Non Traditional Machining

ULTRASONIC MACHINING

Definition:
Ultrasonic Machining is a non-traditional process, in which abrasives contained in a
slurry are driven against the work by a tool oscillating at low amplitude (25-100
microns) and high frequency (15-30 kHz).

Process:
Ultrasonic machining is a mechanical type non-traditional machining process. It is
employed to machine hard and brittle materials (both electrically conductive and non
conductive material) having hardness usually greater than 40 HRC. The process was
first developed in 1950s and was originally used for finishing EDM surfaces.




In ultrasonic machining, tool of desired shape vibrates at ultrasonic frequency ( 19 to
25 kHz. ) with an amplitude of 15-50 Microns over work piece. Generally tool is
pressed down with a feed force F. Between the tool and work, machining zone is
flooded with hard abrasive particles generally in the form of water based slurry. As
the tool vibrates over the work piece, abrasive particles acts as indenter and indent
both work and tool material . Abrasive particles , as they indent , the work material
would remove the material from both tool and work piece. In Ultrasonic machining
material removal is due to crack initiation, propagation and brittle fracture of
material. USM is used for machining hard and brittle materials, which are poor
conductors of electricity and thus cannot be processed by Electrochemical machining
( ECM) or Electro discharge machining (EDM).

The tool in USM is made to vibrate with high frequency on to the work surface in the
midst of the flowing slurry. The main reason for using ultrasonic frequency is to
provide better performance. Audible frequencies of required intensities would be
heard as extremely loud sound and would cause fatigue and even permanent
damage to the auditory apparatus.










Non Traditional Machining


Equipment:

Ultrasonic Machining consists of :
1. High Power sine wave
generator
2. Magneto-strictive Transducer
3. Tool Holder
4. Tool








High power sine wave generator
This unit converts low frequency (60 Hz) electrical power to high frequency (20kHz)
electrical power.

Transducer
The high frequency electrical signal is transmitted to traducer which converts it into
high frequency low amplitude vibration. Essentially transducer converts electrical
energy to mechanical vibration. There are two types of transducer used
1. Piezo electric transducer
2. Magneto-stricitve transducer.

Non Traditional Machining

Piezo electric transducer: These transducer generate a small electric current
when they are compressed. Also when the electric current is passed though
crystal it expands. When the current is removed , crystal attains its original size
and shape. Such transducers are available up to 900 Watts. Piezo electric crystals
have high conversion efficiency of 95%.

Magneto-strictive transducer: These also changes its length when subjected to
strong magnetic field. These transducer are made of nickel , nickel alloy sheets.
Their conversion efficiency is about 20-30%. Such transducers are available up to
2000 Watts. The maximum change in length can be achieved is about 25
microns.

Tool holder. OR Horn.
The tool holder holds and connects the tool to the transducer. It virtually transmits
the energy and in some cases, amplifies the amplitude of vibration. Material of tool
should have good acoustic properties, high resistance to fatigue cracking. Due
measures should be taken to avoid ultrasonic welding between transducer and tool
holder. Commonly used tool holders are Monel, titanium, stainless steel. Tool holders
are more expensive, demand higher operating cost.
Tool holder can be classified as :

Amplifying Tool Holder Non-Amplifying Tool Holder
They give as much as 6 times
increased tool motion. It is achieved
by stretching and relaxing the tool
holder material.
MRR = 10 times the non amplifying
tool.
Non amplifying tool holders have
circular cross section and give same
amplitude at both ends.
Tool
Tools are made of relatively ductile materials like Brass, Stainless steel or Mild steel
so that Tool wear rate (TWR) can be minimized. The value of ratio of TWR and MRR
depends on kind of abrasive, work material and tool materials.

OPERATIONS OF
ULTRASONIC CUTTING.

