CH-

01NON-TRADITI
ONALMACHI
NING
PROCESS

Cont
ent
s:-
1.I
ntr
oduct
ion:
Unconv enti
onalmachini
ngpr
ocess–Need,
Classi
fi
cat
ion,
Bri
efOv
erv
iewof
al
ltechniques(Mer
itsanddemeri
ts)
.

2.
Mechani
cal
Ener
gyBasedPr
ocesses:

Abr
asi
veJetMachi
ning(
AJM)
,Wat
erJetMachi
ning(
WJM)
,

Ul
tr
asoni
cMachi
ning(
USM)–Wor
kingpr
inci
ples,
Equi
pmentused,

Pr
ocesspar
amet
ers,
Appl
i
cat
ions.

3.El
ectr
icalEner
gyBasedPr ocess:El
ectr
icDischargeMachini
ng(EDM)–
Worki
ngPr i
ncipl
es,
Equipment ,
Processparameters,El
ect
rode/Tool ,
Power
Cir
cui
ts.Toolwear,
Diel
ectr
ic,Flushi
ng,WirecutEDM andApplicat
ions.

4.
Chemi
cal
AndEl
ect
roChemi
cal
Ener
gyBasedPr
ocess:

Chemi
cal
Machi
ning(
CHM)–Et
chant
s,Maskant(Techni
quesof

Appl
yi
ngmaskant
s)Pr
ocesspar
amet
ers,
Appl
i
cat
ions.

Pr
inci
plesofECM –Equi
pment
s,El
ect
ri
cal
cir
cui
t,Pr
ocess

Par
amet
ersandAppl
i
cat
ions.

5.Ther
mal
Ener
gyBasedPr
ocess:

LaserBeam Machi
ning(
LBM),
PlasmaAr
cMachi
ning(
PAM)
,

El
ect
ronBeam Machi
ning(
EBM)–Pr
inci
ples,
Equi
pment
,

Ty
pes,
Beam cont
rol
techni
quesandAppl
i
cat
ions.

By
:-SUMI
TGANGULY
1.
INTRODUCTI
ON:
-
Conv
ent
ional
Machi
ningPr
ocess:
-

Convent
ionalmachini
ngpr ocessesmost
lyr
emovemateri
ali
nthefor
m ofchipsbyapply
ing
for
ceont heworkmat er
ialwithawedgeshapecut
ti
ngtoolt
hati
shardert
hantheworkpi
ece
undermachinecondit
ion.

Fi
g:-01

Nont
radi
ti
onal
machi
ningpr
ocess:
-

Nont radi
tionalmachini
ngpr ocess:-
Nont r
adit
ionalmachiningpr ocessdef
inedasagroupof
processt hatremov eexcessmat eri
albyv ar
ioust echni
quesi nvolvi
ngmechani
cal
,ther
mal
,elect
ri
calorchemi calener
gyorcombi nat
ionoft hi
senergies.Butdonotuseasharpcutti
ng
toolasitneedt obeusedfortradi
tionalmachi
ningprocess.

Needofnon-
tr
adi
ti
onal
machi
ningpr
ocess:
-

1.Tomachi net
heexot
icmat
eri
alst
hosewer
edi
ff
icul
ttomachi
nebyconv
ent
ionalmachi
ning
processes.

2.
To ful
fi
llthe r
equi
rement
s ofnew age l
i
ke i
nnov
ati
ve desi
gn,t
ight
ert
oler
ances and
micr
omachini
ng.

3.Toov
ercomedi
ff
icul
tyt
omachi
net
hemat
eri
al.

4.Tof
ull
fi
ll
ther
equi
rementofl
owst
ressesgr
indi
ng.

5.Toobt
aincompl
exshapes.

6.Dr
il
li
ngdeephol
ewi
thsmal
lhol
edi
amet
er.

7.Machi
ningofcomposi
te.

By
:-SUMI
TGANGULY
Compar
isonbet
weent
radi
ti
onal
andnont
radi
ti
onal
machi
ningpr
ocess:
-

Tr
adi
ti
onal
Process Nont
radi
ti
onal
process

1.
Inthi
sprocessf
ormachi
ningt
hetooland 1.I
nthi
sprocessf
ormachi
ningnoneedf
or
workmustbeincont
actwi
theachother
. cont
actbet
weentool
andwor k.

2.
Machi
nabi
li
tydependsonhar
dnessoft
he 2.Machi
nabi
li
tydependsonprocess
workmat
eri
al. par
ametersl
i
kecurrent,
vol
tage,t
emper
atur
e
,r
eact
ion.
3.Excesstool weari
nthi
sprocessbecauseof
di
r ectcontactwit
hworkpi
ece. 3.Ascomparedtotradi
ti
onalpr
ocessl
esstool
wearbecausenocontactwit
hwork.
4.Simpleshapescanbemachi ndeasil
y.
4.Complexshapescanbemachiedeasi
ly
.
5.MRRi shigh.
5.MRRislow.

