https://www.bjultrasonic.com/shop/ultrasonic-horn/ CNC Ultrasonic milling is a relative new process that allows efficient machining of so-called advanced materials such as hardened steels, carbides, glasses and ceramics. https://www.bjultrasonic.com/ With the aid of an ultrasonic spindle, the vibration of the machine is transferred to a diamond tool. The tool vibrates at a rate of 20,000 times per second, and thus removes miniscule particles from the surface of the work piece. The simultaneous circular motion of the tool removes these particles from the working zone. In addition, the continuous separation between tool and work piece, in conjunction with the reduced feed power and lower thermal stress in comparison to conventional methods, leads to a protection of tool and work piece. The process is continuously monitored through intelligent control-algorithms, which makes unattended machining possible.
Programming and subsequent machining is carried out much like conventional milling. Ultrasonic milling makes it possible to machine finished parts in very hard materials at a considerably faster rate than other methods such as diamond cutting tools or grinding.
The only real disadvantages of this machining process are the fairly high cost of the machines and the necessity for the material to be hard. This type of machine requires the material to have a very high hardness to work.