ADVANCE MANUFACTURING

PROCESSES (AMP)
TEACHING SCHEME:
THEORY LECTURE -04 HOURS
PRACTICAL – 04 HOURS
PAPER HOURS – 03 HOURS
Theory ESE – 70 MARKS
Theory PA – 30 MARKS
Practical ESE - 50# MARKS
Practical PA - 50 MARKS
 UNIT-1 Non-Conventional
Machining Processes
Course Outcome – Maintain the non-conventional machining
process to produce complex and hard to machine components.

 Fundamentals of Non- conventional methods – Needs &

types of non-conventional methods. Importance of
methods.
 Working Principle, set up, process parameters of –
EDM,WEDM,ECM,PAM,AJM,USM,EBM & LBM.
 Advantages, Limitations and Applications of –
EDM,WEDM,ECM,PAM,AJM,USM,EBM&LBM
 OVERVIEW
• Second year already u learned basic manufacturing
processes.
• Now it is necessary for a diploma engineer to know
about advancements in the area of manufacturing
processes.
• This subject will help to get familiarize with working
principles and operations performed on :--
 Non conventional machines
 Milling Machines & Process
 Gear manufacturing methods
 CNC Machine & programming
 Automation and Robotics
 Needs of Non-Conventional Machining Processes
 Many new materials were developed to fulfill the need of aircraft
industry, missile technology, space research equipment and nuclear
industry. These materials like carbides, tungsten, ceramics,
tantalum, berylium, uranium, nitoalloy etc.
 These materials are extremely hard and sometimes unmachinable
by traditional machining processes.
 It employs some form of energy like mechanical, thermal, chemical,
electro-chemical etc. for cutting the material.
 Any material can be machined irrespective of its hardness.
 Any complicated shape can be produced on the work piece.
 Very fine holes can be easily drilled.
 Through cutting of any material.
 No mechanical force is exerted on work piece, so fragile work piece
can be machined.
 The part produced are burr-free.
 Importance of Non-Conventional Machining
Processes
Any material can be machined irrespective of
its hardness
To machine complex part geometries that are
not possible to machine by conventional
machining. E.g. square shaped blind holes
To avoid damage to the surface that often
accompanies conventional machining.
To machine deep hole with small diameter.
E.g. 12mm hold with 25mm depth.
To machine composites.
 DIFFERENCE BETWEEN TRADITIONAL AND NON
TRADITIONAL MACHINING PROCESS
No. Parameters Traditional Machining Process Non-Traditional Machining Process
1 Tool It uses cutting tool of fixed It uses some form of energy along with
geometry. tool which does not have fixed geometry.
2 Tool hardness Tool material should be harder than Hardness of tool is independent of the
the metal to be cut. material hardness.
3 Cutting ability Hard metals are difficult to cut and Almost any known hard material can be
sometimes impossible. cut.
4 Complex Difficult to produce complex Complex profiles can easily be obtained.
profile shapes
5 Metal removal Metal is removed in the form of Metal is removed by melting,
method chips vapourization, electrochemical reaction.

6 Metal removal Metal removal rate is Metal removal rate is low.

rate comparatively high.
7 Minute hole Very minute holes cannot be Very fine or minute holes can be easily
produced produced.
8 Example Turning, Milling, Shaping, Drilling EDM,LBM,WEDM,AJM,WJM,USM etc.
etc.
 Types of Non-Conventional Machining Processes
Depending upon the type of energy used,
1) Thermal Energy
 Electric Discharge Machining (EDM)
 Wire cut EDM(WEDM)
 Laser Beam Machining(LBM)
 Electron Beam Machining(EBM)
 Plasma Arc Machining(PAM)
2) Mechanical Energy
 Abrasive Jet Machining (AJM)
 Ultrasonic Machining (USM)
 Water Jet Machining (WJM)
3) Electro-Chemical
 Electro-Chemical Machining
 Electro-Chemical Grinding
4) Chemical
 Chemical Machining
 ELECTRO DISCHARGE MACHINING(EDM)
Tool (Cathode)