As the tool vibrates with a
specific frequency, an abrasive
slurry (usually a mixture of
abrasive grains and water of
definite proportion) is made to
flow through the tool work
interface. The impact force
arising out of vibration of the
tool end and the flow of slurry
through the work tool interface
actually causes thousands of
microscopic abrasive grains to
remove the work material by
abrasion. Material removal from
the hard and brittle materials
will be the form of sinking, engraving or any other precision shape.
Non Traditional Machining

Process parameters
1. Amplitude of vibration ( 15 to 50 microns)
2. Frequency of vibration ( 19 to 25 kHz).
3. Feed force (F) related to tool dimensions
4. Feed pressure
5. Abrasive size
6. Abrasive material
** Al
2
0
3
, SiC, B
4
C, Boron silicarbide, Diamond.
7. Flow strength of the work material
8. Flow strength of the tool material
9. Contact area of the tool
10. Volume concentration of abrasive in water slurry
11. Tool
a. Material of tool
b. Shape
c. Amplitude of vibration
d. Frequency of vibration
e. Strength developed in tool
12. Work material
a. Material
b. Impact strength
c. Surface fatigue strength

13. Slurry
a. Abrasive hardness, size, shape and quantity of abrasive flow
b. Liquid Chemical property, viscosity, flow rate
c. Pressure
d. Density

Process capability

1. Can Machine work piece harder than 40 HRC to 60 HRC like carbides, ceramics,
tungsten glass that cannot be machined by conventional methods

2. Tolerance range 7 micron to 25 microns

3. Holes up to 76 micron have been drilled hole depth upto 51mm have been
achieved easily. Hole depth of 152mm deep is achieved by special flushing
techniques.

4. Aspect ratio 40:1 has been achieved

5. Linear material removal rate -0.025 to 25mm/min

6. Surface finish -0.25 micron to 0.75 micron

7. Non directional surface texture is possible compared to conventional grinding

8. Radial over cut may be as low as 1.5 to 4 times the mean abrasive grain size.




Non Traditional Machining

Applications

1. Machining of cavities in electrically non-conductive ceramics
2. Used to machine fragile components in which otherwise the scrap rate is high
3. Used for multistep processing for fabricating silicon nitride (Si
3
N
4
) turbine blades
4. Large number of holes of small diameter. 930 holes with 0.32mm has been
reported ( Benedict, 1973) using hypodermic needles
5. Used for machining hard, brittle metallic alloys, semiconductors, glass, ceramics,
carbides etc.
6. Used for machining round, square, irregular shaped holes and surface
impressions.
7. Used in machining of dies for wire drawing, punching and blanking operations
8. USM can perform machining operations like drilling, grinding and milling
operations on all materials which can be treated suitably with abrasives.
9. USM has been used for piercing of dies and for parting off and blanking
operations.
10. USM enables a dentist to drill a hole of any shape on teeth without any pain
11. Ferrites and steel parts , precision mineral stones can be machined using USM
12. USM can be used to cut industrial diamonds
13. USM is used for grinding Quartz, Glass, ceramics
14. Cutting holes with curved or spiral centre lines and cutting threads in glass and
mineral or metallo-ceramics

Advantages

1. It can be used machine hard, brittle, fragile and non conductive material
2. No heat is generated in work, therefore no significant changes in physical
structure of work material
3. Non-metal (because of the poor electrical conductivity) that cannot be machined
by EDM and ECM can very well be machined by USM.
4. It is burr less and distortion less processes.
5. It can be adopted in conjunction with other new technologies like EDM,ECG,ECM.

Disadvantages

1. Low Metal removal rate
2. It is difficult to drill deep holes, as slurry movement is restricted.
3. Tool wear rate is high due to abrasive particles. Tools made from brass, tungsten
carbide, MS or tool steel will wear from the action of abrasive grit with a ratio that
ranges from 1:1 to 200:1
4. USM can be used only when the hardness of work is more than 45 HRC.











Non Traditional Machining


Material removal models in USM

Theoretical analysis and experimental results have revealed that USM is a form of
abrasion and material removal in the form of small grains by four mechanisms
1. Throwing of abrasive grains
2. Hammering of abrasive grains
3. Cavitations in the fluid medium arising out of ultrasonic vibration of tool.
4. Chemical erosion due to micro agitation

Material removal due to throwing and hammering is significant and MR due to
cavitations and chemical erosion can be ignored.

Abrasive particles are assumed to be spherical in shape having diameter d
g.
Abrasive
particles move under high frequency vibrating tool. There are two possibilities when
the tool hit the particle.

If the size of the particle is small and gap between the tool and work is large,
then particle will be thrown by tool to hit the work piece.

If the size of the particle is large and gap between tool and work is small,
then particle is hammered over the work surface.

