Non traditional Machining process- Vth sem

Non traditional Machining process- Vth sem

1. CME387 NON-TRADITIONAL MACHINING PROCESSES REGULATIONS-2021 YEAR/SEM:III/V Prepared by. Dr.K.ARUMUGANAINAR,M.E.,Ph.D . ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL ENGINEERING, JP COLLEGE OF ENGINEERING . DEPARTMENT OF MECHANICAL ENGINEERING

2. PRSENTATION OVERVIEW Syllabus Objectives Outcomes Books Availability in Library Hand written notes Ten Nos. University Questions Subject analysis report Student analysis report Subject target PPT [2 units] University Questions analysis with the unit topics

3. SYLLABUS UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Introduction - Need for non-traditional machining processes - Classification of non-traditional machining processes - Applications, advantages and limitations of non-traditional machining processes - Abrasive jet machining, Abrasive water jet machining, Ultrasonic machining their principles, equipment, effect of process parameters, applications, advantages and limitations. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Principles, equipments, effect of process parameters, applications, advantages and limitations of Chemical machining, Electro-chemical machining, Electro-chemical honing, Electro-chemical grinding, Electro chemical deburring.

4. SYLLABUS Contd.. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Principles, equipments, effect of process parameters, applications, advantages and limitations of Electric discharge machining, Wire electric discharge machining, Laser beam machining, Plasma arc machining, Electron beam machining, lon beam machining UNIT-IV NANO FINISHING PROCESSES Principles, equipments, effect of process parameters, applications, advantages and limitations of Abrasive flow machining - Chemo mechanical polishing, Magnetic abrasive finishing, Magneto rheological finishing, Magneto rheological abrasive flow finishing.

5. SYLLABUS Contd.. UNIT – V HYBRID NON-TRADITIONAL MACHINING PROCESSES Introduction - Various hybrid non-traditional machining processes, their working principles, equipments, effect of process parameters, applications, advantages and limitations, Selection and comparison of different non- traditional machining processes.

6. COURSE OBJECTIVES 1. To classify non-traditional machining processes and describe mechanical energy based non-Traditional machining processes. 2. To differentiate chemical and electro chemical energy-based processes. 3. To describe thermo-electric energy-based processes 4. To explain nano finishing processes. 5. To introduce hybrid non-traditional machining processes and differentiate hybrid non-traditional machining processes

7. COURSE OUTCOMES Formulate different types of non-traditional machining processes and evaluate mechanical energy based non-traditional machining processes. 2. Illustrate chemical and electro chemical energy based processes. 3. Evaluate thermo-electric energy based processes. 4. Interpret nano finishing processes. 5. Analyze hybrid non-traditional machining processes and differentiate non-traditional machining processes,

8. BOOKS AVAILABILTY S.NO BOOK DETAILS NO.OF BOOKS AVAILABLE IN LIBRARY 1 Adithan . M., "Unconventional Machining Processes", Atlantic, New Delhi, India, 2009, ISBN 13: 9788126910458 2. Anand Pandey , "Modern Machining Processes", Ane Books Pvt. Ltd., New Delhi, India, 2019 02 2 Anand Pandey , “Modern Machining Processes”, Ane Books Pvt. Ltd., New Delhi, India, 2019 02 TEXT BOOKS

9. BOOKS AVAILABILTY S.NO BOOK DETAILS NO.OF BOOKS AVAILABLE IN LIBRARY 1 Benedict, GF, "Non-traditional Manufacturing Processes", Marcel Dekker Inc., New York 1987. ISBN-13: 978-0824773526 NIL 2 .Carl Sommer , "Non-Traditional Machining Handbook", Advance Publishing., United States, 2000, ISBN-13: 978-1575373256 NIL 3 Golam Kibria , Bhattacharyya B. and Paulo Davim J., "Non-traditional Micromachining Processes: Fundamentals and Applications", Springer International Publishing, Switzerland, 2017, ISBN:978-3- 319-52008-7 NIL 4 Jagadeesha T., "Non-Traditional Machining Processes, I.K. International Publishing House Pvt. Ltd., New Delhi, India, 2017, ISBN-13 978-9385909122 NIL 5 Kapil Gupta, Neelesh K. Jain and Laubscher R.F., "Hybrid Machining Processes: Perspectives on Machining and Finishing", 1st edition, Springer International Publishing., Switzerland, 2016, ISBN- 13: 978-3319259208 NIL REFERENCE BOOKS

10. BOOKS AVAILABILTY S.NO BOOK DETAILS NO.OF BOOKS AVAILABLE IN LIBRARY 1 Un conventional Machining Process - Dr.S.Senthil - Suchitra Publications 03 2 Un conventional Machining Process – Devanathan -AR Publications 01 3 Un conventional Machining Process – Vijayan-Anuradha Publications 01 LOCAL AUTHOR BOOKS Note : I Suggest to give a Local Author book to our students, “ Un conventional Machining Process - Dr.S.Senthil - Suchitra Publications” for their day to day preparation.

11. HAND WRITTEN NOTES First 3 Units Available Remaining Two Units[ 4 and 5] Under Preparation

12. PREVIOUS YEAR UNIVERSITY QUESTION PAPERS CME387 NTMP\NTMP UNIVERSITY QUESTION PAPERS.pdf

13. SUBJECT ANALYSIS REPORT 100% Theoretical Subject Unit 1- AJM,AWJM,USM Unit 2-CHM, ECHM,ECHH,ECHG,ECHD Unit 3- EDM,WEDM,LBM,PAM,EBM,IBM Unit 4- AFM,CMP,MAF,MRF,MRAFM Unit 5- Various Hybrid Non-Traditional Machining Process.

14. STUDENT ANALYSIS REPORT Total No.of Students - 29 Group A Category – 08 Group B Category- 06 Group C Category- 15 Subject Result Target - 26/29= 90% Plan To Achieve – More Writing Practice to be given More Importance Given to Draw the Figure All University Questions are to be discussed in the Regular class No.of Assignments to be Given

15. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES

16. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Presentation overview Introduction - Need for non-traditional machining processes Classification of non-traditional machining processes Applications, advantages and limitations of non-traditional machining processes Abrasive jet machining-principles, equipment, effect of process parameters, applications, advantages and limitations. Abrasive water jet machining-principles, equipment, effect of process parameters, applications, advantages and limitations. Ultrasonic machining-principles, equipment, effect of process parameters, applications, advantages and limitations.

17. TRADITIONAL MACHINING PROCESS DRILLING GRINDING GEAR BROACHING THREAD CUTTING METAL CUTTING SHOULDER TURNING

18. TRADITIONAL MACHINING PROCESS SOME TRADITIONAL MACHING PROCESS DRILLING OPERATION AJM\DRILLING.mp4 FACING OPERATION AJM\LATHE FACING.mp4 GEAR CUTTING OPERATION AJM\INTERNAL GEAR CUTTING.mp4 SURFACE GRINDING AJM\SURFACE GRINDING.mp4

19. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Introduction- Need for non-traditional machining processes Traditional machining is mostly based on removal of materials using tools that are harder than the materials themselves. New and novel materials because of their greatly improved chemical, mechanical and thermal properties are sometimes impossible to machine using traditional machining processes. Traditional machining methods are often ineffective in machining hard materials like ceramics and composites or machining under very tight tolerances as in micro machined components. The need to a avoid surface damage that often accompanies the stresses created by conventional machining. Example: aerospace and electronics industries. They are classified under the domain of non traditional processes.

20. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Classification of Non-Traditional Machining These can be classified according to the source of energy used to generate such a machining action: mechanical, thermal, chemical and electrochemical. Mechanical: Erosion of the work material by a high velocity stream of abrasives or fluids (or both) Thermal: The thermal energy is applied to a very small portion of the work surface, causing that portion to be removed by fusion and/or vaporization of the material. The thermal energy is generated by conversion of electrical energy. Electrochemical: Mechanism is reverse of electroplating. Chemical: Most materials (metals particularly) are susceptible to chemical attack by certain acids or other etchants. In chemical machining, chemicals selectively remove material from portions of the work part, while other portions of the surface are protected by a mask.

21. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Classification of Non-Traditional Machining

22. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Applications of non-traditional machining processes For drilling very small diameter holes in a nozzle of a fuel injection system Non-traditional methods are also used in the automobile industry. Non-traditional machining methods can also be used to machine gears. For machining intricate designs on thin metal sheets, many non-traditional machining processes, such as Laser Beam Machining, are used. For cutting fragile materials like glass, ceramics, and quartz, unconventional machining procedures such as Abrasive Jet Machining can be used.

23. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Advantages of non-traditional machining processes It provides high accuracy and surface finish. No physical tool is used hence, no tool wear occur. They do not generate chips or generate microscopic chips. These are quieter in operation. It can be easily automated. It can machine any complex shape.

24. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Limitations of non-traditional machining processes High initial investment. One of the main disadvantages of machining processes is the high initial investment required to purchase the necessary equipment. ... Long lead times. ... Limited design flexibility. ... Generates waste material. ... Requires skilled workers.

25. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Abrasive jet machining Principles AJM uses a stream of fine grained abrasives (of size 10 to 40 microns) mixed with air or some other carriers gas at high pressure. This stream is directed on the work surface by using a suitable nozzle. The velocity of carries gas or air is up to 200 to 400 m/sec Due to this high speed, impact on the work surface erosion takes places by abrasive particles and metal removes from the work piece.

26. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES CONSTRUCTION-EQUIPMENT

27. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Process In abrasive jet machining (AJM) a focused stream of abrasive grains of Al 2 O 3 or Sic carried by high-pressure gas [Helium (He), nitrogen (N 2 ), hydrogen (H 2 ), and argon ( Ar )] are often used or air at a high velocity is made to impinge on the work surface through a nozzle of 0.3- to 0.5-mm diameter. The work piece material is removed by the mechanical abrasion (MA) action of the high-velocity abrasive particles.   The most essential process parameters of AJM are: Mass flow rate of abrasive particles. Nozzle tip distance from the work piece. ... Pressure of gas used. Velocity of abrasive particles in carrier gas. Mixing ratio of carrier gas. Grain size of the abrasive particles.

28. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Process Parameters on AJM

29. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Effects of abrasives on AJM performance As discussed earlier, shape, size, strength, material and flow rate of abrasive can influence machining performance. Irregular shape abrasives having sharp edges tend to produce higher MRR as compared to spherical grits. Smaller size grits produce highly finished surface but reduce material removal rate (MRR) and thus productivity descends Effects of carrier gas on AJM performance Carrier gas pressure and its flow rate are two paramount factors that determine performance and machining capability. Higher gas pressure reduces jet spreading and thus helps in cutting deeper slots accurately. However, various accessories including pipeline must be capable enough to handle such high pressure without failure. Moreover, increased gas flow rate gives the provision for utilizing higher abrasive flow rate, which can improve productivity

30. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Effects of mixing ratio on AJM performance Mixing ratio (M) is the ratio between mass flow rate of abrasive particles and mass flow rate of carrier gas. It basically determines concentration of abrasives in the jet. Mixing ratio can be increased by increasing abrasive percentage and in such case an increasing trend in MRR can be noticed because larger number of abrasives participates in micro-cutting action per unit time. Effect of stand-off distance on AJM performance Distance from the work surface to the tip of nozzle in abrasive jet machining set-up is called Stand-Off Distance, abbreviated as SOD. Higher SOD causes spreading of jet and thus its cross-sectional area increases with the sacrifice of jet velocity. As a consequent, machining deeper slots or hole becomes difficult; instead a wider area is cut.  .

31. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Effect of impingement angle on AJM performance Impingement angle (θ), also called spray angle or impact angle, is basically the angle between the work surface and abrasive jet axis. Practically it is kept between 60º – 90º in order to get satisfactory performance in AJM. Larger angle tends to create deeper penetration, while smaller angle tends to increase machining area. An impingement angle (θ) between 70º – 80º provides better result in terms of material removal rate in abrasive jet machining.

32. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Material removal rate and its estimation Knowledge of material removal rate (MRR) is beneficial for selecting process parameters and choosing feed rate of the nozzle. It also facilitates accurate estimation of productivity, delivery time as well as production cost. Since only kinetic energy of abrasive grits is utilized for erosion, the analytical formula for MRR can be established by equating available kinetic energy with the work done required for creating an indentation of certain cord length on a specific work material.

33. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Advantages of abrasive jet machining Suitable for removal of deposits on surface Wide range of surface finish can be obtained Process is independent of electrical or thermal properties No thermal damage of work piece Suitable for nonconductive brittle materials Low capital investment Disadvantages of abrasive jet machining Not suitable for soft and ductile materials Abrasives are not reusable Abrasive collection and disposal are problematic Inaccurate cutting and drilling (stray cutting) Limited nozzle life

34. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 AJM [Abrasive Jet Machining] AJM\AJM ANIMATION.mp4 AJM\AJM APPLICATION 1.mp4 VIDEO TUTORIALS

35. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES ABRASIVE WATER JET MACHINING Principle This process works on basic principle of water erosion. In this process, a high speed well concentrated water jet is used to cut the metal. It uses kinetic energy of water particle to erode metal at contact surface. The jet speed is almost 600 m/s. It does not generate any environmental hazards. For cutting hard materials, abrasive particles are used in water jet These abrasive particles erode metal from contact surface.

36. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES

37. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Hydraulic Pump: In the water jet machining process a hydraulic Pump is used to pump the water from storage tank for machining process. It is connected by an electric motor of about 100 Horse power. Hydraulic Intensifier: As the name implies, it is used to increase the water pressure for further process. Hydraulic intensifier accept water from pump at a small pressure about 4 bar. The water pressure at outlet of intensifier is about 3000-4000 bars. Hydraulic Accumulator: Hydraulic accumulator is used when large amount of pressure energy is required for an instant. It used to eliminate pressure fluctuation It supplies fluid at high pressure when required.

38. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Tubing System: Tubes are used to supply high pressure water to the nozzle for further cutting process. It increase the kinetic energy of fluid. It diameter is about 10-14 mm.  It provide flexible movement and does not allow any significant loses. Flow regulator: Flow regulators are used to regulate the flow according to cutting requirement. For high cutting load, high pressurized water is supplied at high rate. Abrasive: Abrasive particles are used in abrasive water jet machining for machine hard material. Generally Aluminium oxide, Silicon carbide etc. used as abrasive particles.

39. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Nozzle: As we know,  nozzles  are used to convert pressure energy into kinetic energy. This nozzle convert high pressure of water into high velocity jet. This high speed water jet strikes at work surface which is used for machining. There is possibility of erosion at orifice of the nozzle due to high pressure water jet. Therefor high wear resistance material is used for nozzle. The size of nozzle is about 0.2 – 0.4 mm. If abrasive water jet machining is used, abrasive particles mixed in water stream before entering into nozzle.

40. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Drain and Catcher The drain and catcher system is used to remove debris and other machined particle form water. It separate metal particle from water and this water is further send to reservoir. It also used to reduce noise associate with WJM. Working: The working of water jet machining can be summarize as follow. First water is filled in water reservoir. It provides water for cutting operation. A pump sucks water from water reservoir and send it to intensifier. Intensifier increases the water pressure from 4 bar to 4000 bars. It sends water to accumulator which store some pressurize water. This high pressure water now sends through tubing system to nozzle. The water passes through flow regulator valve which regulate the flow. Now this high pressure water enters into nozzle. Nozzle converts some pressure energy of water into kinetic energy. A high speed high pressurize water jet is available at nozzle exit. This water jet send to strike at work surface. It erode metal from the contact surface. Thus metal removal take place.

41. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 AWJM [Abrasive Water Jet Machining] AJM\AWJM ANIMATION.mp4 AJM\AWJM APPLICATION.mp4 AJM\AWJM APPLICATION 2.mp4 VIDEO TUTORIALS

42. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Application: It is used in aerospace industries. Abrasive jet machining is used to cut hard metal like stainless steel, titanium, Inconel etc. It is used to machining or cutting reinforced plastic. Use to cut stone which reduce dust in environment. Used to machining PCB.

43. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Advantages: It does not change mechanical properties of work piece. It is useful for machining heat sensitive material. It is environment friendly because it does not form any dust particle and used water as cutting fluid. Good surface finish. No physical tool is require. It can cut both soft and hard material. For machining soft materials, water jet machining is used and for machining hard materials, abrasive water jet machining is used. It is ideal process for laser reflective materials where laser beam machining cannot be used.

44. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Disadvantages: It cannot used for machining material which degrade in presence of water. Low metal removal rate. High initial cost. Thick material cannot be machined easily.

45. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Ultrasonic machining Principle Working of Ultrasonic Machining is: there is gap between tool and work piece about 0.25 mm. The tool is made up of ductile material. Between tool and work piece, there is a slurry of abrasive. Abrasive gets embedded into the tool and during the downward journey of the tool, abrasives hammer the work piece, removing material. This material will be flushed away from the machining area by the flow of the slurry tool is made slightly tapered to produce straight holes.

46. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES

47. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Ultrasonic Machining consists of the following main parts: Power Supply Velocity Transformer Tool Abrasive Slurry Electro-mechanical transducer Abrasive gun Workpiece

48. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Power Supply: The power supply is also called a high-frequency generator or electronic oscillator. The main function is to convert a normal electrical supply that has a frequency range of 50-60 HZ to a high-frequency electrical supply up to range 20-40kHZ but the amplitude of the vibration will be small up to a range of microns Velocity Transformer: Velocity transformer is also called the design of the horn. The function of the horn is to amplify and focus the vibration of the transducer to an adequate intensity for driving the tool to fulfill the cutting operation.

49. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Tool: Hammering is done by a body that is known as the tool and the tool material has been sufficiently ductile so that in itself does not undergo brittle fracture. However, we can not avoid the removal of material from the tool parallel with the work piece, so tool wear is of sufficient degree and it should also be fatigue resistant because in order to increase the material removal rate we are increasing the hammering rate to ultrasonic frequencies.

50. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Abrasive Slurry: Abrasives need to be applied at the site of machining and need to be removed together with machined material from workpiece and tool material, so they are carried in a slurry to and from the site of machining. The tool is pressed against the work piece to create a slight pressure, low enough so as not to crush abrasives and high enough so as to ensure fracturing of the workplace.

51. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Electro-mechanical transducer: The transducer converts electrical energy into mechanical vibration. The high-frequency electrical signal is transmitted to the transducer which converts it into high frequency and has low amplitude vibration. There are two types of transducer used : Piezoelectric transducer Magneto-restrictive transducer. Piezoelectric Transducer: When this transducer is compressed it generates a small electric current. and when an electric current passed through it it will expand. When the current is removed, the crystal attains its original size and shape. these transducers are available up to 900 Watts.

52. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Magneto strictive transducer: When subjected to a magnetic field these type of transducers also changes their shape. These transducers are made of nickel and nickel alloy. Efficiency is about 20-30%. Such transducers are available up to 2000 Watts the maximum change in length is about 25 microns. Abrasive gun: Abrasives are applied at the machining site by being carried in a water medium generally and it is called a slurry. Let’s put volume/volume say 20 parts of abrasives in 100 parts of water and let it be applied by a nozzle or by an abrasive gun that means, by a jet at the machining site so that all the time the machine site is receiving fresh abrasives under a definite pressure and the debris of machining: that means, remove material broken abrasives, all these things are removed by that jet of water and abrasives only

53. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Work piece: Brittle non-conductive materials like engineering ceramics are machined by ultrasonic machining process. It does not thermally damage the workpiece and does not introduce residual stress on the workpiece . 3-D shapes can be intricate from this process on the workpiece .

54. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Ultrasonic Machining Process Working Principle: Working of Ultrasonic Machining is: there is gap between tool and work piece about 0.25 mm. The tool is made up of ductile material. Between tool and work piece, there is a slurry of abrasive. Abrasive gets embedded into the tool and during the downward journey of the tool, abrasives hammer the work piece, removing material. This material will be flushed away from the machining area by the flow of the slurry tool is made slightly tapered to produce straight holes. Upon increasing the viscosity of the carrier fluid material removal rate decreases due to difficulty in flushing. By increasing the frequency, MRR will increase because the number of impacts per unit time will increase .

55. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES By increasing the amplitude, MRR will increase due to the increase in the momentum of abrasives. The amplitude of the vibration may vary from 5 to 75 µm and frequency may vary from 19 to 25 kHz. By increasing the concentration of abrasives, the impact will be there at more places which increases MRR (Material Removal Rate). But when the concentration increases beyond a certain value, due to Collision between the abrasives momentum is lost, decreasing the MRR. By increasing the size of the abrasive, an impact will appear in the larger area. But when the size increases beyond a certain value, the momentum of abrasives will decrease.

56. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Effect of Process Parameters of Ultrasonic Machining Process The major USM process variables effecting Material removal rate Accuracy Surface finish are tool/horn design Power Amplitude Abrasive size and Frequency. The amplitude of the tool motion affects the material removal rate and obtains the maximum size of the abrasive particles which can be used

57. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Application: Ultrasonic Machining is used for the Machining of non-conductive ceramics. Material that has a high scrap rate means fragile material can be machined by this process very effectively. Machining of dies for wire drawing, punching, and blanking operations. It enables a dentist to drill a hole of any shape on teeth without any pain. Used for grinding Quartz, Glass, ceramics. Used to cut industrial diamonds. Also Used for making dies.

58. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Advantages: Ultrasonic Machining can be used machine brittle, non-conductive material, Hard and Fragile material Heat is not generated in this Machining process so there is very little or negligible physical change in the workpiece . Non-metal that cannot be machined by EDM and ECM because of poor electrical conductivity, but can very well be machined by Ultrasonic Machining. It is burr less and distortion fewer processes. It can be adopted in conjunction with other new technologies like EDM, ECG, ECM. The operation is noiseless. Equipment used here in this machining can be used by skilled as well as unskilled operators.

59. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Disadvantages: Material Removal Rate is Low. The energy requirement for cutting is high. The softer material is difficult to machine It is difficult to drill deep holes in Ultrasonic Machining, as there is a restriction of slurry movement. High Tool wear rate due to the movement of abrasive particles.

