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The Ultrasonic Tooling System

The new 100 kHz ultrasonic system UTS2 from son-x GmbH enables direct ultra-precision machining of steel with no geometric restrictions. The UTS2 operates at a unique frequency of 100 kHz, so that maximum efficiency is combined with precision. With the innovative process, steel alloys and some types of glass can be manufactured with the highest quality (Ra <3nm, PV <200 µm). The classic application is the optical mold.

 

The UTS2 works with the principle of ultrasonic-assisted machining. In this case, the diamond tool is set into a linear oscillatory motion in the cutting direction at a frequency of 100 000 Hz.

The high-frequency vibration of the tool causes a repeated separation of the cutting tool and the material. The contact time between diamond and material is only about 2 µs per cycle and overall 20% of the total processing time. The cyclical tool contact is repeated 100 000 times per second.

A large number of positive effects are achieved using this technology, e.g. improved cooling conditions and the interception of chemical wear reactions. This significantly reduces the wear of the diamond and enables the direct cutting of stainless steel.

 

The UTS2 enables direct cutting of steel and some glass materials using monocrystalline diamond tools with ultra-precise accuracy. The piezo-driven ultrasonic tooling system moves the diamond tool in a linear oscillatory motion with a unique frequency of 100 000 Hz, whereby the tool life is extended by orders of magnitude.

As a result of the compact design, the UTS2 can easily be integrated into any commercially available precision and ultra-precision machine. For machines without a vertical axis, a mechanical height adjustment is also provided. The simple and intuitive operation of the UTS2 based on the ‘Plug & Play’ principle allows immediate, efficient integration. The diamond tools are available from commercial providers and are not limited in terms of their tool edge geometry.

 

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With the UTS2, all the benefits of ultra-precision machining are transferred to various materials which previously couldn’t be processed using diamonds. As a result, several new applications for processing arise.

 

  • Optical mold making: The main application of the UTS2is optical mold insert manufacturing. Accurate aspheres, free-form surfaces and microstructured geometries can now be generated directly in hardened steel. These inserts are used in plastic injection molding or precision molding of glass and are more durable than regular inserts.
  • Manufacturing of optics: Some glass materials can be processed, including N-BK7, N-FK5, e.g. for the rapid manufacturing of prototypes
  • Precision mechanical components: Applications involving precision mechanics such as high quality watch components, mirror elements or laboratory standards.
  • Embossing rollers: : For the processing of metal or plastics
Vibration frequency 100 000 Hz
Vibration amplitude 0.1 – 2 µm
Dimensions of the tool holder width/depth/height 79/160/107 (mm)
Dimensions of the ultrasound generator width/depth/height 365/390/135 (mm)
Weight of the tool holder 1.2 kg
Tool overhang (geometrical freedom in Z) >50 mm (variable on demand)
Tool height above the base plate 16 mm (variable on demand)
Electrical requirements 110-220 V, <5 A, 50-60 Hz
Power consumption/strong> average 200 Watt
Recommended lubrication Spray mist
Additional system cooling Not required
Option Microheight adjustment unit or adapter plate
Typical roughness Ra ~3 nm
Typical shape accuracy PV < 200 nm

Roughness Ra

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Shape accuracy PV

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