Low-Stress and High Surface Integrity Ultrasonic Cutting Machining System
This ultrasonic tool machining system is an add-on for machine tools you already own. It superimposes a high-frequency vibration on the normal rotation of the cutting tool, so the tool is not in continuous contact with the workpiece. Cutting resistance drops sharply, residual material is thrown clear of the cut instead...
What This Machine Does
This ultrasonic tool machining system is an add-on for machine tools you already own. It superimposes a high-frequency vibration on the normal rotation of the cutting tool, so the tool is not in continuous contact with the workpiece. Cutting resistance drops sharply, residual material is thrown clear of the cut instead of smearing, and the part leaves the machine with lower residual stress and better surface integrity. That matters most on the materials that punish conventional cutting: hard and brittle stock, adhesive materials that load up a tool, and composites that delaminate. The system supports drilling of microholes and deep holes, milling, grinding and honing. Mechanically it is built to stay out of the way once fitted, with a brushless bearing-free design, wireless power transmission to the rotating tool and maintenance-free uninterrupted operation. XAIMC supplies it as a capability upgrade rather than a new machine purchase, which is the point: the buyer keeps the machine tool, the fixturing and the operators, and changes what the tool does in the cut.
Why Buyers Choose This Machine
- Fits to machine tools already on your floor instead of requiring a new machine purchase
- High-frequency tool vibration cuts cutting resistance, so thin and brittle parts are less likely to crack or chip out
- Low-stress machining leaves less residual stress in the finished part, which reduces distortion after machining
- Residual material is shed from the cutting zone easily rather than welding to the tool on adhesive materials
- One system covers drilling, milling, grinding and honing rather than one process per investment
- Brushless bearing-free construction with wireless power transmission means no slip rings to service and uninterrupted running
Where Low-Stress and High Surface Integrity Ultrasonic Earns Its Place
Problems It Solves
- Conventional cutting forces crack and chip hard brittle materials at the tool exit
- Machined parts move out of tolerance after the cut because the process left residual stress behind
- Adhesive material builds up on the cutting edge and ruins both the tool and the surface
- Deep holes and microholes are hard to hold straight when cutting resistance is high
- Buying a dedicated machine for a difficult material ties up capital that a tooling-level upgrade would not
Who It Is For
- Machine shops that have taken on work in hard brittle or composite materials on existing equipment
- Manufacturers whose parts distort after machining because of residual stress
- Tooling and process engineers evaluating ultrasonic assistance before committing to new machine tools
- Distributors selling machining capability upgrades into precision manufacturing markets
Application Scenarios
- Drilling microholes and deep holes in hard and brittle material where a conventional drill walks or breaks out
- Milling composite material where conventional tooling causes delamination at the exit edge
- Grinding and honing work on parts that must hold surface integrity for fatigue life
- Upgrading an existing machining centre that is struggling with a new difficult-to-machine material
- Machining adhesive materials that build up on the cutting edge and spoil the finish
Technical Detail
Technical Features
- High-frequency tool vibration superimposed on the main tool rotation
- Low-stress machining process for improved surface integrity
- Brushless design with no brush wear parts
- Bearing-free rotating assembly
- Wireless power transmission to the rotating tool
- Maintenance-free operation for uninterrupted running
- Suited to drilling of microholes and deep holes, milling, grinding and honing
- Compatible with various types of machine tool
Specifications
| Machine type | Ultrasonic tool machining system for machine tool upgrade |
|---|---|
| Models | Low-stress and high surface integrity ultrasonic cutting machining system |
| Processes supported | Drilling (microholes and deep holes), milling, grinding, honing |
| Target materials | Hard, brittle and adhesive materials, composite materials |
| Tool motion | Main rotation plus superimposed high-frequency vibration |
| Power transmission | Wireless to the rotating tool |
| Construction | Brushless, bearing-free, maintenance-free |
| Host machine | Suitable for various types of machine tool |
Figures above are taken from the product information we hold. Send us your application and we will confirm the exact specification for the model quoted.
How It Is Built and What Can Be Changed
Operations Performed
- Drilling
- Deep hole drilling
- Milling
- Grinding
- Honing
Quality Control
- Ultrasonic system function checked through a test cut before shipment
- Wireless power transmission verified across the rotating interface
- Tool assembly run-out measured on the assembled unit
- Fit and interface to the stated host machine confirmed before packing
Customisation Options
- Tool holder interface matched to the machine tool you intend to fit it to
- Tool selection specified for the material and hole size you are machining
- Supply voltage and frequency set to your market
- Operating documentation prepared in the language your shop works in
How It Compares With the Alternatives
| Conventional cutting on the same machine tool | Conventional cutting keeps the tool in continuous contact and builds up force; the ultrasonic system interrupts that contact, which is what lowers cutting resistance and residual stress |
|---|---|
| Buying a dedicated machine for difficult materials | The ultrasonic system upgrades the machine tool you already run, so the fixturing programs and operator training stay in place |
| XAIMC ultrasonic turning machining system | The turning system mounts on a lathe tool post for turning work; this system is the rotating-tool version for drilling milling grinding and honing |
Running the Machine
Step 1
Confirm the tool holder interface on your machine tool and specify it with the order
Step 2
Fit the ultrasonic tool holder and connect the generator
Step 3
Select tooling suited to the workpiece material and the hole or feature size
Step 4
Set the ultrasonic system running before entering the cut
Step 5
Take a test cut and check surface finish and edge condition before releasing the batch
Step 6
Keep the tool interface clean so the vibration transmits into the tool properly
Other Machines in Ultrasonic Processing
Questions About Low-Stress and High Surface Integrity Ultras
Will this fit the machine I already have?
It is designed to suit various types of machine tool. Send us the machine make model and spindle or tool holder interface and we will confirm the fit before you order.
What materials is it worth using on?
Hard brittle and adhesive materials, and composite materials. On free-cutting steel and aluminium a conventional tool is usually enough; the benefit shows up where cutting resistance and part damage are the problem.
Does it need regular servicing?
The design is brushless and bearing-free with wireless power transmission, so there are no brushes or slip rings to replace and it is intended for maintenance-free uninterrupted operation.
Which processes can I run with it?
Drilling including microholes and deep holes, milling, grinding and honing. Tell us which of those you need and we will specify the tooling accordingly.
What voltage will it be supplied for?
We set supply voltage and frequency to your market. Confirm your shop supply when you place the order.
What are your trade and payment terms?
FOB CFR and CIF. Payment is 30 percent by T/T on order and 70 percent before shipment, or an irrevocable L/C at sight.
How is it packed for export?
The system is packed for sea or air freight from our storehouse in Xi'an. Tell us your port and preferred incoterm and we will quote packing with the machine.
Request a Quote on the Low-Stress and High Surface Integrity Ultras
Send us the work you need it to do, the voltage on your site and the port you ship to. We will come back with the model, the tooling and the lead time.