Ultrasonic Machining – New in 2018

ULTRASONIC technology enables the economical machining of complex workpiece geometries in demanding high-tech materials like ceramics, glass, corundum, tungsten carbide or even composites and notably the Materion SupremEx material. The kinematic overlapping of the tool rotation with an additional oscillation effects a reduction of the process forces by up to 40 – 50 % in comparison to conventional machining. Depending on the workpiece requirements, this allows higher feed and infeed, longer tool life or significantly better surface finishes of up to Ra < 2.5 µin.

DMG/Mori Ultrasonic 20 and 60

It is important understand that these machines operate as ordinary standard high precision full 5-axis machining centers when the Ultrasonic mode is not enabled.  The Ultrasonic mode is used when the cutting/grinding requirements demand the extra motion of the Ultrasonic actuator, such as when machining hard ceramics and glasses and various other extremely hard materials.  The SupremEx material mentioned above is an excellent example of a material for which the Ultrasonic mode is ideal. SupremEx is a metal matrix with an Aluminum base with SiC grains embedded. The material is composed of an ultrafine, homogeneously dispersed carbide reinforcement with an aluminum alloy. The resulting materials are superior to aluminum with increased strength and greater stiffness.

In short, the Ultrasonic mode allows for machining of hard ceramic and similar materials in an efficient manner while also being able to perform ordinary precision machining.

ARC is one of a very few contract machining companies that have this technology.

Ultrasonic Specifications Linear  20 Linear 60
Table 200 mm x 200 mm 600 mm x 600 mm
Rotating Table Yes Yes
DMG Linear 20 Ultrasonic 5 Axis Mill
Figure 1. DMG Linear 20 Ultrasonic 5 Axis Mill

Typical Parts machined by the “20”

Abutments
Figure 2. Abutments
Impeller
Figure 3. Impeller
6 Bone Plate
Figure 4. 6 Bone Plate
Tooth Bridge
Figure 5. Tooth Bridge

Drawings and sketches may be submitted via our contact page. You will be contacted shortly to discuss your project.

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