Sonic-Mill Ultrasonic Machining

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Applications
There are many diverse applications for the Stationary and Rotary Processes, ranging from the fabrication of small holes in alumina substrates to engraving glassware, to drilling of long holes through fiber-optic glass boules and laser rods. Drilling, engraving, milling, slicing and shaping work can be done in silicon, silicon carbide, silicon nitride, sapphire, glass, quartz, ferrite, alumina, alumina nitride, gallium arsenide, piezoelectrics, ceramic composites and many other technical ceramics.

Stationary Processing Equipment

Summary
The Stationary Sonic-Mill® Process utilizes a power supply that converts conventional line voltage to 20KHz electrical energy. This high-frequency electrical energy is provided to a piezoelectric converter that changes high-frequency electrical energy into mechanical motion. The ultrasonic motion from the converter is amplified and transmitted to the horn and cutting tool. This causes the horn and attached cutting tool to vibrate perpendicularly to the tool face thousands of times per second with no side to side motion.

A recirculating pump forces E/Z Pump™ abrasive, suspended in a liquid medium, between the vibrating tool face and the workpiece. The abrasive particles strike the workpiece at 150,000 times their own weight. These tiny abrasive particles chip off microscopic flakes and grind a counterpart of the tool face.

Benefits
With the Stationary Sonic-Mill® Process the work material is not stressed, distorted or heated because the grinding force is seldom over two pounds. There is never any direct tool-to-work contact and the presence of the cool slurry makes this a cold-cutting process.

Rotary Processing Equipment

Summary
The Rotary Sonic-Mill® Process utilizes a power supply that converts conventional line voltage to 20Khz electrical energy. This high-frequency electrical energy is provided to a piezolectric converter that changes the high-frequency electrical energy into mechanical motion. The ultrasonic motion from the converter is amplified and transmitted to the rotary spindle. This causes the diamond tool attached to the spindle to vibrate perpendicular to the tool face thousands of times per second, with no side-to-side motion.

The spindle speed is variable between 0 and 8,000rpm. This rotation, along with the ultrasonic motion, enhances the cutting action of the attached diamond-plated or -impregnated tool.

Benefits
The combined action of the rotary ultrasonic motion plus a water coolant produces a self-cleaning action that reduces diamond tool binding. This enables fast, efficient cutting at a lighter tool pressure than with conventional machining. Lighter tool pressure is advantageous for drilling small-diameter holes, long deep holes and adjacent holes that are very close to one another. The rotary ultrasonic action causes reduction in friction between the tool and the workpiece which extends diamond tool life and reduces stress caused by conventional diamond tool machining.

How does Ultrasonic Machining work?