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Grinding
2D cutting process
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs. 4
Singh/Melkote/Colton
Why Nontraditional Machining?
Situations where traditional machining processes are
unsatisfactory or uneconomical:
Workpiece material is too hard, strong, or tough.
Workpiece is too flexible to resist cutting forces or too difficult
to clamp.
Part shape is very complex with internal or external profiles
or small holes.
Requirements for surface finish and tolerances are very high.
Temperature rise or residual stresses are undesirable or
unacceptable.
3
2 D
V=
3 2
D 2 dh
2
V= (dh) 3 / 2
3
MRR = V Z f
where V = volume removed by a single grain
f = frequency of operation
Z = number of particles impacting per cycle
= efficiency
Capability
With fine abrasives, tolerance of 0.0125 mm or better can be held.
Ra varies between 0.2 1.6 m.
Ceramic
Ceramic Part
Source: http://www.waterjets.org/
Dimensional Tolerances
Typical range 2 - 5 m
Surface Finish
Typical Ra values vary from 0.3 - 2.3 m
Limitations
Expensive process
Flaring can become large
Not suitable for mass production because of high
maintenance requirements
MRR = C I
where, MRR=mm3/min, I=current in amperes,
=current efficiency, which typically ranges from 90-100%,
C is a material constant in mm3/Amin.
DC VOLTAGE
h = height of crater, mm
D = diameter of crater, mm
K1, K2 = constants depending
h on electrode materials
D and dielectric
n = constant depending on
WORKPIECE work tool combination
(+) The crater volume from geometry,
3
Scheme of Crater Formation Vc = h D 2 + h 2
6 4
MRR = Vc f 3 2 2 3n
where f = frequency of operation and = efficiency Vc = K1 K 2 + K1 W
6 4
MRR = V f h b
where, b = d w + 2s
MRR = mm3/min
Vf = feed rate of wire into the
workpiece in mm/min
h = workpiece thickness or dw = wire diameter in mm
height in mm s = gap between wire and workpiece in mm
Assumptions:
EDM process:
40
Wire diameter: dw=0.2 mm
Gap: s=0.1 mm
Conventional machining: 10
Negative of the part has to be 12.5
removed
12.5 20 20 20 12.5
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs. 39
Singh/Melkote/Colton
Example
Solution:
- EDM process
VEDM = lc*(dw+2s)*t = 1440 mm3
- Conventional machining
VM= Vtotal Vpart = 99500 mm3
- Power comparison
u M VM u EDM VEDM
We will choose machining if
tM t EDM
lets assume tEDM=tM
u EDM VEDM
then machining if
u M VM
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs. 40
Singh/Melkote/Colton
Reverse micro-EDM
Fabrication of high aspect ratio micro-electrode arrays
Electron Ground
State Photon
Nucleus
Orbits
sem i in f in ite
2 q ( x x ') 2 + ( y y ') 2 + ( z z ') 2
dT '( x, y, z, t ) = 3
ex p [ ]
4 a ( t t ')
C (4 a ( t t ')) 2
t '= t
2 Pdt ' ( x vt ' x ') 2 + ( y y ') 2 + ( z z ') 2
dT '( x, y, z, t ) =
t '= 0
3
ex p [
4 a ( t t ')
]
C (4 a ( t t ')) 2
2dt ' 2P 2( x '2 + y '2 ) ( X x ')2 + (Y y ')2 + ( Z z ')2
dT ' = 3
2
exp[
2
]dx ' dy 'exp[
4a(t t ')
]
C (4 a(t t ')) 2
y 2 x '2 y + 2 x '2
[ erf ( ) + erf ( )]
2 a ( t t ') 2 a ( t t ')
Rectangular
2 q d t ' z2
T T0 = 3
exp[ ]
4 a ( t t ')
4 b l C ( 4 a ( t t ') ) 2
l b
( ( x v t ') x ') 2 ( y y ') 2
l e x p [
4 a ( t t ')
] d x '
b
e x p [
4 a ( t t ')
]d y '
Dimensional Tolerance
Typical ranges from 0.015 - 0.125 mm
Surface Finish
Ra varies between 0.4 6.3 m.
Limitations
Localized thermal stresses, heat affected zones, recast layer and
thermal distribution in thin parts
Difficulty of material processing depends on how close materials
boiling and melting points are
Hole wall geometry can be irregular
The cutting of flammable materials is usually inert gas assisted