From the geometry


AB
2
= AC
2
+ BC
2


2
2
2 2
r
d d
g g
+
|
|

\
|
=
|
|

\
|

2
2
2 2
r
d d
g g
=
|
|

\
|

|
|

\
|


r
2
= -
g
d +
2
Neglecting
2
term we
can write
r =
g
d

Volume of the material removed is the volume of the hemispherical crater due the
fracture per grit per cycle.

Volume of the material removed

(

=
3
r
3
4
2
1
= ( )
(

2
3
r
3
4
2
1


=K1 ( )2
3

g
d where K1 is constant ----------------------------------------------------(1)

Non Traditional Machining

Number of impacts (N) on the work piece by the grits in each cycle depends on
number of grits beneath tool at any time. This is inversely proportional to diameter
of grit.

N =
(
(

2
2
g
d
K
, where K2 is constant ----------------------------------------------------(2)

All the abrasive particle under the tool need not be necessarily effective


MRR =

effective being under tool

particle abrasive of Pr
cycle per
impact of

second
per cycles
of
cycle per grit per
removed
material the of Volume
.
obability Number
Number
X X X


MRR =
3
2
g
2

d
K
f K using =K1 ( )2
3

g
d , we have

MRR = K1 K2 K3 f
g
d
3

This is the general Material removal equation -------(3)

Model 1 : Grain Throwing model

It is assumed that a particle is hit and thrown by the tool on to work surface.
Assuming sinusoidal vibration. Displacement of the tool (y) is given in time period
(t) and amplitude (a/2) of oscillation.

X = ( ) t f 2 S
2
in
a

Velocity =
.
V = ( ) t f 2 f 2 x
2
Cos
a

Velocity = Max V
.
= f a
Let us assume that grits also move with same velocity Max V
.
, then we can write
Kinetic Energy = KE =
(
(

\
|
2
.
max
V M
2
1
= ( )
(

\
| 2 3
f a
6 2
1

g g
d -------------------(4)

(
(
(

grit the of energy kinetic the g calculatin here

are we because mass the calculate taken to be to has grit the of diameter the : Here NOTE

Non Traditional Machining

A grit penetrates to the depth equal to into the work piece. The work done by the
grit is given by

W D by the grit = F
2
1
-------------------------------------------------------------(5)
Also we know the Flow strength of material =
2
r
F
w

= or F =
2
r
w
--------(6)
Using (6) in (5) we have,

W D by the grit = d
2
1
g w
------------------------------------------------------(7)

W D by the grit should be equal to the Kinetic energy of the particle

d
2
1
g w
= ( )
(

\
| 2 3
f a
6 2
1

g g
d

Simplifying we have

w
g

6
d f a
g
= ---------------------------------------------------------------------(8)

Using this (8) in the general equation (3), we have

Volumetric material removal rate due to throwing mechanism


V
throwing
= K1 K2 K3 d
g
f
5/2

4
3
w
g
2 2
6
a
(
(

----(9)



Model 2: Grain Hammering Model

When the gap between the tool and the work
piece is smaller than the diameter of the grit
it will result into partial penetration in the tool
( )
t
as well as in the work piece ( )
w
. The
values of ( )
t
and ( )
w
depends on the
hardness of the tool and work piece material,
respectively. Force F acts on abrasive particle
only for a short time ( ) T during the cycle
time T. During this time period, the
abrasive particle is in contact with the tool
and work piece both. The mean force (F
avg
) on the grit can be expressed by
Non Traditional Machining

F
avg = ( )

T
t F
T
0
1
dt
-------------------------------------------------------(10)
Here F(t) is the force at any instant of time t. Force on the grit by the tool starts
increasing as soon as grit gets in contact with both tool and the work piece at the
same time. It attains maximum value and then starts decreasing until attains the
zero value. Hence the momentum equation can be written as

( ) dt
1
0

T
t F
T

= T
F

2
------------------------------------------------(11)


Total penetration due the hammering is given by

= ( )
w
+( )
t

a/2 is amplitude of oscillation of the tool. The mean velocity of the tool during the
quarter cycle is given by
( )
( ) 4 /
2 /
T
a
Therefore , time ( ) T required to travel from A
to B is given by the following equation

a
T
T
2

= ---------------------------------------------------------------------------(12)

Using (12) in equation (11)

F
avg =
2
1 T
F
T

=
a
T F
T 2

2
1
=
a
F
4

F = F
avg |

\
|

a 4
-----------------------------------------------------------------------------------(13)

Let N be the number of grains under the tool , Stress acting on the tool ( )
t

and work piece ( )
w
can be found as follows.

