Special Theory of Ultrasonic Machining

A model is proposed for the mechanism of material removal in ultrasonic machining. From this model and fundamental physical principles, a machining rate equation is derived for the special case where solid, circular tools are used in conjunction with a puddled slurry. A comparison of the predictions of the theory with the experimental data shows that the theory gives the correct relationship between the machining rate and the variables involved in the machining process. Suggestions for the improvement of the ultrasonic machining process are presented, and the method to be used in generalizing the theory is outlined. The poor reproducibility of the machining rate measurements is explained on the basis of the machining rate equation.