Cl
assi
fi
cat
ionsofnont
radi
ti
onal
machi
ningpr
ocess:
-

Classi
fi
cati
onisdoneont
hebasi
soft
het
ypeofener
gyusedi
nwor
kingzonef
ormat
eri
al
removalacti
on.

1.
Mechani
cal
Ener
gy:
-

a)Abr
asi
vej
etmachi
ning.(
AJM)

b)Wat
erj
etmachi
ning.
(WJM)

c)Ul
tr
asoni
cmachi
ning.(USM)

2.Ther
moel
ect
ri
cal
ener
gy:
-

a)El
ect
ri
cdi
schar
gemachi
ning.
(EDM)

b)Wi
recutEDM (
WEDM)

c)Laserbeam machi
ning.
(LBM)

d)
Plasmaar
cmachi
ning.
(PAM)

e)El
ect
ronbeam machi
ning.
(EBM)

3.El
ect
rochemi
cal
ener
gy:
-

a)El
ect
rochemi
cal
machi
ning.
(ECM)

By
:-SUMI
TGANGULY
4.Chemi
cal
ener
gy:
-

a)Chemi
cal
machi
ning.

2)Mechani
cal
ener
gybasedpr
ocess:
-
a)Abr
asi
vej
etmachi
ning(
AJM)
:-

Inthi
smachiningprocesst hepr ocessofmater
ialr
emov i
ngtakespl
aceduet oimpingementof
abrasi
veparti
cleswi t
hhi ghv elocit
yont hewor ksurf
ace, duetot hislocal
izedimpactof
abrasi
ve par
ti
cles the Wor kpiece mater
ialgetsfract
ure,due to bri
tt
lef r
actur
e which i
s
responsi
blef
orremov alofmat erial
.

Fi
g:-
02

Wor
king:
-

At ypicalset -
upofabr asiv ej etmachi ningisshowni nFi g.
.Theabr asi
veparti
clesareheldi nthe
hoppert hroughwhi chitisf edI ntothemi xi
ngchamber .Aregulat
orcontrol
sthef l
owofabr asi
ve
particles.Gasathi ghpr essur ei ssuppl
iedtothemi xingchambert hr
oughapipel i
ne.Apr essure
gauge andar egulat
ori si ncor poratedinthepipelinet ocontrolthegasflowandi tspressur e.
Themi xingchamber ,theabr asivepar t
icl
esisv i
br at edbyt hedev i
ce andt heampl i
tudeof
thesev ibrati
onscont r
olst hef l
owofabr asi
veparticles.Theseabr asi
veparti
clestravelthrough
thehose andent erintot henozzl e.Thecont rolvalve andpr essuregaugecont r
olsthef l
owof
abrasi vepar t
icl
es.Thisout goinghi ghspeedst eam t hatcomesoutoft henozzl eisknownas
abrasi vej et
.Whensuchj eti mpingesont heworkpi ece,theer osioncausedbyt hei
ri mpact
enabl est heremov alofmet al .Lbsaa

By
:-SUMI
TGANGULY
Pr
ocesspar
amet
ers:
-

1.Abr
asi
vemater
ialusedi
sAlumi
nium oxi
deorsi
l
iconcar
bideorsodi
um bi
car
bonat
ethegr
ain
si
zeshoul
dbe10t o50micromet
re.

2.Pr
essur
eofgas2-
10at
m andgasusedi
sai
r,ni
tr
ogen,
CO2.

3.Thenozzl
emustbeofhar
dmat
eri
all
i
ket
ungst
encar
bide.

Appl
i
cat
ion:
-

1.Fi
nddr
il
li
ngandcut
ti
ngt
hinsect
ionofmet
al.

2.Thepr
ocessi
smadet
heusedf
orsur
faceet
chi
ng.

,
3.Fast
ingandabr
adi
ngofgl
assar
ti
cles.

4.Machi
ningofbr
it
tl
emat
eri
alsl
i
kegl
ass,
cer
ami
c,r
efr
act
ori
eset
c.

b)Wat
erj
etmachi
ning(
WJM)
:-

Wat erJetMachi ni
ng(WJM)alsocal l
edwat erj
etcutting,
isanon-traditi
onalmachini
ngpr ocess
i
n whi ch high-vel
oci
tyjetofwat erisused t or emov emat eri
alsf rom thesur f
aceoft he
workpiece.WJM canbeusedt ocutsof t
ermaterial
sl i
keplasti
c,r
ubberorwood.I nor dertocut
hardermat erial
slikemetal
sorgr anit
e,anabr asiv
emat eri
alismi xedi nthewater.Whenan
abrasivemat eri
ali
susedinthewat erforthemachiningprocessthani tiscall
edAbrasiveWater
JetMachi ni
ng( AWJM) .

Fi
g:-
03

WORKI
NG:
-

Fi
rstwat
eri
sfi
l
ledi
nwat
err
eser
voi
r.I
tpr
ovi
deswat
erf
orcut
ti
ngoper
ati
on.