60. UNIT-1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 USM [Ultrasonic Machining] AJM\USM ANIMATION 3 D.mp4 AJM\USM ANIMATION.mp4 AJM\USM APPLICATION.mp4 VIDEO TUTORIALS

61. UNIVERSITY QUESTIONS ANALYSIS WITH THE UNIT TOPICS CME387 NTMP\University Questions analysis with the unit topics.docx

62. THANK YOU

63. UNIT-2 CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES

64. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES PRSENTATION OVERVIEW Principles, equipments, effect of process parameters, applications, advantages and limitations of Chemical machining Principles, equipments, effect of process parameters, applications, advantages and limitations of Electro-chemical machining Principles, equipments, effect of process parameters, applications, advantages and limitations of Electro-chemical honing Principles, equipments, effect of process parameters, applications, advantages and limitations of Electro-chemical grinding Principles, equipments, effect of process parameters, applications, advantages and limitations of Electro chemical deburring .

65. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Chemical machining Principle: The working principle of chemical machining is based on chemical etchant. An etchant is a mixture of strong chemical acids which are reactive to metal. When the work piece is dipped in the etchant, the etchant reacts with the work piece causing a uniform rate of dissolution of metal from the work piece. To obtain a desired shape or structure, an elemental coating that is non-reactive to a chemical reagent called ‘ Maskant ’ is applied on the work piece before machining. Localized machining is achieved by applying a suitable mask on all the areas where we do not want the etchant to react. Thus, exposing the machining zone for the necessary removal of metal.

66. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES CONSTRUCTION

67. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES It consists of the following parts: Tank Heating coil Stirrer and Work piece 1. Tank: This process has a tank with its face open. The tank is built of strong metal coated with materials that are non-reactive to etchant depending on the applications and concentration of chemical reagent. 2. Heating coil: A heating coil is mounted at the lowest section of the tank to maintain the temperature of the tank at a constant level. It is practical that in any metal removal process the heat generation is natural. Also, the coil does cooling in necessary conditions.

68. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 3. Stirrer: A stirrer is placed in the etchant whose main purpose is to mix the etchant consistently to maintain a uniform concentration and heat along the volume of the etchant. It is well known to us that the hot particles always accumulate at the top, leaving the cold below. So, to spread the heat uniformly along the etchant, the stirrer is used. The stirrer also helps in the flushing of dissolved metal from the work piece simultaneously breaking the bubbles formed during machining due to oxidation. 4. Work piece: The work piece is held in the etchant by the use of a hanger in the case of small applications. The length of the hanger is fastened over a masked area so that the fixing of the work piece does not disturb the machining zone. In the case of a larger work piece, fixtures coated with rubbers and polymers are used to hold the work piece.

69. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Chemical Machining Process Working Principle

70. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Chemical Machining involves four major processes performed in a series: 1 . Cleaning: Cleaning is a preparatory process to ensure that the surface of the work piece is free from contaminants, rust, and foreign particles. It is usually performed by high-pressure water jets, alcoholic solutions, and diluted HCl . 2. Masking: It is a process of applying maskant over the surface of the work piece. A layer of polymer or rubber is coated on the work piece. Masking is done to prevent the area which does not require machining from the etching process. Masking is done all over the work piece except the areas to be machined.

71. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 3. Etching: This is the process in which the required metal removal takes place. After perfect masking, the work piece is dipped into the tank of the chemical reagent with the heater and the stirrer turned ON. As soon as the work piece is dipped, the etchant starts to react with the non-masked areas of the work piece. The highly concentrated acid begins to react with the work piece altering its chemical features. This reaction causes the predefined portions to melt and separate from the work piece layer by layer. This is calculated by the formula. E=S/T, where, E = Etch rate , S = Depth of cut required. T = Time in seconds.

72. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 4. De masking: De masking is a process of peeling off the maskant that was applied before the etching process. Once the maskant is removed from the work piece, the work piece is again sent to cleaning operation where any leftover etchant is washed away by pressurized cold water. The work piece is then dried up and ready for final dispatch. Chemical Machining Operation Types: 1. Chemical milling  (CHM): This operation is performed to obtain pockets, contours on the work piece or to remove bulk material from the work piece.

73. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 2 .  Chemical engraving  (CHE): This operation is performed to reproduce a special design on a work piece with a lot of precision. E.g., titles, brand names, serial numbers, etc. 3 .  Chemical polishing  (CHP): This operation is performed to make up a fine finishing or deburring of the work piece. This is possible by using of usage of lighter diluted chemical reagent. 4 .  Photochemical machining  (PCM): Photochemical machining is a process of manufacturing stress-free and crack-free components. PCM is used where micro details are to be machined on a work piece.

74. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Chemical Machining Applications: Weight reduction of complex contours, impossible by conventional methods. Machining of thin and delicate components. Used to machine the contours present inside a hole. Used in automobile and aviation industries. Making of fine screens and meshes. Removal of metal where the holding of a work piece is difficult.

75. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Chemical Machining Advantages: This machining process removes metal uniformly. Good surface finish with close tolerances. Complex contours can be easily machined. Material removal along all the axes at the same time. Less skilled operator is required. No mechanical stress is produced on the workpiece . Low initial cost. Low machining cost.

76. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Chemical Machining Disadvantages: Less operator safety, a minor spill of etchant on the skin can cause harm to the operator. Chances of corrosion after the days of machining. Machining of alloys can lead to poor surface finish. Process is not eco-friendly. Disposal of byproducts can cause harm to the surrounding. Material Removal Rate (MRR) is less in comparison with other machining processes. Chances of bubble formation, which may result in improper machining.

77. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 Chemical Machining CHM UNIT 2\Chemical machining Animation.mp4 CHM UNIT 2\Chemical Etching_ A Tour Through The Process (3D Animation).mp4 CHM UNIT 2\Chemical Machining Application.mp4 VIDEO TUTORIALS

78. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electro-chemical machining Principle: Electrochemical Machining (ECM), characterized as non-traditional machining, is an advanced machining, non-contact, reverse electroplating process (ECM removes material instead of depositing it). In ECM, a high electric current is passed between the tool and work piece through a conductive fluid. The high current and the conductive fluid are used to ionize and remove the metal atoms of the work piece yielding a burr-free surface.

79. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES CONSTRUCTION

80. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrochemical Machining consists of following main parts: Power supply Electrolyte Work piece Tool Feed Unit Tank Work piece holding table Pressure gauge Flow meter Flow control valve Pressure relief valve Pump Reservoir tank Filters Sludge container Centrifuge Fume extractor Enclosure

81. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 1.Power supply: Voltage must be kept low to avoid short-circuit because the gap between the tool and work piece is low for high-pitched correctness Material removal rate ∝ Current density. Therefore, high current values are used for the ECM process. The following are the power supply parameters for the ECM process: The power source is electrical in ECM Type: Direct current Current capacity: 50 to 40,000 A Voltage kept small ( to prevent short-circuit ) : 2- 35 V

82. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 2.Electrolyte: Electrolytes are conductive fluid and are selected in parity with electrodes. Some electrolyte-electrodes combination is given below: Sodium chloride ( NaCl ) at a concentration of 20% is used for ferrous alloys. Sodium nitrate (NaNO3) is used for ferrous alloys. Hydrochloric acid ( HCl ) is used for Nickel alloys. A mixture of sodium chloride ( NaCl )and sulphuric acid (H2SO4) makes use for nickel alloys. A mixture of 10% hydrofluoric acid (HF), 10% hydrochloric acid ( HCl ), 10% nitric acid (HNO3) applied for Titanium. Sodium hydroxide ( NaOH ) is for tungsten carbide (WC).

83. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrolytes must have the following properties: High conductivity Low viscosity Low toxicity and corrosively Chemical and electrochemical stability for better material removal rate 3 functions of electrolyte are: Carries current between the tool and work piece Removes the product from the internal electrode gap Removes the heat produced due to passage of the current.

84. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrolyte parameters in ECM are as follows: Temperature : 20 °C – 50 °C Flow rate: 20 liters /min per 100 A current Pressure: 0.5 to 20 bar Dilution:100 g/l to 500 g/l 3.Work piece: A work piece is an object that needs to be machined from which material goes into the solution. The work piece is made the anode in ECM. The material removal rate or machining is only dependent upon the atomic weight and valency of the work material.

85. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 4.Tool: The tool is used to remove material from the work piece. It is made the cathode and connected to the negative terminal of the power supply. The tool is selected and manufactured keeping in mind the following properties: Good conductor of electricity. Rigid enough to take up the load and fluid pressure. Chemically inert with respect to the electrolyte. Easily formable and machinable to the desired shape. Should be manufactured with great accuracy

86. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 4.Feed Unit: The servo motor is used to provide the controlled feed to the tool for material removal from the work piece. Feed rate is 0.5 mm/min to 15 mm/min. Tank : It holds the electrolyte in which the tool and work piece are immersed. Work piece holding table : The work piece holding table holds the work piece firmly. Pressure gauge : This shows the pressure at which the electrolyte is supplied to the tool. Flow meter : This shows the rate of flow of electrolyte to the machining area. Flow control valve : Helps in controlling the rate of flow of electrolytes. Pressure relief valve:  The pressure relief valve opens and bypasses the electrolyte to the tank in case the pressure rises in the supply lines.

87. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 5.Pump: The pump helps in circulating the electrolyte. The rate of pumping and pressure at which electrolytes will be pumped should be decided beforehand depending on the application or requirement of the process. Therefore, the pump for pumping electrolytes should be decided accordingly. Reservoir tank : Stores the electrolyte

88. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES 6.Filters: The filter helps in filtering the impurities present in the electrolyte which may choke the supply lines. Sludge container : Stores the sludge produced during the machining. Centrifuge : A centrifuge is a device that uses centrifugal force to separate the sludge from the electrolyte. Fume extractor : A fume extractor is a device that uses a fan with a negative draft to pull fumes and dust out of the enclosure. Enclosure : The entire system of ECM is put into an enclosure so that any toxic fumes produced in the machining process do not affect the environment and operator.

89. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrochemical Machining Working Principle Let us take an example of the machining of an iron work piece. The iron work piece is assembled in the work piece holding table. The tool is brought close to the work piece. The two electrodes immersed in the electrolytic solution of NaCl (common salt solution). The cathode (tool) and anode (iron work piece) are connected to the negative and positive terminal of the power supply (usually around 10 V) respectively. The electrolyte from the reservoir tank is continuously pumped, streaming through the hole in the tool, into the gap between the tool and the work piece with the help of a circulating pump. The tool feed system advances the tool towards the work piece. Reactions at the anode are called anodic reactions. Reactions at the cathode are called catholic reactions.

90. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Basic reactions for sodium chloride electrolyte: Disassociation of sodium chloride: NaCl ————→  Na +  + Cl – Disassociation of water:                  H 2 O  ————→  H +  + OH – Cathodic Reactions: Hydrogen ions take away electrons from the cathode (tool) to form H 2  gas. 2H +  + 2e –  ————→ H 2 ↑

91. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrochemical Machining Advantages: Complex and concave curvature parts can be produced easily using concave and convex tools. More complex geometries can be produced using a single connected CNC machine. Since there is negligible tool wear, the same tool can be used for producing an infinite number of components. Since there is no direct contact between the tool and work material, there are no forces and residual stresses. An excellent surface finish is produced with no thermal damage due to atomic level dissolution Less heat is generated.

92. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrochemical Machining Disadvantages: The saline(acidic) electrolyte can cause corrosion of the tool, work piece, and equipment. High specific energy consumption. ECM can machine only electrically conductive work material. It can not be used for soft material. A large production floor is required. ECM poses health and environmental concerns.

93. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrochemical Machining Application: Electrochemical Machining is used for Die sinking and hole-contouring operation. Grinding, by combining with grinding processes (using the negatively charged abrasive grinding wheel) to remove material. The process is also referred to as electrochemical grinding. Cutting cavities, drilling deeper and even irregular-shaped holes in complex structures like jet engine turbine blades.

94. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 Electro Chemical Machining CHM UNIT 2\ECM ANIMATION.mp4 CHM UNIT 2\ECM APPLICATION.mp4 VIDEO TUTORIALS

95. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrochemical Honing ( ECH )  Principle: ECH is a process in which the metal removal capabilities of ECM are combined with the accuracy capabilities of honing. The process consists of a rotating and reciprocating tool inside a cylindrical component. Material is removed through anodic dissolution and mechanical abrasion – 8% or more, of the material removal, occurs through electrolytic action

96. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrochemical honing Tool

97. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES ECH tool construction Tool consists of a hollow stainless steel body that has expandable, nonconductive honing stones protruding from at least three locations around the circumference The honing stones are identical with those used in conventional honing operations, except that they must resist the corrosiveness of the electrolyte The honing stones are mounted on the tool body with a spring-loaded mechanism so that each of the stones exerts equal pressure against the work piece The length of the stones is selected to be approximately one-half of the length of the bore being processed.

98. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Working of electrochemical honing :  At the beginning of the ECH cycle, the stones protrude only 0.075-0.127mm from the stainless steel body, establishing the gap through which the electrolyte flows The electrolyte enters the tool body via a sliding inlet sleeve from which it exits into the tool-work piece gap through small holes in the tool body After passing through the gap, the electrolyte flows from the work piece through the gap at the top and bottom of the bore The mechanical action of the tool is the same as with conventional honing; the tool is rotated and reciprocated so that the stones abrade the entire length of the bore

99. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrolytes used in ECH are essentially the same as those used in ECM, although the control of pH, composition and sludge is less critical because the abrasive action of the stones tends to correct any resulting surface irregularities As in ECM, the electrolytes are re circulated and reused after passing through appropriate filtration, and the most commonly used electrolytes are sodium chloride and sodium nitrate.

100. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Process parameters of electrochemical honing : Machines are available that deliver up to 6000 amp Current density at the work piece can range from 12 to 47amp/cm 2 Working voltages are 6-30 VDC The electrolyte is delivered to the work area at pressures of 0.5-1 MPa ECH can remove materials at rates up to 100% faster than conventional honing, the gain being more pronounced as the material hardness increases Machine capacities are currently able to accommodate bore lengths up to 600 mm and bore diameters from 9.5 to 150 mm.

101. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Advantages of electrochemical honing :  Increased MRR particularly on hard materials Since most of the material is removed electrochemically, honing stone life is greatly extended Burr-free operation Unlike conventional honing, no micro-scratches are left on the work surface Less pressure required between stones and work Reduced noise and distortion when honing thin-walled tubes Cooler action leading to increased accuracy with less material damage As with all ECM-based processes, ECH imparts no residual stresses in the work piece Capable of achieving surface finishes of 0.05μ and dimensional accuracies of ±0.012mm

102. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Limitations of electrochemical honing :  High capital cost Corrosive environment High preventive maintenance cost Non-conductive materials cannot be machined Requires disposal and filtering of electrolyte

103. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 Electro Chemical Horning CHM UNIT 2\ECHH ANIMATION.mp4 CHM UNIT 2\ECHH APPLICATION.mp4 VIDEO TUTORIALS

104. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electro-chemical grinding Principle: The term grinding refers to a machining process in which the material is removed from the surface of the work piece. And the term electrochemical resembles the mode of energy used for the machining process. Electrochemical grinding is a combination of electrochemical machining and grinding processes. The major difference between ECM and ECG is that In ECG grinding wheel is used instead of a cutting tool. Electrochemical grinding is done when there is a need to remove the material from the surface of the work piece. It is generally used when the mechanical or traditional grinding of a work piece takes a lot of effort due to the hardness of the work piece.

105. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Construction of Electrochemical Grinding

106. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Various parts involved in an electrochemical grinding setup are as follows: DC power supply Work Table and fixture Electrolyte tank Pump Filter Pressure Gauge and flow meter: Nozzle Sleeve Grinding wheel and Collecting tank

107. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES DC Power supply: A DC power supply with low voltage and high current is used for providing electrical energy to the setup. The voltage is kept low to avoid the generation of heat and for safety purposes as well. High current on the other hand promotes a faster process. Work Table and Fixture: For any machining process, it is important to provide a rigid base and restrict all the degrees of freedom of the work piece. The worktable provides rigid support to the work piece and fixtures are used to clamp the work piece. Electrolyte tank: An electrolyte tank is a reservoir in which the electrolyte is stored. An electrolyte is a conducting solution that plays an important role in electrochemical grinding. The first function of electrolyte is to complete the circuit by providing a conducting medium.

108. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Pump: A pump is used to carry the electrolyte from the electrolyte tank to the nozzle. The pump used is generally electrically driven. Filter: The electrolyte passes through a filter where all the micro impurities get filtered and pure Electrolyte is obtained . Pressure Gauge and flow meter: Pressure gauge and flow meter are safety equipment that shows pressure and flow of the electrolyte respectively. If any of these values become more than the safety limit the operator simply turns off the equipment. Nozzle: A nozzle is a device with decreasing cross-section area, which is used to direct the electrolyte to the correct position. The decreasing area helps in increasing the velocity of the electrolyte which in turn removes the material from the work piece.

109. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Sleeve: A sleeve is used to transfer electrical energy to the grinding wheel. Grinding wheel: The grinding wheel is the most important and unique part of the electrochemical grinding machine. It is connected to the negative terminal of the power supply and acts as the cathode. The grinding wheel is made of insulating materials such as diamond and aluminum oxide. The wheels rotate and increase the flow of the electrolyte.

110. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Collecting tank: A collecting tank is used to collect all the used electrolyte which is then disposed or reused as per the requirement. Electrochemical grinding Working In detail: The working principle of electrochemical grinding is When a metal surface is acted upon with an electrolyte under a high current, the metal surface gets oxidized to form an oxide layer (corrosive layer). This layer is removed with the action of a flowing electrolyte and rotating grinding wheel. Metal is removed in the form of an oxide layer to obtain an n surface finish.

111. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES The work piece to be machined is first kept on the worktable and then clamped using fixtures. The grinding wheel is placed at the required position. A gap is maintained between the work piece and the grinding wheel. This gap is generally 0.02mm. Now the power supply is switched on. The pump is then driven to supply the electrolyte to the required position. At first, the electrolyte passes through a filter where all the impurities are filtered. Then the electrolyte is passed through a pressure gauge where the operator checks for the correct pressure. Then electrolyte is passed through a flow meter where flow is checked by the operator. After passing through all the stages the electrolyte reaches the nozzle. Nozzle increases the velocity of the electrolyte and sprays it over the work piece.

112. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES As soon as the electrolyte comes in contact with the work piece and the grinding wheel, the circuit is completed which results in Oxidation of the metal surface. This forms a layer of oxide which is removed by the flow of electrolyte and the Abrasive particles in the grinding wheel. After the grinding is done, the flow is stopped and the power supply is switched off. The work piece is then unclamped and the remaining electrolyte is wiped out from the surface

113. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Applications of Electrochemical Grinding: ECG is used for grinding turbine blades. It is used in aerospace industries for grinding honeycomb. Also used for finishing hard surfaces. It is also used for creating sharp objects. It is also used for grinding fragile articles. Advantages of Electrochemical Grinding: The accuracy of electrochemical grinding is very high. As there is no contact of the tool with the work piece. A high tolerance can be obtained. The process does not leave any scratches on the surface of the work piece. The heat generated during the operation is very less.

114. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Disadvantages of Electrochemical Grinding: The metal removal rate is low, about 15mm/s Power consumption is very high as there is a need to drive the grinding wheel and pump as well. The initial cost of the equipment is also high. The production rate is low. Disposing of waste electrolytes becomes a problem, which makes the process non-eco-friendly. A large area is required for setup.

115. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 Electro Chemical Grinding CHM UNIT 2\Electrochemical Grinding Animation.mp4 CHM UNIT 2\Electrochemical Grinding Application.mp4 VIDEO TUTORIALS

116. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Electrochemical Deburring Principle: The word deburring means removal of burr from the source of any work piece to provide a smooth finished surface. The term electrochemical means the mode of energy used for deburring . Together electrochemical chemical deburring refers to a machining process in which burrs are removed using electrochemical energy.

117. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Need of Electrochemical Deburring : Removal of burrs is considered a serious problem in Many industries which deal with high accuracy. A burr can sometimes have sharp edges which may harm the operator or a worker hence it is important to remove it. It can cause cracks on the surface of the mating parts. As the pressure increases when the area of contact decreases. It also lessens the beauty of the work piece. Electrochemical deburring is also important for deburring hard metals.

118. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES CONSTRUCTION OF ELECTROCHEMICAL DEBURRING

119. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Components of Electrochemical Deburring : Supply tank Pumps Collection tank Reaction tank DC power supply Base Electrolyte and Tool

120. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Supply tank: The tank carrying electrolyte for its supply is called a supply tank. Pumps: There are two pumps P1 and P2. P1 is used to supply electrolytes to the reaction tank and P2 is used to supply the electrolyte from the collection tank to the supply tank. Collection tank: The tank which collects the filtered electrolyte is called a collection tank. Reaction tank: The area or the container carrying the tool-work piece and the electrolyte are called a reaction tank. The electrochemical reaction between the work piece and the tool takes place in the reaction tank. The tank is designed in such a way that there is a constant flow of electrolytes in the tank to carry the slag.

121. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES DC power supply: The voltage values of the DC power supply used in electrochemical deburring are low. But the current value is high, this promotes faster removal of metal from the surface of the work piece. Base: The base here is made of a conducting material that is used to keep the work piece stable. The base also connects the two work pieces electrically. DC supply is given to the base which connects the two work pieces. Electrolyte: The electrolyte is a solution of simple salt with water. It is generally a conductive solution of Sodium chloride and Sodium nitrate in water. For general applications Sodium, nitrate and water are mixed in the ratio of 2:1. The temperature of the electrolyte is maintained at 20 degree Celsius for best results. The mixture of several salts is used in the case of metals like titanium.

122. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Tool: The Tool is the most important component of an electrochemical deburring setup. For various purposes, various different tools are used. It consists of a conductometric which is insulated from the outside. The tool acts as the cathode which is connected to the negative terminal of the DC power supply. A gap of 0.5-1 mm should be maintained between the work piece and the tool. The basic procedure to design an electrochemical deburring tool is as follows. If the height of the work piece is 15mm and the height of the burr is 2mm. Then the tool has to be designed in such a way that its height should be more than 15 + 2 = 17mm. It should be insulated till 15mm so that the material removal takes place above 15mm which removes the burr.

123. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES The Electrochemical deburring works on the principle of reverse electroplating. According to Faraday’s law of electrolysis, the amount of metal displaced is directly proportional to the electric current. When a high current is applied to the electrochemical deburring setup the material removal takes from the work piece to the tool. The removal takes place from the gap between the tool and the work piece. The material does not get deposited on the tool, it flows away due to the flow of the electrolyte. In this way, a highly finished surface is obtained.

124. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES The work piece is kept on the base and the tool is positioned between the work pieces. The work piece is connected to the positive terminal of the DC power supply. And the tool is connected to the negative terminal of the DC power supply. The pump is activated and the flow of electrolytes is started. The electrolyte reaches the reaction tank by passing through a filter. Then the DC power supply is switched on and the reaction starts. Electron transfer takes place between the work pieces and the electrolyte. The electron transfer results in the removal of burrs from the surface of the work piece. The remaining electrolyte is made to flow through the filter (F2) into the collection tank. From the collection tank, the electrolyte is again supplied to the supply tank. And the process is repeated. Once the burr is removed the power supply is switched off and the work piece is removed.

125. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Advantages of Electrochemical Deburring : Electrochemical deburring is a highly accurate process which gives excellent surface finish. Heat generation is negligible. There are no thermal stresses developed in the workpiece . No wear of tool takes place. The efficiency is more. Faster process increases productivity of the plant. Quality products are manufactured.

126. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES Disadvantages of Electrochemical Deburring : High initial cost of the equipment. Different tool must be designed for different work pieces. Complex process. Highly skilled operator is required. Only the work pieces that conducts electricity can be machined. Applications of Electrochemical Deburring : It is used for deburring of gears. It is also used for removing sharp edges from highly precise equipment. Also be used for surface finishing of hard materials.

127. UNIT-II - CHEMICAL AND ELECTRO CHEMICAL ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 Electro Chemical Deburring CHM UNIT 2\Electrochemical Deburring Animation.mp4 CHM UNIT 2\ Deburring and edge radius of drilled holes on stainless steel plate using an Apex Model 2037M-DSS.mp4 VIDEO TUTORIALS

128. UNIVERSITY QUESTIONS ANALYSIS WITH THE UNIT TOPICS CME387 NTMP\UNIT-II University Questions analysis with the unit topics - II UNIT.docx

129. THANK YOU

130. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES

131. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES PRSENTATION OVERVIEW Principles, equipments, effect of process parameters, applications, advantages and limitations of Electric discharge machining Principles, equipments, effect of process parameters, applications, advantages and limitations of Wire electric discharge machining Principles, equipments, effect of process parameters, applications, advantages and limitations of Laser beam machining Principles, equipments, effect of process parameters, applications, advantages and limitations of Plasma arc machining Principles, equipments, effect of process parameters, applications, advantages and limitations of Electron beam machining Principles, equipments, effect of process parameters, applications, advantages and limitations of lon beam machining

132. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Electric discharge machining Principles: Electric discharge Machining (EDM) is a non traditional machining and electro thermal process in which material from the work piece is removed by using electrical discharges (sparks). It was first observed in 1770 by Joseph Priestley. In an EDM machine, the material is removed by rapidly recurring (repeating) discharges of current in between the electrodes. The electrodes are separated by a dielectric liquid and a high voltage is applied across them. It is used to machine those materials which are difficult to machine and have high strength temperature resistance. EDM can be used to machine only electrically conductive materials. Otherwise, it cannot be used. One of the electrodes is called a tool and the other is called as a work piece. Here the tool is connected to the negative terminal of the power supply and the work piece is connected to the positive terminal.

133. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Equipment

134. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Components of EDM Machining DC Power Generator Work piece Component Fixture Component Dielectric Fluid Pump Component Filter in a Machine Tool Holder Electrode Tool Tool Feed Control

135. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES DC Power Generator A DC power generator is the power supply for the EDM machining process. The negative terminal is connected to the tool while the positive terminal is connected to the part being machined (i.e. the work piece). Different types of power generators are used such as: Resistance-capacitance type (RC type) relaxation generator Rotary impulse type generator Electronic pulse generator Hybrid EDM generator Work piece Component A work piece is the part to be machined. It’s fixed in the dielectric container using a fixture and is connected to the positive terminal of the power supply.

136. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Fixture Component The fixture is used for holding the workpiece properly in the dielectric container. Dielectric Fluid The dielectric medium plays a key role in the functioning of the EDM Machining process. Usually, the dielectric fluid is hydrocarbon oil with low viscosity. The dielectric serves to separate the work piece and the electrode. During the EDM machining process, as the spark is produced, a surge of current takes place when the dielectric is ionized to form a column or path in the tool. After this happens, the dielectric medium ruptures when the gap between the tool and work gap is about 0.03 mm at about 7V.

137. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Functions of the Dielectric Fluid The dielectric fluid must remain electrically non-conductive to the time when the breakdown voltage is reached (i.e. its dielectric strength must be high) Once the breakdown voltage is attained, instantly, it should breakdown electrically. The dielectric fluid must deionize the spark gap (i.e. after the discharge has occurred, it must quench the spark rapidly) It carries away the metal particles that have been removed from the arc gap. The dielectric fluid acts as a good cooling medium.

138. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Desirable Properties of Dielectric Fluid High level of electrical strength for proper insulation High fire and flashpoints in order to prevent fire hazards Good wetting properties and low viscosity Chemically neutral in order to prevent corrosion Non-toxic in nature Low decomposition rate for a high life expectancy Low cost Good quenching properties Common Dielectric Fluids The most commonly used dielectrics are hydrocarbon and mineral oil, which have low viscosity. The different types of dielectric fluids are paraffin oil, lubricating oil, transformer oil, and deionized water. Distilled water is used when higher rates of material removal are required.

139. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Pump Component A pump is used as a passage for the dielectric fluid to flow from the base of the container to the tool and the part to be machined such that more MRR takes place. Filter in a Machine A filter removes any irregularities or dust particles that may be present in the dielectric medium. The filter is situated just above the pump. Tool Holder The tool holder serves to hold the tool properly. Electrode Tool Any electrical conducting material can work as an electrode tool in EDM machining. The shape of the tool is transferred in the cavity cut during machining in EDM machining processes. Thus the shape and accuracy of the machined surface are fully dependent on the electrode’s shape and accuracy. Erosion takes place on both the tool and the work piece during cutting.

140. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Tool Feed Control During the course of the EDM machining process, the material is removed from the part to be machined and the electrode tool. This increases the gap that is between the work and the tool. The tool must be fed properly using a device that controls the feed in order to maintain a constant gap and arcing voltage to prevent the occurrence of a short circuit.

141. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Working Principle In this process, work piece should be well electric conductive. Only electric conductive material can be machined by this method. The working of EDM is as follow. First both work piece and tool are submerged into dielectric fluid. The dielectric fluid help to control the arc discharge. This also removes suspended particles of work piece material and tool from the work cavity. A servomechanism is used which maintains a very small gap between the work piece and the tool. This gap is desirable for proper arc formation. It is about the thickness of human hair. The tool is made as the opposite shape of work piece. A high frequency current supplied to electrode, which produces a spark between the tool and work piece. This spark generates high in work cavity.

142. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES The metal removed from the work piece due to erosion and evaporate ion. The chips or suspended particle between tool and work piece should be removed to prevent them to form bridge that causes short circuit. This is done by continuous supply of dielectric fluid. The EDM produce a cavity slightly larger than the electrode because of overcut

143. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Process parameters Electric discharge machining Pulse on time Current and voltage Material removal rate Flushing Pressure Tool shape Cutting Speed Duty factor Electrode rotations

144. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Applications of EDM Machining It is used to make holes with sizes that are less than 0.1 mm. It is utilized in die sinking or die manufacturing, fixtures, and gauging. It is used to make holes in air brakes or pneumatic brakes. It is used in press tools and extrusion dies. It is utilized in die molds for plastics. It is applied in die-casting dies and mold inserts. EDM machining is utilized in the repair of worn dies for hot and cold forging and re-machining. It is used to make forging dies like connecting rod forging dies etc. EDM machining is used in Sintering dies. It is used in calibrating tools.

145. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Advantages of EDM Machining It can be used even in the heat-treated condition, and for any hard material. Complicated shapes made on the tool are able to be reproduced. A high accuracy can be achieved; about 0.005 mm. Economically, a good surface finish can be achieved; up to 0.2 microns. Machining time is not more than the conventional machining process. Mechanical stresses are not developed in this process (the tool and work do not have contact). The tool life is longer due to proper lubrication and cooling. Hard surfaces that are also resistant to erosion can be developed easily on the dies. It can be applied to any material that is electrically conductive.

146. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Disadvantages of EDM Machining Excessive wear of the tool Reproduction of the sharp corner is not possible Change in metallurgical properties of materials due to the development of high heat. The material to be machined must be an electrical conductor Requirement for redressing of a tool for deep holes Over-cut is formed Expert machinists are hard to find

147. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 Electric discharge machining EDM\EDM ANIMATION.mp4 VIDEO TUTORIALS

148. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Wire electric discharge machining Principle: Wire EDM machining (Electrical Discharge Machining) is an electro thermal production process where a thin single strand metal wire, along with de- ionised water (used to conduct electricity) allows the wire to cut through metal by the use of heat from electrical sparks, while preventing rust .

149. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Equipment

150. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES 1. CNC Tools The CNC tools control the entire operation of the Wire EDM machining process. Controlling the entire operations include being in control of the sequencing of the wire path and being able to manage the cutting process automatically. 2. Power Supply The power supply unit is the component that delivers pulses (from 100V to 300V) to the wire electrode and the work piece . Furthermore, it controls the frequency and strength of the electrical charges that pass through the wire electrode to interact with the work piece. 3. Wire The wire serves as the electrode to create the electrical discharge. The shape and thickness of the work piece directly influence the wire’s diameter. Typically, one can use wires with diameters ranging from 0.05 to 0.25mm. The main types of wires used include

151. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Brass Wires Brass is the most common EDM wire material because of its excellent conductive properties. It is an alloy of copper and zinc, and the higher the zinc content, the faster the wire cuts. However, there should be a balance because when the zinc content is over 40%, this decreases the corrosion rate of the brass wire . Zinc coated Wires As the name implies, you obtain it by applying a coating of pure zinc or zinc oxide on the wire surface. Manufacturers use zinc-coated wires because it improves the machining speed. 4. Dielectric Medium The wire-cut EDM process must be carried out in a tank filled with dielectric fluid. This liquid prevents the tiny particles from the work piece from getting attached to the wire electrode. The most common medium is deionized water which cools the process and gives the work piece a good surface finish.

152. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES 5. Electrodes The electrodes in the machine are the wire (cathode) and the work piece (anode). The servo motor controls the wire electrode, ensuring it does not come in contact with the work piece at any point during the wire EDM cutting process.

153. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Working Principle of WEDM Machining Figure shows the working principle of wire cut electrical discharge machining. In this type of machining the wire is used as the form of tool electrode. It is very thin wire of diameter 0.05mm to 0.25mm. The wire is connected to the negative terminal and work piece is connected to the positive terminal of the DC power supply same as the working of electro discharge machining. The dielectric is calculated to the storage of tank at high pressure pump. The spark can be generated due to current flowing from a wire and the process is done.

154. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Controlling Parameters of WEDM: Following are the controlling parameters of wire-cut electrical discharge machining are as follows, Discharge Current:  The discharge current in between 20 to 30 amperes. Duration of pulse:  The high duration of pulse goes produce more removal rate and low duration of pulse produce low removal rate. Frequency of pulse:  The frequency of pulse in between 50KHz to 1MHz. Wire Diameter:  The diameter of thin wire is 0.05mm to 0.25mm. Wire Speed:  The speed of wire is about 5 to 200 mm/sec.

155. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Advantages of WEDM: Following are the advantages of wire-cut electrical discharge machining are as follows, It gives high accuracy. There is no need of storage of tool is required. There is low operating skill is required. Smooth complex surfaces can be possible to machining. A good surface finish can be obtained. Disadvantages of WEDM: Wire EDM is not suitable for plastics, composites, and natural materials. It only functions on conductive materials. Cuts relatively slowly. ... Consumable costs are high, as the wire cannot be reused

156. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Applications of WEDM: The following are the applications of wire-cut electrical discharge machining are as follows, It works for production of prototypes. It is used for making of stamping dies, drawings, extrusion tools, etc. IT is used for making blanking dies, plastic molding dies, stamping dies, etc. It is used for gauges, cam discs. It is used to machining larger parts that need to hold accurate tolerances. It is also used for making of small series of spare parts.

157. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Differences Between EDM Wire Cutting And Conventional EDM The wire-cut EDM process is an improvement on conventional EDM. Their mode of operation is similar. However, they have significant differences . Below is a few difference between both machining process . Electrode As stated above, the electrode used in wire EDM cutting is a thin heated wire. In contrast, conventional EDM uses highly conductive metals like graphite or copper electrodes to produce electrical charges. The electrodes are in different shapes and sizes, which affects their smoothness. For example, a round electrode produces the smoothest surface. Then a square, triangle, and diamond. When the electrode is inserted into the work piece , it forms a mold leaving a ‘negative’ impression of its shape.

158. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES Speed of Machining The electrodes of conventional EDM must come in different shapes. As a result, manufacturers must create and shape them before the machining process, and this takes time. In contrast, the wire EDM machine is ready to use as soon as the wire is in position. This makes it appropriate for applications that must need to be completed quickly. Accuracy Wire EDM machining makes use of wire as the electrode. As a result, they have better accuracy than conventional EDM. For example, the wire electrode allows them to cut at a thickness of about 0.004inches. Due to their accuracy, they become better suited for machining parts with complex shapes and designs, unlike the conventional EDM, which is more suitable for more rigid cuts.

159. UNIT-III THERMO-ELECTRIC ENERGY BASED PROCESSES S.NO PROCESS Animation Video Real time Application 1 Wire Electric discharge machining ..\..\NTMP PPT PRESENTATION-19.07.2023 - Copy\New folder\EDM UNIT III\WIRE EDM - ANIMATED VIDEO 9 - ANUNIVERSE 22.mp4 VIDEO TUTORIALS