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Metal Ultrasonic Machining (USM) is a non-traditional machining process that uses ultrasonic vibrations to remove material from a workpiece. Here's a simple explanation:

Ultrasonic Vibrations:

A tool, typically a metal horn or blade, is vibrated at ultrasonic frequencies (usually around 20 kHz) by a transducer.

Abrasive Slurry:

A mixture of abrasive particles and a liquid (usually water or oil) is introduced between the vibrating tool and the workpiece.

Contact with Workpiece:

The vibrating tool makes intermittent contact with the workpiece, and the abrasive slurry aids in material removal.

Erosion and Material Removal:

The combination of ultrasonic vibrations and abrasive action causes erosion, removing material from the workpiece.

Contour Following:

The process is capable of following intricate contours and shapes, producing complex profiles.


Used for machining hard and brittle materials such as ceramics, glass, and certain metals.


USM is known for its ability to machine intricate shapes with high precision and without generating significant heat.

In simple terms, Metal Ultrasonic Machining is a method of removing material from a workpiece using ultrasonic vibrations and an abrasive slurry, offering precision machining for hard and brittle materials.

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