By
:-SUMI
TGANGULY
Apumpsuckswat
erf
rom wat
err
eser
voi
randsendi
ttoi
ntensi
fi
er.

I
ntensi
fi
eri
ncreasesthewaterpr
essur
efr
om 4bart
o4000bar
s.I
tsendswat
ert
oaccumul
ator
whichst
oresomepr essur
izewat
er.

Thishi
ghpressur
ewat ernow sendsthroughtubi
ngsy
stem t
o nozzl
e.Thewat
erpasses
thr
oughfl
owregul
atorv
alv
ewhichregul
atethefl
ow.

Now t
hishi
ghpressurewat
erent
ersi
ntonozzl
e.Nozzl
econv
ert
ssomepr
essur
eener
gyof
wat
erint
oki
net
icenergy.

Ahi
ghspeedhi
ghpr
essur
izewat
erj
eti
sav
ail
abl
eatnozzl
eexi
t.

Thi
swaterj
etsendt
ostri
keatwor
ksur
face.I
ter
odemet
alf
rom t
hecont
actsur
face.Thus
metal
remov
alt
akepl
ace.

APPLI
CATI
ON:

1.
Iti
susedi
naer
ospacei
ndust
ri
es.

2.
Abr
asi
vej
etmachi
ningi
susedt
ocuthar
dmet
all
i
kest
ainl
essst
eel
,ti
tani
um,
Inconel
etc.

&I
tisusedt
omachi
ningorcut
ti
ngr
einf
orcedpl
ast
ic.

3.
Uset
ocutst
onewhi
chr
educedusti
nenv
ironment
.

4.
Usedt
omachi
ningPCB.

C)Ul
tr
asoni
cmachi
ning(USM)
:-

Bri
ttl
ef ractur
eofwor kpiecemat eri
alduet o ul
tr
asonicimpactofabrasiv
egr ain.
Theterm
ul
trasonicr ef
erstowav esofhi ghf r
equency,gener
allyabovetheheari
ngr angeofnor mal
humanear ,i.
e.generall
yabov e20kHz.I nthisprocess,acutti
ngtoolisgivesmechanical
vi
brati
onsot hati
toscill
at esaxiall
yathi ghfr
equencyinabrasi
veslur
ryagai
nstthestati
onary
workplece.Thetoolhast hesameshapeast heshapet obemachined.Thei mpactoft he
abr
asivecauset hemet alr emov alfrom theworkpiece.Thismethod i
sgener al
lyused to
machinehar dandbrit
tlemat erial
s.

By
:-SUMI
TGANGULY
 Fi
g:-04

Wor
king:
-

Inthisprocessasof tductil
emat eri
altoolisal
lowedtovibrateatveryhighfr
equencyandata
constantflow ofabr asi
vesluryi
smai ntainedinthegapbet weent oolandworkpiece.Dueto
vibr
atingtool,thei mpactoft oolwhichar ecomingont heabr asivegrai
naregoi ngtobe
tr
ansf er
redt othewor kpi
ecemat eri
al.Thisvibr
atingi
mpactofabr asivegrai
nont hework
surfaceisresponsibleforbri
tt
lefr
actureofthewor kmat
erial.Theconstantf
lowisalsohelpi
ng
i
nr emov aloffr
acturedwor kmateri
al.

Appl
i
cat
ion:
-

1.Cut
ti
ngi
nter
nal
thr
eadsi
ncer
ami
candgl
assesbyr
otat
ingt
hewor
kpi
ece

2.Cut
ti
ngofi
ndust
ri
aldi
amonds.

3.Manuf
act
uri
ngofwi
redr
awi
ng,
punchi
ngandbl
anki
ngdi
es.

4.Coi
ningofgl
assandcer
ami
cs.

2)Ther
moel
ect
ri
cal
ener
gybasedpr
ocess:
-
a)El
ect
ri
cdi
schar
gemachi
ning(
EDM)
:-

EDM worksonpr i
nci
plethatheatenergyisgenerat
edbyaspar kisusedtoremovemat er
ial
fr
om theworkpi
ece.Al
soknownasspar kerosi
on.Itisthepr
ocessofmater
ialr
emov albased
on t
he pri
ncipl
e oferosi
on ofmet albyan i nt
errupt
ed el
ect
ri
c Sparkdi
scharge between
el
ect
rodetool(cat
hode)andwor kpi
ece(anode)
.

Fi
g:-
05

By
:-SUMI
TGANGULY
Wor
king:
-

Inthi
spr ocessbotht het oolandwor kpi
eceareimmer sedindielect
r i
cf l
uid.Thewor kpi
eceis
connectedt opositi
vet erminalandt oolisconnectedt onegativet erminal.Thetoolendi s
broughtnearthewor kpi
ecebyaser vomot or
.Asmallgapofabout0. 1t o0.5 mm i smaintai
ned
i
n between t ooland Wor kpiece.When a di f
fer
ence ofpot entiali s appli
ed bet
ween t wo
conductorsthedielectr
icf l
uidwi l
lionise.Thepotenti
aldif
ferencer eachesathi gh,Sparkwil
l
occur.
Ther epeti
ti
veSpar kreleaseit
sener gyi
ntheform ofheatandmel tsthemet al
.

