Non Conventional Machining Processes

All Types Of Non Conventional Machining Processes or Non Conventional Manufacturing Processes

1. Non-Convectional Machining Processes GROUP ACTIVITY DIV-13 By Roll No- 113056 TO 113069

2. Machining Processes Manufacturing Processes can be broadly divided into two groups: Primary Manufacturing Processes : Provide basic shape and size Secondary Manufacturing P rocesses : Provide final shape and size with tighter control on dimension, surface characteristics Material removal processes once again can be divided into two groups Conventional Machining Processes Non-Conventional Manufacturing processes

3. Convectional Machining Processes Conventional Machining Processes mostly remove material in the form of chips by applying forces on the work material with a wedge shaped cutting tool that is harder than the work material under machining condition . The major characteristics of conventional machining are: Generally macroscopic chip formation by shear deformation • Material removal takes place due to application of cutting forces – energy domain can be classified as mechanical • Cutting tool is harder than work piece at room temperature as well as under machining conditions

4. Non-Convectional Machining Processes Non-conventional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be used for traditional manufacturing processes .

5. Non-Convectional Machining Processes The major characteristics of Non-conventional machining: 2. In this process, there may not be a physical tool present. For example in laser jet machining, machining is carried out by laser beam. However in Electrochemical Machining there is a physical tool that is very much required for machining 3. In this process, the tool need not be harder than the work piece material. For example, in EDM, copper is used as the tool material to machine hardened steels. 4. Mostly this processes do not necessarily use mechanical energy to provide material removal. They use different energy domains to provide machining. For example, in non conditional processing mechanical energy is used to machine material, whereas in ECM electrochemical dissolution constitutes material removal.

6. Classification of NCP processes CLassification of NCP processes is carried out depending on the nature of energy used for material removal. 1. Mechanical Processes Abrasive Jet Machining (AJM) Ultrasonic Machining (USM) Water Jet Machining (WJM) Abrasive Water Jet Machining (AWJM) 2. Electrochemical Processes Electrochemical Machining (ECM) Electro Chemical Grinding (ECG) Electro Jet Drilling (EJD) 3. Electro-Thermal Processes Electro-discharge machining (EDM) Laser Jet Machining (LJM) Electron Beam Machining (EBM) 4. Chemical Processes Chemical Milling (CHM) Photochemical Milling (PCM)

7. Needs for Non Traditional Machining Extremely hard and brittle materials or Difficult to machine materials are difficult to machine by traditional machining processes . When the workpiece is too flexible or slender to support the cutting or grinding forces . When the shape of the part is too complex.

8. Mechanical Processes

9. Abrasive Jet Machining Abrasive Jet Machining (AJM), also known as micro-abrasive blasting, is a mechanical energy based unconventional machining process used to remove unwanted material from a given workpiece. The process makes use of an abrasive jet with high velocity, to remove material and provide smooth surface finish to hard metallic workpieces

10. Abrasive Jet Machining AJM set-up

11. Ultrasonic Machining(USM) This machining uses ultrasonic waves to produce high frequency force of low amplitude, which act as driving force of abrasive . Ultrasonic machine generates high frequency vibrating wave of frequency about 20000 to 30000 Hz. This high frequency vibration transfer to abrasive particle contains in abrasive slurry. This leads indentation of abrasive particle to brittle work piece and removes metal from the contact surface. USM for machining brittle work material Material removal primarily occurs due to the indentation of the hard abrasive grits on the brittle work material.

12. Ultrasonic Machining(USM)

13. Ultrasonic Machining Equipment

14. Water Jet Machining A water jet cutter, also known as a water jet or waterjet, is an industrial tool capable of cutting a wide variety of materials using a very high-pressure jet of water, or a mixture of water and an abrasive substance . The term abrasive jet refers specifically to the use of a mixture of water and abrasive to cut hard materials such as metal or granite, while the terms pure waterjet and water-only cutting refer to waterjet cutting without the use of added abrasives, often used for softer materials such as wood or rubber.

15. Water Jet Machining(USM)

16. Water Jet Equipment

17. Abrasive Water Jet Machining The primary difference between pure and abrasive waterjet cutting is whether additives are mixed into the pressurized water that streams from the  machine nozzle . In pure waterjets, the pressure of the water alone, when forced through a tiny orifice, is used to cut through materials like foam .

18. Abrasive Water Jet Machining • Extremely fast set-up and programming • Very little fixturing for most parts • Machine virtually any 2D shape on any material • Very low side forces during the machining • Almost no heat generated on the part • Machine thick plates Advantages of AWJM

19. Electro-Chemical Processes

20. Electro-Chemical Machining (ECM) The process of removing a  metal   or   alloy from a material, through   electrolytic   action .   Works on the principle of electrolysis . Low DC voltage, very High current ( 700A)

21. Electrochemical grinding Combines electrochemical machining with conventional grinding Grinding wheel is the cathode Metal bonded wheel with diamond or Al 2 O 3 abrasive Majority of material removal from electrolytic action (95%) therefore very low wheel wear Much faster than conventional grinding

22. Electrochemical grinding

23. Electro-Jet Drilling It is a process in which a negatively charged stream of acid electrolyte is impinged on the workpiece to form a hole Electro jet drilling (EJD) is one such technique , which is finding ever-increasing applications in several industries including aerospace, medical, automobile and micro fabrication (electronic and computers).

24. Electro-Jet Drilling

25. Electro-Thermal Processes

26. Electrode Discharge Machining (EDM) The tool acts as a cathode (typically graphite) is immersed in a Dielectric fluid with conductive workpiece DC voltage (~300V) is applied. As voltage builds up over gap between workpiece and tool, eventually you get dielectric breakdown (sparking at around 12,000 deg F ) The sparking erodes the workpiece in the shape of the tool Cycle is repeated at 200,000-500,000 Hz

27. Electrode Discharge Machining (EDM)

28. Laser Beam Machining Lasers are high intensity focused light sources CO 2 Most widely used Generally more powerful that YAG lasers Cutting operations commonly Nd:YAG (Neodymium ions in an Yttrium Aluminum Garnet) Less powerful Etching/marking type operations more commonly Limited in depth of cut (focus of light) Would limit workpiece to less than 1 inch (< ½” typically)

29. Laser Beam Machining

30. Electron Beam Machining Electron - beam machining  (EBM) is a process where high-velocity  electrons  concentrated into a narrow beam  are directed toward the work piece, creating heat and vaporizing the material. EBM can be used for very accurate cutting or boring of a wide variety of metals .  The process of heating by electron beam  is used for annealing, welding or metal removal.

31. Electron Beam Machining

32. Chemical Processes

33. Chemical Milling Chemical milling  or industrial  etching  is the subtractive manufacturing process of using baths of temperature-regulated  etching chemicals  to remove material to create an object with the desired shape.   It  has applications in the printed circuit board and  semiconductor fabrication industries. It is also used in the aerospace industry  to remove shallow layers of material from large aircraft components, missile skin panels, and extruded parts for airframes

34. Chemical Milling

35. Photo Chemical Milling Photochemical machining  ( PCM ), or   photo etching , is a chemical milling process used to fabricate sheet metal components using a  photo resist  and etchants to corrosively machine away selected areas . Industrial applications include fine screens and meshes, apertures and masks, battery grids, fuel cell components, sensors, springs, pressure membranes, heat sinks, and much more.