Ultrasonic machining is an advanced manufacturing technology that uses high-frequency vibration energy for precision processing of materials, widely used in the drilling, cutting, and surface treatment of hard and brittle materials such as ceramics, glass, gemstones, and composite materials. In the process of ultrasonic machining, amplitude is a key parameter that directly affects processing efficiency, processing quality, and tool wear. Therefore, the rational selection of amplitude is crucial for optimizing the processing process.



One, Basic Concept and Function of Amplitude



Amplitude refers to the displacement amplitude of the tool end vibration driven by the ultrasonic transducer, usually measured in micrometers (μm). In ultrasonic machining, amplitude determines the impact force between the tool and the workpiece, directly affecting the material removal rate and the quality of the processing surface. Generally, the larger the amplitude, the stronger the impact force, the higher the material removal rate; however, excessive amplitude can also lead to increased tool wear or even damage, affecting processing accuracy.



Two, Influencing Factors of Amplitude Selection



1. Workpiece Material Properties

Materials with different hardness, brittleness, or toughness require different amplitude parameters. For example, when processing high-hardness, high-brittleness ceramic materials, a larger amplitude is usually required to improve material removal efficiency; while for softer or easily fractured materials, a smaller amplitude should be selected to avoid damage caused by excessive impact.



2. Processing Type and Requirements

Different processing methods (such as drilling, milling, polishing, etc.) have different requirements for amplitude. Generally, larger amplitude is adopted in rough processing to improve efficiency, while smaller amplitude is required in precision processing to ensure surface smoothness and flatness.



3. Tool Material and Structure

The material of the tool (such as diamond, hard alloy) and its structure (such as shape, size) will also affect the selection of amplitude. High-strength, high-wear-resistant tools can withstand the impact under larger amplitude, thereby improving processing efficiency.



4. Equipment Power and Frequency Matching

There is a certain relationship between the working frequency and amplitude of the ultrasonic machining system, usually high frequency corresponds to smaller amplitude, while low frequency can achieve a larger amplitude output. At the same time, the maximum output power of the equipment also limits the range of available amplitude.



Three, Amplitude Optimization Strategies in Practical Applications



To achieve the best processing effect, amplitude optimization should be combined with experimental and theoretical analysis. A common method is to determine the material removal rate, surface roughness, and tool wear under different amplitudes through trial processing, establish a relationship curve between amplitude and various indicators, and then select the amplitude value with the optimal comprehensive performance.



In addition, in recent years, with the development of intelligent control technology, more and more ultrasonic machining systems have started to adopt adaptive control technology, adjusting amplitude parameters in real-time to adapt to changes in processing status, further improving processing efficiency and stability.



Four, Conclusion



In summary, amplitude is one of the key variables affecting the processing performance in ultrasonic machining. Its selection should be comprehensively considered based on material properties, processing requirements, tool performance, and equipment parameters. By scientifically and reasonably selecting amplitude, not only can the processing efficiency and quality be improved, but also the tool life can be extended and production costs can be reduced. In the future, with the increasing diversity and intelligence of material processing needs and the development of intelligent manufacturing technology, the amplitude control in ultrasonic machining will become more refined and automated.