Di
elect
ri
cfl
uid:
-

1.I
tact
sasaconduct
ingmedi
um wheni
oni
sedandconv
eyst
hespar
k.

2.I
tfl
ushesoutt
heer
odedpar
ti
clesf
rom t
hewor
kinggap.

3.I
tcool
stheSpar
kregi
onandkeepst
heel
ect
rodeandwor
kpi
ececool
.

Char
act
eri
sti
csofdi
-el
ect
ri
cfl
uid:
-

1.
Itshoul
dhav
ehi
ghdi
elect
ri
cst
rengt
hsoi
tdoesnotbr
eakdownel
ect
ri
cal
l
y.

2.Shoul
dhav
elowv
iscosi
ty.

3.I
tshoul
dhav
econt
rol
l
edl
evel
oft
oxi
cit
y.

4.I
tshoul
dhav
ehi
ghf
lui
dit
y.

5.I
tshoul
dbecheapandeasi
l
yav
ail
abl
e.

Ex:
-Ker
oseneoi
l
,di
sti
l
ledwat
er,
miner
aloi
let
c.

Pr
ocesspar
amet
ers:
-

1.Spar
kgap:-keepi
ngthesparkgapatconst
antv
alue.I
fthegapi
ncr
easesMRRget
ssl
ower
andpoorsur
facefi
nishi
sobt
ained.

2.Suppl
yvol
tageandcur
rent
:-i
trangesbet
ween0.
5At
o400Aand50Vt
o400VDCsuppl
y.

3.Resist
anceandcapacit
ance:
-Increaseincapaci
tancewi l
lresul
tini
ncreaseofmat
eri
al
removalr
ateanddecr
easei
nresi
stancewill
resul
tini
ncreaseofmetalr
emovalr
ate.

4.Pulsedur
ati
on:-Thepul
sedur
ati
onr anges f
rom 2to2000microsecond.Decr
easei
npul
se
durat
ionwil
lresul
tinhi
ght
oolwear
.Increasei
npulsedur
ati
onresul
tinlowerMRR.

5.Spar
kfr
equency
:-I
tisabout1000spar
k/sec.Thei
ncr
easei
nspar
kfr
equencyr
esul
tin

By
:-SUMI
TGANGULY
i
mpr
ovedsur
facef
ini
sh.

Appl
i
cat
ionofEDM:
-

1.I
tisextensiv
elyusedformachi
ningexot
icmat
eri
alsusedi
naer
ospacei
ndust
ry,r
efr
act
ory
mater
ial
s,hardcarbi
deandHar
denSt eel
.

2.Fordr
il
li
ngmi
crohol
esi
nfuel
inj
ect
ornozzl
es.

3.I
ntool
maki
ng.exampl
e:-Pr
esst
ool
,Ext
rusi
ondi
es,
for
gingdi
esandmoul
ds.

4.Forpr
oduci
ngi
ntr
icat
eandi
rr
egul
arshapedpr
ofi
l
e.

b)Wi
recutEDM (
WEDM)
:-

El
ect
ri
cdi
schargewi
recut
tingisaprocessofproduci
ngcomplex2Dand3Dshapesusi
nga
si
mplewi
reer
odingt
hemateri
alfr
om anelect
ri
cal
l
yconduct
ingmater
ial
.

Theelectr
odewireistypi
call
ymadeofcopperorbrasswit
ha0. 05to0.25mm diameterwhi
chi
s
woundbet weent hetwospool s.Thewiremov espastthewor kpieceatfastr ateupto3
m/minute.TheSpar kisst r
uctbetweenthemov i
ngelectr
odewi r
eandWor kpiece,t
her
eby
removingthemat er
ial
.Thedi el
ect
ri
cmostcommonl yusedi sadeionisedwaterappli
edasa
l
ocali
sedstream r
atherthansubmergi
ngthewhol
ewor kpi
ece.

Fi
g:-
06

By
:-SUMI
TGANGULY
Pr
ocesspar
amet
ers:
-

1.Di
schargecur
rent:
-Thewirebei
ngsmal
lindiameterandcannotcar
rycur
rentmor
ethan30A
.Mater
ial
removalrat
eincr
easeswit
hthei
ncreasi
ngcurrent
.

2.Pulsedurati
on:-i
ncr
easei
nfi
rstr
elat
ionr
esul
tinmor
eremov
alofmat
eri
alandr
educe
sur
faceroughness.

3.Pulsef
requency
:-MRRi
ncr
easeswi
tht
hei
ncr
easespul
sef
requency
.Thi
sresul
tinbet
ter
sur
facefi
nish.