Non Traditional Machining

( )
w
w
N
F

g
d
= --------------------------------------------------------------------(14)

( )
t
t
N
F

g
d
= ---------------------------------------------------------------------(15)

w
t
t
w

=

From the equation (2), (13) and (14) we have

( )
w
w
N
F

g
d
= =
) d K2(
d a 4
w g
2
g

avg
F
=
|
|

\
|
+1 ) ( d K2
d a 4
2
w g
g
w
t
avg
F

Writing
w
t

= , rearranging we have

( ) 1 K2
d F 4

w
avg
+
=

a
w


Volumetric material removal rate from the work piece due to hammering mechanism
can be evaluated using the equation (3) as follows:

MRR = K1 K2 K3 f
g
w
d
3

V
Hammering
= K1 K2 K3 ( )4
1
g
d f
( )
4
3
w
avg
1 K2
d F 4
(

+
a
----------(16)













Non Traditional Machining

PROBLEM 1 : Find out the approximate time required to machine a hole of
diameter equal to 6.0 mm in a tungsten carbide plate ( Flow strength of work
material = 6.9 x 10
9
N/m
2
) of thickness equal to one and half times of hole
diameter. The mean abrasive grain size is 0.015mm diameter. The feed force is
equal to 3.5 N. The amplitude of tool oscillations is 25 microns and the frequency is
equal to 25 kHz. The tool material is copper having flow strength= 1.5 x 10
9
N/m
2
.
The slurry contains one part of abrasives to one part of water. Take the values of
different constant as
K1 = 0.3 , K2 = 1.8x 10
-6
( In SI units) and K3= 0.6 and abrasive slurry density =
3.8 g/cm
3
. Also calculate the ratio of the volume removed by throwing mechanism to
the volume removed by hammering mechanism.


Data Given:

Diameter of the hole = 6mm = 6 x10
-3
m
Depth of hole = 1.5d = 9 x 10
-3
m
Mean abrasive size (d
g
) = 1.5 x 10
-5
m
Feed force (F) = 3.5 N
Amplitude of oscillation = a/2 = 25x10
-6
m
Frequency of oscillation = f = 25000 CPS
Flow strength of work material =
2 9
N/m 10 9 . 6 x
w
=
Flow strength of tool material =
2 9
N/m 10 5 . 1 x
t
=
Abrasive grain density
g
= 3.8x 10
3
kg/m
3

6 . 4
material tool of Strength Flow
material work of Strength Flow
= = =
t
w

K1 = 0.3 , K2 = 1.8x 10
-6
( In SI units) and K3= 0.6


Solution

Grain Throwing Model:

Let us use equations we have developed for the Grain Throwing model

Penetration in work piece due to throwing is given by
w
g
throwing

6
d f a
g
= = ( ) ( ) ( )
( )
9
3
5 4 6
10 9 . 6 6
10 8 . 3
10 5 . 1 10 5 . 2 10 50
x x
x
x x x x x

=1.78x10
-5
mm
Volume removed by throwing is given by
MRR
Throwing
= K1 K2 K3 f
g
throwing
d
3

Substituting all the values we have

MRR
Throwing
= 0.3x1.8x10
-6
x0.6x2.5x10
4
( )
2
3
5
10 5 . 1
10 78 . 1

x
x
= 4.97 x10
-3
mm
3
/s
Non Traditional Machining



Grain Hammering Model

Penetration in work piece due to hammering is given by
=
Hammering

( ) 1 K2
d F 4
w
avg
+
a
=
( ) ( ) 1 6 . 4 ) (1.8x10 10 9 . 6
) 10 5 . 1 ( ) X215X10 (2 X3.5x 4

6 - 9
5 -6
+

x
x x
= 2.192x10
-4
mm

Volume removed by throwing is given by
MRR
Hammering
=K1 K2 K3 f
g
Hammering
d
3

= 0.3x1.8x10
-6
x0.6x
( )
4
2
3
4
10 5 . 2
10 5 . 1
10 192 . 2
x x
x
x

= 0.2146 mm
3
/s


Total MRR = MRR due to throwing action + MRR due to hammering action
= 4.97 x10
-3
mm
3
/s + 0.2146 mm
3
/s
= 0.21957 mm
3
/s


Volume of the hole to be drilled =
|

\
|
9 6
4
2
x x

= 254.416 mm
3


Time required to drill a hole =
action hammering and ing both throw to due MRR Volumetric
drilled be to hole the of Volume



=
21957 . 0
416 . 245
= 1158.70 seconds = 19.31 Minutes

Ration of the volumetric MRR due to throwing and hammering is given by

Hammering
Throwing
MRR
MRR
= 023 . 0
2146 . 0
00497 . 0
=
Thus, it is evident that the material removed by hammering is much more than by
throwing ( approximately 45 times) hence , for approximate calculations, MRR by
throwing can be ignored.

