The global ultrasonic equipment market has experienced remarkable growth, rising from $6.13 billion in 2015 to $8.13 billion by 2023. This increase highlights the growing adoption of ultrasonic technology in the manufacturing sector.

 

China is actively working to enhance the localization of high-end ultrasonic equipment, aiming to strengthen their competitiveness in the global manufacturing market. Ultrasonic machining provides numerous advantages such as high precision, improved surface finishes and quality, reduced tool wear and enhanced efficiency. By embracing Conprofe’s Ultrasonic Machining Technology, manufacturers can achieve significant advancements in their processes.

 

How Ultrasonic Machining Technology Works

Ultrasonic Machining Technology converts ultrasonic electrical oscillations into mechanical vibrations. While the tool rotates, it applies vibrations at tens of thousands of times per second on the tooltip, creating periodic separation between the tool and the workpiece during the machining process. This results in smoother chip removal, better cooling, and improved consistency of the processed surface, significantly enhancing machining efficiency, extending tool life, and improving the surface quality of the workpiece.

• In ultrasonic-assisted machining, the ultrasonic generator is activated by high-frequency alternating electrical energy, driving the transducer and amplitude transformer to resonate as a whole. Energy is transmitted in the form of longitudinal waves from point A through point B to point C.
• Once activated, the resonator vibrates with minimal elongation and contraction. Points A and C move away from or approach the node of the resonator (point B) simultaneously, while point B remains stationary throughout the vibration process.

 

 

Unique Advantages of Ultrasonic Machining:

High Ultrasonic Frequency Vibration Acting on Tooltip (15-70kHz)

– Controls microcracks

– Reduces cutting force and improves machining efficiency

– Increases tool life

– Reduces workpiece burrs

– Improves surface quality

 

 

Five Highlight Technologies of Ultrasonic Spindle：

• Power of 350W: Designed for high-demand applications, ensuring superior cutting precision.
• Patent Sine Wave Drive Technology: The ultrasonic power supply outputs a sine wave waveform to drive the ultrasonic tool holder, resulting in a more stable ultrasonic amplitude and allowing for finer, more linear amplitude adjustments.
• Amplitude Closed-Loop Linear Control: Before machining, the tool amplitude is measured through an in-machine amplitude measuring device designed by Conprofe. During machining, the ultrasonic system monitors the voltage, current, and phase signals of the ultrasonic tool holder, enabling real-time compensation and stabilization of the tool’s amplitude.
• Adaptive Control Technology: The Ultrasonic Machining System monitors the changes in ultrasonic frequency and power in real time during the machining process, adaptively adjusting the frequency to its optimal state. This adjustment can be completed within 1 second, ensuring efficient and precise processing.
• Communication with CNC Controller: The ultrasonic system establishes communication with the CNC system, allowing the ultrasonic operating interface to be displayed within the CNC system’s control interface. This integration enhances usability and streamlines operation, providing seamless control over the machining process.

 

Applications in Challenging Materials：

Ultrasonic Machining Technology is highly effective for machining three key material categories: hard-brittle materials, composite materials, and hard-to-cut metals, including single-crystal silicon, ceramics, quartz glass, titanium alloys, carbon fiber reinforced composites, etc.

Moreover, numerous test cuts have demonstrated that ultrasonic machining consistently outperforms traditional drilling in terms of hole drilling across all material types, including PEEK, titanium alloy, HRC56 mold steel, carbon-ceramic composites, sapphire, and silicon carbide (SiC).

This technology is revolutionizing industries such as aerospace, semiconductors, medical devices, and electronics, where precision and material integrity are crucial.

 

 

Join us in exploring the possibilities of Ultrasonic Machining Technology and push the boundaries of high-end manufacturing!