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MP PPT Final
MP PPT Final
machining process
NONTRADITIONAL
MACHINING PROCESS
BY:
Krishna jadhav
Pratik gode
Sandesh thoke
Sushmita sarnaik
(134110027)
(134110028)
(134110029)
(134110030)
Nontraditional Processes
Defined
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 tool in the conventional sense
NONTRADITIONAL MACHINING
AND THERMAL CUTTING
PROCESSES
I.
II.
III.
IV.
Chemical machining
Electrochemical Machining Processes
Mechanical Energy Processes
Thermal energy processes
Classification of Nontraditional
Processes by Type of Energy Used
Chemical milling
Chemical blanking
Chemical engraving
Photochemical machining
CHM history
Diagram of CHM
Maskants
Masking material which is called maskant
is used to protect work piece surface from
chemical etchant.
Polymer or rubberbased materials are
generally used for masking procedure
The selected maskant material should
have following properties
Masking material
Nickel Polymer
Neoprene
Magnesium
Polymer
Polymer
Titanium
Polymer
Silicon
Polymer
Etchants
Etchants are the most influential factor
in the chemical machining of any
material.
Various etchant are available due to
workpiece material.
The best possible etchant should have
properties as follow
Concentrations, etching
temperatures for various
materials in chemical machining
Material
Chemical
etchant
Concentrati
on
Etching
Etch rate
Temperatu (mm/min)
re (C)
Aluminium
and alloys
FeCl3
12-18B
(*)
49
0.0130.025
Steel
FeCl3
42 B
54
0.025
Nickel
FeCl3
42 B
49
0.13-0.38
% 12-15
32-49
1.0
Magnesium HNO3
Silicon
HNO3
---
38-49
Very slow
Common specifications of
CHM
Maskant thickness is generally kept
about 0.2 mm.
Etching depth is up to 10 mm is
applied.
Accuracy of 0.01to 0.015 mm can be
obtained.
MRR for common materials is about
140 to 160 cm3/min.
Workpiece thickness is less than 10
mm can be suitably machined.
Applications
Widely used to produce microcomponents.
In industries like MEMS and semiconductor
industries.
Complex parts and integrated circuits.
Electrochemical Machining
(ECM)
Material removal by anodic dissolution,
using electrode (tool) in close proximity to
the work but separated by a rapidly
flowing electrolyte.
Applications of ECM
Can be perform on all conducting materials.
Machining of heat-resisting alloys, cavities
in forging
Multiple hole drilling.
It can be used for DIE-SINKING operation.
Drilling a jet engine turbine blade.
Applications of ECG
Any material which is electrically
conductive.
Hardened steel, cemented carbides &
similar materials.
Mainly applied to resharpening tools which
are difficult to grind.
Working of ECD
ECD removes metal by non-contact,
Electrochemical action.
Method is fast, highly selective & safe.
Uses a low voltage, DC current & non-toxic
electrolytes.
Material is remove in fine metal hydroxide
particles which can be further filtered &
removed .
Electrochemical machining
Electrochemical grinding
Electrochemical debburing
Ultrasonic Machining
(USM)
Abrasives contained in a slurry are driven at high
velocity against work by a tool vibrating at low
amplitude and high frequency
Tool oscillation is perpendicular to work surface
Tool is fed slowly into work
Shape of tool is formed in part
USM Applications
Hard, brittle work materials such as
ceramics, glass, and carbides.
Also successful on certain metals, such as
stainless steel and titanium.
Shapes include non-round holes, holes
along a curved axis.
Cutting of industrial diamonds.
WJC Applications
Usually automated by CNC or industrial robots to
manipulate nozzle along desired trajectory.
Used to cut narrow slits in flat stock such as
plastic, textiles, composites, floor tile, carpet,
leather, and cardboard.
Not suitable for brittle materials (e.g., glass).
WJC advantages: no crushing or burning of work
surface, minimum material loss, no
environmental pollution, and ease of automation.
Application of AJM
Usually performed manually by
operator who directs nozzle
Normally used as a finishing process
rather than cutting process
Applications: deburring, trimming and
deflashing, cleaning, and polishing
Work materials: thin flat stock of hard,
brittle materials (e.g., glass, silicon,
mica, ceramics)
Ultrasonic Processes
Electric Discharge
Processes
Metal removal by a series of discrete
electrical discharges (sparks) causing
localized temperatures high enough to
melt or vaporize the metal
Can be used only on electrically
conducting work materials
Two main processes:
1. Electric discharge machining
2. Wire electric discharge machining
EDM Applications
Tooling for many mechanical processes:
molds for plastic injection molding,
extrusion dies, wire drawing dies, forging
and heading dies, and sheet metal
stamping dies
Production parts: delicate parts not rigid
enough to withstand conventional cutting
forces, hole drilling where hole axis is at
an acute angle to surface, and machining
of hard and exotic metals
Wire EDM
Special form of EDM that uses small
diameter wire as electrode to cut a narrow
kerf in work
Manufacturers of machine
NAME OF MACHINE MANUFACTURERS
LOCATION
Ultrasonic machine
Jaipur.
Ultrasonic machine
Johnson plastosonic
Pvt.Ltd
Pune.
K & K engineers
Delhi.
R. K. Transonic Pvt.
Ltd
Noida.
Kp Tech Machine
Pvt. Ltd
Ahmedabad.
Manufacturers of machine
NAME OF
MACHINE
MANUFACTURERS
LOCATION
Electrochemical
machine
Janetta Enterprise.
Bharuch, Gujrat.
Electrochemical
grinding
Consort India.
Noida, Uttar
pradesh
Electrical discharge
machine
USHA Tech.
New Delhi.
Electron beam
machine
Gandhinagar,
Gujrat.
Mysore tech
Tumkar,karnataka.
Jiangsu, China