Practice Problem
1. Cylindrical impression of 10mm diameter and 1mm deep is to be made on WC
specimen. Feed force is constant and is equal to 5N. Average diameter of
grains in slurry is 10 microns. Tool oscillates with the amplitude of 30 microns
at 20 kHz. Abrasive and water ratio in the slurry is 1. Flow strength of WC
work piece is 7000 N/mm
2
and that of the copper is 1500 N/mm
2
. Calculate
the time required to complete the job. Assume K1=0.3 K2 = 1.8mm
2
and
K3=0.6. Make the assumption if necessary.
2. Derive an equation suggested by Shaw to obtain volumetric material removal
rate considering both throwing and hammering mechanisms.
Non Traditional Machining


Machining characteristics

Following are the USM process criteria
1. Material removal rate
2. Geometrical accuracy
3. surface finish
4. Out of roundness

Process criteria are generally influenced by the process parameters
The characteristics of above process parameters on process criteria are as follows

1. Effect of amplitude on MRR
Increase in amplitude of vibration
increases MRR. To maximize the
amplitude of vibration concentrator
should operate at resonance
frequency. Under certain
circumstances this limits also the
maximum size of abrasive to be
used.






2. Effect of Frequency on MRR
Frequency has significant effect on MRR.
Frequency used for machining process must
be resonant frequency to obtain the greatest
amplitude at the tool tip and thus achieve the
maximum utilization of the acoustic system.



3. Effect of abrasive grain size
An increase in abrasive grain size results in
higher MRR but poorer surface finish.
Maximum MRR is achieved when abrasive
grain size is comparable with amplitude of
vibration of the tool. Hardness of the
abrasives and method of introducing the
slurry has also effect on MRR.








Non Traditional Machining

3. Effect of Applied static load
(Feed force).
MRR increase with the feed force. Maximum
MRR depends on the amplitude of vibrations.
Surface finish is found to be little affected by
the applied static load. Higher loads, contrary
to expections, do not give give a rougher
finish. Surface finish, In fact,improves
because the grains are crushed to small size
with higher loads.



4. Effect of Slurry, Tool and Work Material.
MRR increases with slurry
concentration. Slurry saturation occurs at
30 to 40% abrasive/water mixture.
Material Removal rate drops with
increasing viscosity.
The pressure with which the slurry is
fed into the cutting zone affects MRR . In
some cases MRR can be increased even ten
times by supplying the slurry at increased
pressure.
The shape of the tool affects the
MRR. Narrower rectangular tool gives more
MRR compared to square cross section.
Conical tool gives twice MRR compared to cylindrical tool.
The brittle behavior of material is important in determining the MRR. Brittle
material can be cut at higher rates than ductile materials.












Non Traditional Machining

Design of Horn ( Velocity Transformer)

The function of horn ( also called concentrator) is to amplify and focus vibration of
the transducer to an adequate intensity for driving the tool to fulfill the cutting
operation. They are made of a hard, non magnetic and easily machinable steel
having good fatigue strength like K-Monel,Metal bronze and Mild steel. Linearly
tapered and exponentially taped horns have lengths equal to one-half of the wave
length of sound in the metal of which they are made.

1 Design of Exponential Concentrator of Circular cross section.
Let us consider case of exponential horn
with circular cross section. This type of the
horn is used for cutting large diameter
through holes in work piece.

K= transformation ratio amplification ratio

K =
1
S
S
d
D
o o
=
Where D
o
is the larger diameter
d is the smaller diameter
S
o
is the area of the larger section
S
1
is the area of the smaller section

Taper index for an exponential horn

( )
L
K ln
==
The value of K should be chosen taking into
consideration machining condition and the
properties of magnestrictive materials K = 3 to 4 for fine machining and 4 to 5 for
rough machining.