4.Wir
edi ameterandwi respeed:
-thewor
lddiamet
ershoul
dbeunif
orm ot
herwi
seitwil
laff
ect
thei
ntensit
yofspar k.Thewirespeedi
sinrange0.
5to150mm/ sec.Thecut
ti
ngratedepends
uponthethicknessofwor kpi
ece.

5.Wiret
ensi
on:-Aser
iesoftensi
onroll
eri
spr
ovi
dedt
okeept
her
equi
redt
ensi
on.Thewi
re
tensi
oni
s50%-60%ofi
tstensi
l
estr
ength.

6.Di-
elect
ri
cfl
ow:
-Thesuppl
yofdi
elect
ri
cfl
uidshoul
dbecont
inuous.I
tshoul
dhav
elow
vi
scosi
tyandhi
ghcool
i
ngr
ate.

Appl
i
cat
ions:
-

i
)Punchesanddi
esusedi
npr
esst
ool
scanbemade.

i
i
)Fort
hepr
oduct
ionofmoul
dsanddi
es.

i
i
i)Usedt
ocutoutcompl
excont
our
sinel
ect
ri
cal
l
yconduct
ivewor
kpi
eces.

i
v)Si
mpl
e,f
latshapes,
whi
chusual
l
ywoul
dbest
amped,
maybeaj
obf
orwi
reEDM when

t
heyr
equi
reasuper
iorqual
i
tyedge.

v
)Cy
li
ndr
ical
pinsassmal
las5mm i
ndi
amet
ercanbemachi
ned.

c)Laserbeam machi
ning(
LBM)
:-

Inthi
spr ocess,mater
iali
sr emovedbymelti
ngandv apor
izat
ionduet oheatproducedfr
om
conversionofkineti
cenergyofphotonsf
rom l
aserbeam.I
nthislaseri
sgener
all
yusedwhichis
generatedbyusi ngRubycrystal
.

AXenoncoi
l
edt
ubei
spl
acedar
oundaRubyr
odandt
hecompl
etesy
stem i
spl
acedi
nsi
dea

By
:-SUMI
TGANGULY
contai
nerwit
hinter nalsurf
acehighl
yr ef
lecti
ng.Throughatri
gger
ingcir
cuitaf
lashi
spr oduced
i
nxenont ubewhi chdi rect
lyorindi
rectl
yf al
lsontheRubyr odandduet othi
sRubyrodgi ves
l
aserbeam.Thisemi t
tedlaserbeam isfurtherf
ocusedusingalenssy st
em t
omeett hewor k
surf
aceatapointt heheatsopr oducedisresponsibl
efori
nstantmelt
ingofworkmater
ial.

Fi
g:-
07

Wor
kingofsol
i
dst
atel
aser
:-

Solidstatelaserarelaserbasedonsol i
dst ategainmedi um suchascr ystall
i
neRuby .The
crystal
li
neRubyi susedf orlaseract i
on.ItisAl uminium oxidedopedwi thchr omium ions
i
mpur i
ti
es.Chromium i
onsconcent rati
onisabout0. 05%.Thechr omium play
sani mportantrole
forlaserbeam product
ion.Chromi um absorbanyr adi
ati
onitreceiv
es.Flashlampsur r
ounding
theRubyr oadproduceslight
.Thisl i
ghtexcit
et hechromium ionsofRubycr ystaltohighener gy
l
ev el,whileonretur
njourneytot henor malstatethisexcit
edi onsathighener gylevelrel
ease
thephot ons.Thi
sdesiredenergyisobt ai
nedint heform ofshortdur
ati
onpul se.

Pr
ocesspar
amet
ers:
-

a)Focall
ength:
- Theworkpi
eceshoul
dbeplacedcl
osedt
othel
ensf
ormachi
ning.I
ffocal
l
engthisl
ess,
strai
ghthol
ewil
lbepr
oduced.

b)Flashl
amp:-I
toper
at esatar
ateof12f
lashesev
erysi
ngl
emi
nut
e.I
tshoul
dbekeptwar
mto
obtainmaxi
mum ef
fi
ciency.

c)Powerdensi
ty:
-Formachi
ningoper
ati
ont
hepowerdensi
tyshoul
dbehi 5×107 w/
gher(1.
cm2).

By
:-SUMI
TGANGULY
Appl
i
cat
ionsofLBM

i
)Dr
il
li
nghol
esi
nsur
gical
needl
es,
diamondwi
redr
awi
ngdi
es,
nyl
onbut
tonset
c.

i
i
)Cut
ti
ngorengr
avi
ngpat
ter
nsont
hinf
il
ms.

i
i
i)Tr
immi
ngofsheetmet
alandpl
ast
icpar
ts.

i
v)Non-
cir
cul
arhol
escanbemachi
nedwi
tht
heai
dofCNC

v
)Iti
sal
sousedf
orwel
dingofmet
als.

d)Pl
asmaar
cmachi
ning(PAM)
:-

Whengasesar
eheat
edt
oat
emper
atur
eabov
e5500°
C,t
heyar
epar
ti
all
yioni
zedandexi
t

i
nthef
orm ofmi
xtur
eoff
reeel
ect
rons,posi
ti
vel
ychar
gedi
onsandneut
ralat
oms.Thi
s

mi
xtur
eist
ermedaspl
asma.Theheatcont
entofpl
asmai
sresponsi
blef
ormel
ti
ngof

wor
kmat
eri
al.Thepl
asmaJetheatupt
hewor
kpi
ecewher
ethej
eti
mpi
nges,causi
nga

qui
ckmel
ti
ng.