Dielectric
Spark
fluid

DC supply Spark gap

Ionized fluid

Work piece (anode)

WORKING PRINCIPLE OF EDM

Working principle of EDM
 WOKRING PRINCIPLE OF EDM
 EDM works on the principle that heat energy generated by a
spark is used to remove material from the work piece.
 The tool & work piece are seperated by a small gap called as
spark gap.
 The gap varies from 0.01 to 0.5 mm.
 The tool & work piece both are immersed in the dielectric
fluid.
 When supply is made ON, thousands of sparks are produced
per second. The duration of each spark is very short.
 When the spark comes in contact with the dielectric fluid in
the spark gap, the fluid gets ionized. It allows current to flow
between tool and work piece.
 A very high temp. of around 100000c generated in the spark
region, As a result, the material gets melted and is removed
from work piece.
SET UP OF EDM

EDM Set-up
Set up of EDM
 SET-UP OF EDM
• It consists of the four major components:
1) Tool & Work piece
2) Dielectric fluid system
3) R-C circuit and power supply unit
4) Tool feed mechanism
1. Tool & Work piece :
 The tool & work piece is kept in a reservoir & is connected to DC
power supply.
 The tool is connected to negative terminal, so it becomes cathode
while work piece is connected to positive terminal so it becomes
anode.
 Work piece is mounted fixture.
 SET-UP OF EDM
2. Dielectric system
 The reservoir is filled with dielectric fluid such that the spark
gap is immersed in it.
 Dielectric is continuously flushed into the spark gap. The used
dielectric is filtered and recirculated in to the reservoir.
3.R-C circuit
 A resistor R is connected in series and a capacitor C is
connected in a parallel.
 When the supply is made ‘ON’ the capacitor voltage
Starts rising continuously. When the capacitor voltage equals
the breakdown voltage, a spark discharge will occur in the spark
gap.
 Resistor R in the circuit prevents the charging of capacitor
before the spark gap is deionized.
 SET-UP OF EDM
4. Tool feed mechanism
Since during operation both the tool & work
piece are eroded, it is necessary to feed the
tool continuously towards the work piece so
as to maintain the spark gap.
This can be achieved by a suitable tool feed
control mechanism along with servo
mechanism system.
 DIELECTRIC FLUID
• A dielectric fluid is a liquid which acts as a
insulator at one time and to act as a
conductor at other time
• DIELECTRIC FLUID USED :
paraffin oil
Transformer oil
Lubricating oil
Kerosene
Distilled water etc.
FUNCTIONS OF DIELECTRIC FLUID
It should act as an insulator until the required
breakdown voltage is attained.
It should act as a conductor, once the
breakdown voltage is reached.
It should clean the spark gap by carrying away
the molten metal.
It should cool the tool, work piece and the
spark region.
It should deionize the spark gap rapidly after
the discharge has occurred.
 PROPERTIES OF DIELECTRIC FLUID
It should have low viscosity.
It should have high flash point.
It should have controlled level of toxicity.
It should have freedom from acid and alkaline
products.
It should have high dielectric strength.
It should be easily available.
It should have high fluidity.
 TOOL USED IN EDM
The tool or electrode material is classified into
two groups:
Metallic group : copper, brass, aluminum,
steel, zinc, tungsten alloy.
Non-Metallic group : graphite
Graphite is inexpensive and easily available.
 REQUIREMENT OR PROPERTIES OF TOOL
MATERIAL
It should be good conductor of electricity.
It should have high thermal conductivity.
It should be cheap and readily available.
It should have low wear rate.
It should have low electric resistance.
It should have good machinability.
It should have high melting point.
 PROCESS PARAMETES
• Supply voltage
• Breakdown voltage
• Resistence and capacitance
• Spark gap setting
• Pulse duration
• Spark frequency
 ADVANTAGES OF EDM
Any material can be machined irrespective of
its hardness.
Any complicated shape can be produced on
the work piece
There is no physical contact between the tool
and work piece therefore no stresses are
produced in the work piece.
Very fine holes can be easily drilled.
A very good surface finish can be obtained.
 DISADVANTAGES OF EDM
Metal removal rate is slow.
Overcut is formed.
Cannot produce very sharp corners.
Excessive tool wear occurs during machining.
Power consumption is high.
Unable to machine electrically non-conductive
material.
 APPLICATIONS OF EDM
 It is used in stamping tools, wire
drawing and extrusion dies,
forging dies
 In machining delicate work piece
like copper parts are used for
fitting in vacuum tubes.
 For machining of exotic materials
used in aerospace industries.
 In resharpening of cutting tools
and broaches.
 In microhole drilling.
 Internal threads can be produced
in harder material by using a
rotary spindle.
 WIRE CUT EDM

