Process capability: Ultrasonic machining (USM) is best suited for which type of material/application?

Difficulty: Easy

Correct Answer: Glass

Explanation:


Introduction / Context:
Ultrasonic machining is a non-thermal, non-electrochemical process that removes material by micro-chipping with abrasive slurry agitated at ultrasonic frequency. It excels on hard, brittle, non-conductive materials.



Given Data / Assumptions:

  • Abrasive slurry and vibrating tool at ~20 kHz.
  • Low cutting forces compared to conventional machining.
  • Focus on “best suited” application class.


Concept / Approach:
USM is particularly effective for brittle materials (glass, ceramics, carbides) where conventional tools would wear rapidly or cause cracking. Among the options, glass is prototypical: hard, brittle, and non-conductive, making USM ideal. While USM also machines sintered carbides, it is not preferred for ductile tool steels.



Step-by-Step Solution:

Identify target material class: hard and brittle → glass fits perfectly.Consider carbides: also machinable by USM but typically slower and with higher tool wear than EDM/ECM alternatives for some shapes.Tool steels: ductile and better handled by grinding/milling/EDM; USM is not “best”.Therefore, among given choices, “glass” is the best-suited exemplar.


Verification / Alternative check:
Applications include drilling glass, ceramics, sapphire, and ferrites with minimal edge chipping compared to conventional drilling.



Why Other Options Are Wrong:

  • Tool steels: USM is inefficient; conventional or EDM are better.
  • Sintered carbides: machinable, but “best suited” highlights classic non-conductive brittle materials such as glass.
  • All of these: incorrect because USM is not best for ductile tool steels.


Common Pitfalls:
Confusing the broad capability with best suitability; “best” refers to the class where USM clearly outperforms traditional cutting.



Final Answer:
Glass

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