ABSTRACT

The Ultrasonic Machining (USM) process begins with the conversion of low-frequency electrical energy to a high-frequency electrical signal, which is then fed to a transducer. For efficient material removal to take place, the tool and toolholder must be designed with consideration given to mass and shape so that resonance can be achieved within the frequency range capability of the USM machine. Piezoelectric transducers used for USM generate mechanical motion through the piezoelectric effect by which certain materials, such as quartz or lead zirconate titanate, will generate a small electric current when compressed. Whenever possible, USM tools to be used for hole drilling are constructed from easily obtained materials such as music wire, stainless steel tubing, or hypodermic needles. The more power available in a USM machine, the larger the frontal-cutting area that can be supported. Therefore when drilling large size holes, the machine power requirements can be reduced by trepanning the shape with a hollow tool.