Fi
g:-
08

By
:-SUMI
TGANGULY
Wor
king:
-

Thepl
asmai
sgener
atedbysubj
ect
ingaf
lowi
nggast
otheel
ect
ronsbombar
dmentofan

ar
c.Fort
hisar
cissetupbet
weenel
ect
rodeandanodi
cnozzl
e.Thegasi
ssupposedt
o

f
low t
hrought
hisar
candt
hehi
ghv
eloci
tyofel
ect
ronsoft
hear
ccol
l
idewi
tht
hegas

mol
ecul
escausi
ngi
oni
zat
ion.Thesei
oni
sedpar
ti
clesandf
reeel
ect
ronsr
ecombi
nedi
nto

at
omsandt
hent
omol
ecul
est
hisgi
vesr
iset
oexot
her
micr
eact
ion.Duet
othi
sthe

t
emper
atur
eofgasi
ncr
easesandwheni
tcomesoutt
hrought
henozzl
epl
asmaj
eti
s

obt
ained.The t
emper
atur
eint
hispl
asmai
sresponsi
blef
ormel
ti
ngwhi
l
ethev
eloci
tyof

pl
asmai
sresponsi
blef
orpl
ast
icact
ionofmol
tenmat
eri
al.

Pr
ocesspar
amet
ers:
-

1.St
andof
fdi
stance:
-Thest
andofdi
stancedependsont
het
hicknessoft
hemet
alt
ocut
.

Ty
pical
val
ueofst
andupdi
stancev
ari
esf
rom 5mm t
o10mm.

2.Cut
ti
ngspeed:
-Incr
easei
ncut
ti
ngspeedr
educest
hedept
hofi
mmer
sionoft
hepl
asma

j
et,
l
eadi
ngt
onar
rowi
ngoft
hecuti
nlowerpor
ti
on,wher
eas,decr
easei
nthe cut
ti
ng

speedwi
l
lcauset
heopeni
ngoft
hecutatt
hebot
tom.

3.Powersuppl
y:
-ADCpowersuppl
yof400V,
200KW andupt
o1000Ai
ssuppl
i
edy
othe

nozzl
e.

4.Gassuppl
y:
-Thef
lowr
ateofgasi
sdi
rect
lypr
opor
ti
onal
tot
het
hicknessoft
hemat
eri
al.

Appl
i
cat
ion:
-

i
)Forst
ockcut
ti
ng,
plat
ebev
eli
ng,
shapecut
ti
ngandpi
erci
ng.

i
i
)Inmanuf
act
ureofaut
omot
iveandr
ail
loadcomponent
s.

By
:-SUMI
TGANGULY
i
i
i)i
tcancuthotext
rusi
ont
odesi
redl
engt
h.

e)El
ect
ronbeam machi
ning(
EBM)
:-

El
ect
ron beam machi
ning i
sat
her
malpr
ocess used f
ormet
alr
emov
aldur
ing t
he

machi
ningpr
ocess.I
ntheel
ect
ri
calbeam machi
ning,
elect
ri
calener
gyi
susedt
ogener
ate

t
heel
ect
ronswi
thhi
ghener
gy.I
ntheEl
ect
ronBeam Machi
ningpr
ocess,ahi
ghv
eloci
ty

f
ocusedbeam ofel
ect
ronsar
eusedt
oremov
ethemet
alf
rom t
hewor
kpi
ece.These

el
ect
ronsar
etr
avel
i
ngathal
fthev
eloci
tyofl
i
ghti
.e.
,1.
6x10^
8m/
s.Thi
spr
ocessi
sbest

sui
tedf
ort
hemi
crocut
ti
ngofmat
eri
als.

Fi
g:-
09

WORKI
NG:

1.
InEBM,f
ir
stt
heel
ect
roni
sgener
atedbyt
hecat
hodeandanannul
arbi
asedgr
iddoes

notal
l
owst
heel
ect
ront
odi
ver
ge.

By
:-SUMI
TGANGULY
2.
From t
heannul
arbi
asgr
id,t
heel
ect
ronpr
oducedbyt
hecat
hodei
sat
tract
edt
owar
ds

t
heanodeandgr
adual
l
yit
svel
oci
tyi
ncr
eases.Ast
heel
ect
ronbeam l
eav
est
heanode

sect
ion,
itsv
eloci
tyr
eachest
ohal
foft
hev
eloci
tyoft
hel
i
ght
.