• Wire cut EDM is same as that of EDM.

• It can be used only when the work piece to be cut has a through
hole in it or the cut is taken from the outer edge into the work piece
• It uses wire of about 0.3 mm as diameter as a tool.
WIRE CUT EDM
WIRE CUT EDM
 WIRE CUT EDM PRINCIPLE
• It works on the principle that the
heat energy generated by a spark
is used to remove the material
from the work piece.
• It uses a wire of about 0.3 mm
diameter as an electrode or tool.
• A constant gap of 0.5 mm is
maintained between the wire
and work piece with the help of
control system as shown in fig.
• The wire is continuously moved
at a constant speed through the
work piece.
• A dielectric fluid is constantly
flushed in the area of machining.
 WIRE CUT EDM PRINCIPLE
 When the machine tool is
switched ‘ON’ sparks are
generated between the tool
and the work piece.
 When the spark comes in
contact with the dielectric
fluid in the gap, the fluid
gets ionized and it allows
the current to flow between
the tool & work piece.
 Heat is generated during
the sparking process results
in melting of the work
piece.
 These melted particles of
the metal are then driven
away by the dielectric fluid.
 SET UP OF WIRE CUT EDM (WEDM)
• It consists of four main components
1. Power supply system
2. Di-electric system
3. A CNC control system (w/p positioning unit)
4. Wire drive system
1.Power supply system
 The work piece is kept on a table
 The tool is connected to negative terminal, so that it
becomes cathode, while work piece is connected to
positive terminal and becomes anode.
 The tool & work piece is connected to DC power
supply.
 SET UP OF WIRE CUT EDM (WEDM)
2. A dielectric system
 Deionized water is used as a dielectric fluid in WEDM. It
gives high metal removal rate and better surface finish.
 A nozzle is employed to inject the dielectric fluid in the
machining area.
 Both the work piece and the wire are constantly flushed
with dielectric fluid at the area being machined.
 The dielectric also serves as a coolant.
3. A CNC control system
 A CNC control system is used for the movement of work
table.
 The table has movement in two axis (direction)
 The table can also be moved in both the directions
simultaneously for taking contouring cuts.
 SET UP OF WIRE CUT EDM (WEDM)
4.Wire drive system
This system performs three
functions
1) To feed the fresh wire for
machining (wire feed
mechanism).
2) To take-up the used wire (wire
take-up mechanism).
3) To keep the wire under
appropriate tension so that it
moves in the machining area as
a straight wire.
 The wire is used only once
because due to sparking which
takes place at the surface of the
wire, the wire no longer remains
round.
 SET UP OF WIRE CUT EDM (WEDM)
5.Dielectric flow
A nozzle is employed to inject the dielectric
fluid in the machining area.
The supply of dielectric should be continuous
and enough to allow the sparking.
The dielectric fluid can be reused, but only
after filteration.
CONTROLLING PARAMETERS IN WEDM
• The main process parameters or controlling
parameters in WEDM are :
1.Discharge current
2.Pulse duration
3.Pulse frequency
4.Wire speed
5.Wire tension
6.Dielectric flow
 ADVANTAGES OF WEDM
Straight holes can be produced to close
tolerances.
As a NC unit is used, the machine can be
operated for longer period of time.
High degree of accuracy & good surface finish
can be obtained.
Very sharp angles can be cut with almost no
radius.
The part produced are burr-free.
 DISADVANTAGES OF WEDM
Wire cannot be reused, because due to
sparking the wire no longer remains round.
