Upgrading Existing Machines with Ultrasonic Machining
When hard, brittle, adhesive or composite materials defeat your current machines, replacing them is one answer. Adding ultrasonic assistance to the tool on the machines you already own is usually the cheaper one.
Where This Usually Goes Wrong
Cutting resistance on hard and brittle material is high, residual material clings to the workpiece, and the machined surface carries stress. A new machine does not change that physics. Superimposing high-frequency vibration on the tool does.
Stage by Stage
Identify the limiting material
Problem. Buying a new machine for a material problem does not solve the material problem
How we handle it. We start from what you cannot currently machine acceptably — hard, brittle, adhesive or composite — rather than from your machine list.
Check the host machine
Problem. A system that does not fit the existing machine is no upgrade at all
How we handle it. The ultrasonic tool processing system is suitable for various types of machine tools. We confirm the interface against your specific machine before quoting.
Select the operation
Problem. Drilling, milling, grinding, honing and turning have different system requirements
How we handle it. The tool processing system covers drilling including microholes and deep holes, milling, grinding and honing. Heavy-duty turning uses the separate ultrasonic turning system.
Confirm the benefit case
Problem. An upgrade justified on feel rather than on a measurable gain is hard to defend internally
How we handle it. The gains available are reduced cutting resistance, easier removal of residual material, low-stress machining, improved surface integrity, and for turning, chip breaking and tool savings.
Install and run
Problem. Rotating tooling with power fed to it is normally a maintenance liability
How we handle it. The system uses wireless power transmission and is brushless and bearing-free, which is what allows maintenance-free uninterrupted operation.
Upgrading Existing Machines with Ultrasonic Machining Questions
Will it fit my existing machine?
The system is designed to suit various types of machine tools. Send us the machine make, model and spindle interface and we will confirm before quoting.
Which is the right system, tool processing or turning?
The tool processing system covers drilling, milling, grinding and honing. The turning system is for heavy-duty cutting where chip breaking and tool life are the issue.
What maintenance does it need?
It is brushless, bearing-free and maintenance-free, with power delivered wirelessly to the rotating tool.
Work Through It With an Engineer
Send us what you already have and what you are trying to do. We will tell you what is missing and in what order to buy it.