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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.

Applications:

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

Advantages:

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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