3.
Aft
ert
hat
,itpassest
otheser
iesofmagnet
icl
enses.Themagnet
icl
ensesal
l
owsonl
y

conv
ergentbeam t
opasst
hroughi
tandcapt
urest
hedi
ver
gentbeam f
rom t
hef
ri
nges.

Andt
henahi
ghqual
i
tyel
ect
ronbeam i
smadet
opasst
hrought
heel
ect
romagnet
icl
ens

anddef
lect
orcoi
l
s.

4.
The el
ect
romagnet
icl
ens f
ocuses t
he el
ect
ron beam t
othe desi
red spoton t
he

wor
kpi
ece.Thedef
lect
orcar
eful
l
ygui
dest
hebeam t
othedesi
redl
ocat
ionsandi
mpr
oves

t
heshapehol
e.

APPLI
CATI
ON:

1.
Usedf
ormaki
ngt
urbi
nebl
adesf
orsuper
soni
caer
oengi
nes.

2.
Iti
sal
sousedt
omanuf
act
uref
iel
demi
ssi
oncat
hodes,
int
egr
atedci
rcui
ts,
andcomput
er
memor
ies.

3.Usedf
ormaki
ngdr
awi
ngdi
esandf
lowor
if
ices.

4.
Usedf
orf
ri
ll
i
ngsy
nthet
icj
ewel
sint
hewat
chi
ndust
ry.

5.
Usedf
ormi
cro-
machi
ningoft
hinmat
eri
als

3)El
ect
roChemi
cal
ener
gy:
-

a)El
ect
rochemi
cal
machi
ning(
ECM)
:-

Thi
spr
ocessi
sbasedonr
ever
seel
ect
rol
ysi
spr
ocess.I
nthi
spr
ocesst
her
emov
alof

mat
eri
alt
akespl
aceduet
oiondi
spl
acement
.Accor
dingt
othepr
inci
pleofel
ect
rol
ysi
sthe

f
lowofcur
rentt
hroughanyel
ect
rol
ytei
sal
way
saccompl
i
shedwi
thdi
ssol
uti
onofmat
ter
.

By
:-SUMI
TGANGULY
 Fi
g:-
10

Wor
king:
-

Theobj
ect
ivei
nel
ect
rol
ysi
sist
odeposi
tmat
eri
alont
hewor
kpi
ece,
whi
l
einECM our

obj
ect
ivei
stor
emov
emat
eri
alf
rom t
hewor
kpi
ece.Thati
swhyt
heWor
kpi
ecei
smade

anodeandt
ooli
smadecat
hode.Whencur
rentofhi
ghamper
eandl
owv
olt
agei
ssuppl
i
ed

t
hrought
heel
ect
rol
yte.Thedi
ssol
uti
onofanodeoccur
s,howev
erdi
ssol
uti
onoccur
sat

bot
htheel
ect
rodebutdi
ssol
uti
onr
ateatanodei
s hi
ghandi
tispr
opor
ti
onalt
othegap

bet
weenwor
kpi
eceandt
het
ool
.Thef
ir
stdi
ssol
uti
onoccur
swhent
hegapi
smi
nimum

andaf
tersomet
imer
epl
i
caoft
ool
shapei
sgoi
ngt
obedev
elopedonwor
kpi
ece.

Pr
ocesspar
amet
ers:
-

i
)vol
tage:
-2t
o35V(DC)

i
i
)Cur
rent
:-50t
040000A

i
i
i)Wor
kinggap:
-0.
1mm t
o2mm

By
:-SUMI
TGANGULY
i
v)El
ect
rol
ytet
emper
atur
e:-20°t
o50°C

v
)El
ect
rodemat
eri
al:
-copper
,br
assandbr
onze.

v
i)El
ect
rol
yte:
-Sodi
um chl
ori
de,
Sodi
um ni
tr
ate,
pot
assi
um ni
tr
it
e.

Appl
i
cat
ion:
-

1)I
tcanbeusedf
ordi
e-si
nki
ngoper
ati
ons.

2)Dr
il
li
ngaj
etengi
net
urbi
nebl
ade.

3)Mul
ti
plehol
edr
il
li
ng.

4)St
eam t
urbi
nebl
adescanbemachi
nedwi
thi
ncl
osel
i
mit
s.

4)Chemi
cal
machi
ning:
-

Chemi
calmachi
ningi
stheol
destoft
henon-
tr
adi
ti
onalpr
ocesses.I
twasbasedont
he

obser
vat
iont
hatchemi
cal
sat
tackmet
alsandet
cht
hem,t
her
ebyr
emov
ingsmal
lamount

ofmat
eri
alsf
rom t
hewor
kpi
ece.
Thi
spr
ocessi
scar
ri
edoutbyusi
ngr
eagent
soret
chant
s,

suchasaci
dsandal
kal
i
nesol
uti
ons.Themechani
sm i
stousechemi
calr
eact
ionbet
ween

t
hemat
eri
aloft
hewor
kpi
eceandsomechemi
calr
eagent
,sot
hatt
hepr
oduct
soft
he

r
eact
ioncanber
emov
edeasi
l
y.Thus,t
hesur
faceoft
hewor
kpi
ecei
set
chedaway
,

exposi
ngt
hel
owerl
ayer
s,andt
hepr
ocessi
scont
inuedunt
ilt
hedesi
redamountof

mat
eri
ali
sremov
ed.

