Ultrasonics + milling offers new solution to modern problem

The Ultrasonic HSC 20 Linear has been developed with the mould and die, optical, medical semiconductor, automotive and sensor industries in mind. These sectors are demanding the productivity, accuracy and shorter lead time advantages of single operation technology when machining the likes of hardened material, moulds, lenses and prisms, implants, silicon, sapphire, carbon fibre, ceramics and graphite type materials. As a result, the added cost of grinding and special process finishing operations, often required on these difficult to machine materials, can often be reduced or eliminated altogether. With a working envelope of 200 mm in X, Y and Z axes and controlled by Siemens 840D Powerline control, the machine uses its Ultrasonic HSK –Actor system to generate an axial oscillation of a diamond tool at a frequency of up to 48,000 times a second. These pulsing cycles are combined with a simultaneous rotation of the tool having a diameter between 0.3 mm and 3 mm at up to 12,000 rpm to remove micro-particles from the surface of the workpiece. By maintaining a precise and continuous gap between the tool and workpiece, forces normally created in a conventional machining process are considerably reduced and high orders of surface finish can be maintained up to 0.2 micro-metres Ra with less possibility of surface damage to the part and extending the life of the tool. In addition, the Ultrasonic HSC 20 Linear is a high productivity milling platform through its high speed machining capability, with spindle speeds up to 40,000 rpm, and the high dynamic advantages created through the use of linear drives and hydrostatic guideway technology. Axis acceleration of 1.4 g is achievable and the machine can be specified with a four or five-axis configuration. Continuous adaptive feed control is included with a further option of either 16 or 32 tool capacity magazine with automatic tool change. The tool magazine can hold tools up to 30 mm diameter, and accept both conventional and the ultrasonic tools to enable the combination of the two processes into a single programmed automated cycle.