The SoneX process uses a formed cutting tool called a sonotrode that is vibrated at ultrasonic frequencies against the workpiece. Abrasive particles suspended in a flushing fluid are drawn into the machining gap by the vibrations. This action causes the particles to gently and uniformly grind the workpiece material away, leaving a precise reverse form of the sonotrode shape.
Intricate Detail
SoneX is especially effective in the forming of intricately detailed configurations that require sharp internal corners and superior surface finishes. Low machining forces permit the manufacture of fragile electrodes too intricate to be machined conventionally. SoneX abrading speeds typically range from 1.5-3.5 cubic inches (25-60 cubic cm) per hour.
Penetration depths of up to 2 inches (50 mm) are possible on three-dimensional shapes up to 3.5 inches (90 mm) in diameter. Surface finishes range from 8-60 micro inches (0.2-1.5 micron). Accuracies of 0.0004 inch (0.010 mm) are typical; tolerances of 0.0002 inch (0.005 mm) can be achieved for custom applications.