By
:-SUMI
TGANGULY
 Fi
g:-
11

Wor
king:
-

1.Cl
eani
ng:
-Int
hecl
eani
ngpr
ocess,t
hewor
kpi
ecesar
ecl
eanedt
oremov
eoi
l
,gr
ease,

dust
,oranysubst
ancef
rom t
hewor
kpi
ecesot
hatf
urt
herpr
ocessi
ngcanbecompl
eted

pr
oper
ly.
Cleani
ngsar
enecessar
ytoensur
epr
operadhesi
onofmaski
ngmat
eri
alt
othe

wor
kpi
ece.I
nthecaseofmaski
ngdebuggi
ng,
str
ayEt
chi
ngoccur
s.

2.
Maski
ng:
-Maski
ngi
sdoneusi
ngmaski
ng.Thesemasksar
einer
tinnat
ureanddonot

r
eactwi
tht
hechemi
cal
susedi
nthemachi
ningpr
ocess.Themaskedt
obeusedshoul
dbe

aneasyst
ri
pemask.I
nthi
smaski
ngpr
ocess,t
hepar
tsoft
hewor
kpi
ecet
hatar
enot

machi
nedar
emaskedusi
ngamasksot
hatt
hemachi
nedpar
tisexposedt
othechemi
cal

usedi
nthemachi
ningpr
ocess.

3.Scr
ibi
ng:
-Af
tert
hemaski
ngpr
ocess,maski
ngi
sper
for
medt
oremov
efr
om t
hear
eaof

By
:-SUMI
TGANGULY
t
​
hewor
kpi
ecet
hati
stobemechani
zedsot
hatachemi
calr
eact
ioncanoccuront
hatpar
t

oft
hewor
kpi
ece.Af
tert
hescr
ibepr
ocess,
onl
ythosear
east
hatar
etobemechani
zedar
e

exposedt
ochemi
cal
machi
ning.

4.Et
chi
ng:
-Af
terf
il
ter
ing t
hewor
kpi
ece,i
tisi
mmer
sed i
n a cont
ainercont
aini
ng a

chemi
calt
hatunder
goesachemi
calr
eact
ionwi
tht
hewor
kpi
ece.Whent
hewor
kpi
ecei
s

i
mmer
sedi
nsi
det
hechemi
cal
,thear
eat
hati
smaskeddoesnotunder
goanychemi
cal

r
eact
ion,
andt
hear
eat
hati
snotmaskedunder
goesachemi
calr
eact
ionwi
tht
hechemi
cal

andt
hemat
eri
alunmaskedar
eaof​
t
hewor
kpi
ece.Iwi
l
lst
artmov
ingawayf
rom i
t.
The

et
chi
ngpr
ocessi
susual
l
yper
for
medatanel
evat
edt
emper
atur
e

5.Demaski
ng:
-Af
tert
heet
chi
ngpr
ocess,t
hemasksar
eremov
edf
rom t
hear
eaof​
t
he

wor
kpi
ece,whi
chi
snotmechani
zed,andt
heoxi
del
ayeri
sal
sor
emov
edf
rom t
hear
eaof

t
​
hewor
kpi
ece,
whi
chi
smechani
zed.

6.Washi
ng:
-Af
tert
hedemaski
ngpr
ocess,
thewor
kpi
ecei
sthor
oughl
yri
nsedunderf
resh

wat
ert
ocompl
etel
yremov
eanysubst
ances,
etc.
,fr
om t
hesur
faceoft
hewor
kpi
ece.

Appl
i
cat
ion:
-

1)Shal
l
owcav
iti
espr
oducedonpl
ates,
sheet
s,f
orgi
ngs,
andext
rusi
ons.

2)Chemi
cal
mil
l
ingusedi
ntheaer
ospacei
ndust
ryf
orpar
tsl
i
kewi
ngs.

3)Topr
oducedecor
ati
vesur
facesonel
evat
ordoor
s,asht
ray
s,panel
s,i
nst
rumentdi
alset
c.

4)Pr
ocessi
sal
sousedf
ormi
croel
ect
roni
cdev
icesl
i
kecomput
ers,
tel
evi
sion,
elect
ri
cmot

t
elephonesy
stem,
medi
cal
inst
rument
set
c.

5)Topr
oducespeci
algeomet
ri
cshapesonr
adarr
efl
ect
ors,
heatexchanger
set
c.

By
:-SUMI
TGANGULY