provided optimized process parameters for machining potassium dihydrogen phosphate crystal, a processed surface quality with Ra value of 33nm and subsurface damage depth value of 6.38 mm was achieved. Now this process is used in many industries to remove metal due to its lower cost, no heat generation, and effective machining. It is employed to machine hard and brittle materials (both electrically conductive and non conductive material) having hardness usually greater than 40 HRC. It is based on impact erosion. This user-friendliness is further boosted by CELOS apps developed specifically for ultrasonic machining, which visualise ULTRASONIC technology cycles and key process parameters such as frequency, amplitude and output. But how to realize grinding parameter optimization, that is, the maximum processing efficiency, on the premise of the assurance of best workpiece quality is a problem that needs to be solved urgently. USM Machining Rate The cutting rate in USM depends on 1. • It uses formed tools, vibrations of high frequency and a suitable abrasive slurry mix. Working of ultrasonic machining equipment USM applications, advantages and limitations Process variable and their effect on the ultrasonic machining The machining rate and accuracy of USM depend on many factors. Hence ultrasonic drilling will demonstrate strong competition to the conventional as well as the nonconventional machining processes for this composite material. The use of abrasives to shape parts is probably the oldest material removal process. machining parameter of the ultrasonic machining such as the majorly discuss is the material removal rate and the surface finish these parameters are definitely would influence the selection of the different non-traditional machining process and also it will influence the selection of the various Input parameters This machining process comes into existence in 1950 for finishing EDM surface. It has five main components in its working. The experimental investigations take into account the effect of the key rotary ultrasonic machining input parameters including the ultrasonic power, spindle speed and feed rate on the output responses of cutting force, exit chipping, surface roughness, hole cylindricity and overcut errors, and surface integrity. Ultrasonic machining is of particular interest for the cutting of non-conductive, brittle workpiece materials such as engineering ceramics. Another function used for the first time worldwide is the monitoring and tracking as well as of frequency and amplitude during the ongoing machining process. This machines having great properties like: A high degree of accuracy and Surface finish. In this Research, Taguchi optimization methodology is used to optimize Rotary Ultrasonic Machining (RUM) parameters for face milling of zirconia ceramic. They are important because Introduction They can be used on all types of materials ranging from soft metals to hardened steels and hard nonmetallic materials such as Ultrasonic Machining • It is a mechanical material removal process, used to erode material in the form of fine holes and cavities in hard or brittle workpiece. The high rate of metal removal and so on. Ultrasonic Machining PPT with PDF Seminar Report: Ultrasonic machining is a mechanical material removal process that uses formed tools, vibration of high frequency and abrasive slurry mix.It works on a frequency of more than 20000 Hz. The selection of optimum process parameters is crucial for advanced machining processes, as these processes incur high initial investment, tooling cost, and operating and maintenance costs. This article presents optimization aspects of an important advanced machining process known as ultrasonic machining (USM). In consideration of machining cost, because ultrasonic drilling can provide simultaneous multi-hole drilling, it is more economical than the above-mentioned processes. •USM is able to effectively machine all materials harder than HRc40, whether or not material is an electrical conductor or an insulator. In this paper, a review of machining process parameters for different materials is done in ultrasonic machining (USM). RSM was employed for developing empirical models. Influence of main machining parameters such as spindle speed, abrasive grit size, vibration amplitude on the material removal rate (MRR) was studied. Keywords Potassium dihydrogen phosphate crystal, rotary ultrasonic machining, surface roughness, subsurface defect depth Machining involves material removal process its lower cost, no heat generation, and effective machining of ceramics! Vibrating at a very high frequency this machines having great properties like: a degree. 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