Ultrasonic machining is an easy-to-use technology that allows a mold manufacturer to machine very hard or brittle materials with flexibility and accuracy. Ultrasonic machining centers can perform both conventional and ultrasonic machining operations. By combining these technologies in one machine, the user has the capability to machine across the entire material spectrum.
For those looking to add machining equipment to the shop floor, consider an ultrasonic machine. It gives the user flexibility and the ability to machine any material a customer may throw at you.
Ultrasonic Basics and Benefits
In ultrasonic machining, an electrical HF-signal is transmitted via induction through a small air gap from a stationary coil located on the spindle to a rotating coil located on the HSK toolholder. The high frequency supplied to the piezo elements of the actuating toolholder generates a corresponding vibration on the tip of the tool between 20 to 50 kHz.Another benefit to using ultrasonic machining is the resulting excellent surface quality. A finish of Ra<0.2 micron can be achieved, depending on the material. Also, there is enhanced flushing of the machined particles located in the cutting zone due to the ultrasonic motion of the tool in combination with the inner coolant supply.
For moldmakers, ultrasonic machining can be useful when considering materials that have typically not been machined in the past. One such material is carbide. Usually carbide is machined using an EDM process. Ultrasonic machining—on the other hand—can machine carbide directly in one set-up with minimal tool wear and eliminates the need to produce electrodes.