The length of the horn or concentrator L is usually chosen as half wave (n=1) or full
wave (n=2).

Length of the exponential Horn is given by

L =
( )
2
n 2
ln
1
f
C
)
`

K n


And the variation of D is given by


X -
o
exp D

= D - this is also called Law of change of shape.

A check must be made to ensure that operating frequency exceeds critical frequency
c
f given by

2
C
f
C
=

Non Traditional Machining

Problem 1
Design a HALF WAVE steel exponentially tapered concentrator with circular cross
section to work at a frequency of 20 kHz. The transducer has larger diameter of
100mm and smaller diameter of 4mm. Take the velocity of sound in steel C= 5x10
6

mm/sec.
Data given
D
O
= 100mm
d = 4mm
f = 20kHz = 20000 CPS.
C= 5x10
6
mm/sec.
n = ( because it is half wave horn)

1. Concentrator ratio or Amplification ratio or
Transformation ratio.
K = 20
4
100
= =
d
D
o


2. Length of exponential horn
L =
( )
2
n 2
ln
1
f
C
)
`

K n
=
( )
2
6
2
1
2
20 ln
1
20000
5x10
2
1

x = 172.7 mm
3. Taper index for an exponential horn

( )
017344 . 0
7 . 172
) 20 ln( K ln
= = ==
L


4.Law of change of shape is given by
017344 . 0 X -
o
exp 100 exp D

= =

D

5.Check the critical frequency
Hz
x
x
C
f
C
13803
10 5
2
017344 . 0
2

6
= = =

> operating frequency of 20000 Hz

Design is safe, therefore Concentrator will work satisfactorily.

Law of change of shape is given in following table.














X (mm) 0.017344X
( ) X 017344 . 0
exp

100
( ) X 017344 . 0
exp


0 0 1 100.00
10 -0.173 0.8408 84.08
30 -0.520 0.5943 59.43
50 -0.867 0.4201 42.01
70 -1.214 0.2970 29.70
90 -1.561 0.2099 20.99
110 -1.908 0.1484 14.84
130 -2.255 0.1049 10.49
150 -2.602 0.0742 7.42
170 -2.948 0.0524 5.24
173.7 -3.013 0.0492 4.92 ( 4mm)
Law of change of shape
0
20
40
60
80
100
120
0 50 100 150 200
Lenght of horn
D
i
a
m
e
t
e
r

o
f

h
o
r
n


Profile vary
like this
Non Traditional Machining

2 Design of Exponential Concentrator of Rectangular cross section.
Let us consider case of exponential horn with Rectangular cross section. This type of
the horn is widely used in ultrasonic cutting.

K= transformation ratio amplification
ratio

K =
1 1

a
a
S
S
o o
= =
Where,
S
o
is the area of the larger section
S
1
is the area of the smaller section
a
o
and a
1
are widths at larger and
smaller end.

Taper index for an exponential horn

( )
L
K ln
==

The length of the horn or concentrator L is usually chosen as half wave (n=1) or full
wave (n=2).

Length of the exponential Horn is given by

L =
( )
2
n 2
ln
1
f
C
)
`

K n



And the variation of D is given by


X -2
o
exp a

= a - this is also called Law of change of shape.

A check must be made to ensure that operating frequency exceeds critical frequency
c
f given by

2
C
f
C
=











Non Traditional Machining

Problem 2
Design a HALF WAVE steel exponentially tapered concentrator with rectangular cross
section to work at a frequency of 20 kHz. The transducer has larger rectangular
cross section of 100x100mm and smaller rectangular section of 4x4mm. Take the
velocity of sound in steel C= 5x10
6
mm/sec.

Data given
a
O
= 100mm
a
1
= 4mm
f = 20kHz = 20000 CPS.
C= 5x10
6
mm/sec.
n = ( because it is half wave horn)


1. Concentrator ratio or Amplification ratio or
Transformation ratio.
K = 47 . 4
4
100

1 1
= = = =
a
a
S
S
o o


2. Length of exponential horn
L =
( )
2
n 2
ln
1
f
C
)
`

K n
=
( )
2
6
2
1
2
47 . 4 ln
1
20000
5x10
2
1

x = 138.47 mm``
3. Taper index for an exponential horn

( )
0108138 . 0
47 . 138
) 47 . 4 ln( K ln
= = ==
L


4.Law of change of shape is given by
X
a
021627 . 0 X -2
o
exp 100 exp a

= =



5.Check the critical frequency
8606 5 . 1
10 5
2
0108138 . 0
5 . 1
2

6
X
x
x X
C
f
C
= = =

> operating frequency of 20000 Hz

Design is safe, therefore Concentrator will work satisfactorily.
Law of change of shape is given in following table.

