The basic principle of ultrasonic machining is to use mechanical vibrations at ultrasonic frequencies (usually 15kHz to 40kHz) to drive the tool head to impact the workpiece at high frequency, while also assisting with abrasive suspension liquid for material removal. This processing method is particularly suitable for hard brittle materials such as ceramics, glass, and quartz and is widely used in aerospace, electronics, optics, and other fields.



To improve the efficiency of ultrasonic machining, efforts can mainly be made from the following aspects:



1. Optimization of Process Parameters



The efficiency of ultrasonic machining is affected by various parameters, such as vibration frequency, amplitude, feed pressure, abrasive particle size, and concentration. By reasonably adjusting these parameters, the material removal rate can be significantly improved. For example, appropriately increasing the amplitude can enhance the impact force of the tool on the workpiece; choosing the appropriate abrasive particle size can improve the processing speed while ensuring the quality of the processing.

　　2. Improvement of Tool Material and Structure



The material and structural design of tools also have an important impact on processing efficiency. The use of high-strength, high-wear-resistant tool materials (such as hard alloy or diamond-coated tools) can reduce tool wear, extend service life, and thereby reduce the frequency and time cost of tool replacement. In addition, optimizing the shape and structural design of tools can help improve the efficiency of energy transfer and enhance processing stability.



3. Introduction of Intelligent Control System

　　The introduction of automation and intelligent control technology in modern manufacturing is a key means to improve processing efficiency. By monitoring the force, temperature, and vibration state during the processing process in real-time through sensors, and combining feedback control systems to automatically adjust parameters, optimal processing conditions can be achieved, which not only improves efficiency but also ensures the consistency of processing quality.



4. Application of Multi-energy Field Composite Processing Technology



Combining ultrasonic processing with other processing methods (such as laser-assisted, electrochemical processing, and grinding processing) to form composite processing technologies is one of the current research hotspots. For example, laser-assisted ultrasonic machining can reduce the brittleness of the material by preheating, thereby improving the material removal efficiency and reducing tool wear.



In summary, by optimizing process parameters, improving tool design, introducing intelligent control, and developing composite processing technologies, the efficiency of ultrasonic machining can be effectively improved. In the future, with the continuous emergence of new materials and new processes, ultrasonic machining will play an even more important role in precision manufacturing.