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.
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.
|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|
Shape accuracy PV