frequency mechanical motion, and an abrasive slurry. Fundamentals of ultrasonic machining processes, mechanism of material removal rate with literature and model and also basic influences of some parameters during USM process are presented in Chapter 2. This machining process comes into existence in 1950 for finishing EDM surface. Process: Ultrasonic machining is a mechanical type non-traditional machining process. defects in ultrasonic machining and other thermal-based machining processes like electric discharge machining, laser beam machining, etc. 10.49 to 10.55 show how the material removal rate in ultrasonic machining process varies with other process parameters. This article presents optimization aspects of an important advanced machining process known as ultrasonic machining (USM). USM Machining Rate The cutting rate in USM depends on 1. Ultrasonic machining is non-traditional machining process which is used to machine brittle and hard material. The optimum selection of process parameters is essential for advanced machining processes, as these processes incur high initial investment, tooling cost, and operating and maintenance costs. 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