`




`






X
(mm)
0.021627X
( ) X 021627 . 0
exp

100
( ) X 021627 . 0
exp


0 0 1 100.00
10 -0.21627
0.8055 80.55
20 -0.43254
0.6489 64.89
40 -0.86508
0.4210 42.10
60 -1.29762 0.2732 27.32
80 -1.73016
0.1773 17.73
100 -2.1627
0.1150 11.50
120 -2.59524
0.0746 7.46
138.7 -2.9996649 0.0498 4.98 (4mm)
Law of change of shape
0
10
20
30
40
50
60
70
80
90
100
110
0 20 40 60 80 100 120 140
Lenght of horn
D
i
a
m
e
t
e
r

o
f

h
o
r
n


Profile vary like
this
Non Traditional Machining

3 Design of Exponential Concentrator of hollow cylindrical cross section.
Let us consider case of exponential horn with hollow cylindrical cross section. This
type of the horn is widely used trepanning that is cutting along contours of the
desired opening.
K= transformation ratio amplification ratio

K =
( )
( ) ( )

2
1
2
2
D D
D
a
o

=

Where,
D
o
= diameter of the larger section(outside)
D
1
= diameter of the smaller section (inside)


Taper index for an exponential horn

( )
L
K ln
==

The length of the horn or concentrator L is
usually chosen as half wave (n=1) or full
wave (n=2).

Length of the exponential Horn is given by

L =
( )
2
n 2
ln
1
f
C
)
`

K n



And the variation of D is given by

( ) exp - 1 D
X 2 -
o

= D - this is also called Law of change of shape.


A check must be made to ensure that operating frequency exceeds critical frequency
c
f given by

2

5 . 1
C
f
C
=












Non Traditional Machining

Problem 3
Design a steel exponentially tapered concentrator to work at a frequency of 20 kHz.
The transducer has hollow cylindrical cross section of larger diameter =9mm and
smaller diameter of 7mm.( thickness of tool =1mm) Take the velocity of sound in
steel C= 5x10
6
mm/sec. take wave number =0.425.

Data given
D
O
= 9mm ;D
1
= 7mm
f = 20kHz = 20000 CPS.;C= 5x10
6
mm/sec.
n = 0.425
1.K= transformation ratio amplification ratio

K =
( )
( ) ( )

2
1
2
2
D D
D
a
o

=
=
( )
( ) ( )

7 9
9
2 2
2

=
=1.59099
Where,
D
o
= diameter of the larger section(outside)
D
1
= diameter of the smaller section (inside)

2. Length of exponential horn
L=
( )
2
n 2
ln
1
f
C
)
`

K n
=
( )
2
6
.425 0 2
59099 . 1 ln
1
20000
5x10
425 . 0
)
`

x = 107.84 mm

3. Taper index for an exponential horn

( )
0043058 . 0
84 . 107
) 59099 . 1 ln( K ln
= = ==
L


4.Law of change of shape is given by
( ) exp - 1 D
X 2 -
o

= D = ( ) exp - 1 9
X 043058 . 0 -2x


5.Check the critical frequency
5150 3430 5 . 1
10 5
2
0043058 . 0
2

5 . 1
6
= = = = X
x
x
C
f
C

> operating frequency of 20kHz

Design is safe, therefore Concentrator will work satisfactorily.















X
(mm)
0.008611x 1-
( ) X 008611 . 0
exp


d
(mm)
0 0
0 0
10 0.08611 0.2872 2.585
20 0.17222
0.39775 3.58
30 0.25833
0.47714 4.29
40 0.3444
0.5397 4.858
50 0.4305 0.5915 5.323
60 0.5166
0.6352 5.72
100 0.8611
0.7598 6.83
107.8 0.9282
0.7776 7
L aw o f ch an g e o f s h ap e
0
1
2
3
4
5
6
7
8
9
10
0 20 40 60 80 100 120 140
L e n g t h o f h o r n
D
i
a
m
e
t
e
r

o
f

h
o
r
n


Profile vary like
this