If proper tension in wire is not maintained, the
surface finish will be poor.
Only electrically conductive material can be
machined.
Residual stresses are induced in the work
piece during machining.
 APPLICATIONS OF WEDM
 Punches and dies used
in press tools can be
made.
 For the production of
moulds and dies.
 Used to cut complex
contours in electrically
conductive work
pieces.
 Cylindrical pins as small
as 5 mm in diameter
can be machined.
LASER BEAM MACHINING
 LASER BEAM MACHINING
 LASER (Light Amplification by Stimulated
Emission of Radiation).
 A laser converts electrical energy into a highly
coherent light beam.
CHARACTERISTICS OF LASER
 A laser beam is highly monochromatic.
 Laser ray is highly pure beam of light.
 It is an intense beam of light.
 Highly directional
 Highly collimated.
 The light produced by laser is coherent.
 TYPES OF LASER
1) Gas laser-
 Helium-neon laser
 Carbon dioxide laser
 Metal ion laser
2) Solid laser-a solid state laser is one in which
the atoms that emit light are fixed within a crystal
or glassy material.
 Ruby rod (the chromium atoms embedded in the
ruby’s aluminum oxide crystal).
3) Semiconductor Laser
 Silicon laser
LASER BEAM MACHINING
 LASER BEAM MACHINING
 The ruby rod laser material is in the form of
crystal of aluminum oxide that contains about
0.05 % chromium.
 The ruby rod is in the form of cylindrical crystal of
10 mm diameter and 100 mm length.
 The ends of ruby rod are made reflective by
mirrors as shown in fig.
 Two parallel to each other are provided at each
end to reflect the incoming light.
 One of these mirrors is fully reflective while the
other is partially reflective to allow the light to
pass through it.
 LASER BEAM MACHINING
 When the light is thrown by the flash lamp on the
ruby rod, the chromium atoms inside it get
excited to higher energy level.
 The excited atoms emit photons before it returns
to its normal state. The photons come out from
the transparent mirror in the form of laser beam.
 When it is focused through the lens, this laser
beam fall on the work piece. As a result the beam
melts the work piece, vapourizes it and
penetrates into it.
 ADVANTAGES OF LBM
 As there is no tool, there is no question of tool
wear.
 Extremely small holes can be drilled.
 It can cut through air, gas, vacuum and even
through liquid.
 Angular drilling or cutting can be obtained by
tilting the work piece.
 The process can be used for cutting, drilling and
welding.
 No mechanical force is exerted on the work piece,
so fragile work piece can be machined.
 DISADVANTAGES OF LBM
High capital and operating cost.
It cannot cut highly conductive and reflective
material.(e.g. Al, Co and their alloy).
Life of flash lamp is short.
Skilled operator is required for controlling the
process.
Only small amount of material can be
removed.
 APPLICATIONS OF LBM
Cutting of engraving patterns on thin films.
Trimming of sheet metal and plastic parts.
Non-circular holes can be machined with the
help of CNC.
It is also used for welding of metals.
Laser is also used in communication.
It is also used as entertainment in theatres
and light shows.
PLASMA ARC MACHINING
 PLASMA ARC MACHINING
• Three three states of matter are solid, liquid
and gases.
• The fourth state of matter is obtained when
gases are heated to temp. about 5500 c .
• At this temp, the gases are partially ionized
and exist in the form of a mixture of free
electrons, positively charged ions and neutral
atoms. This mixture are termed as plasma.
 PRINCIPLE OF PAM
• When a high velocity jet of plasma is directed
on the work piece surface by means of a
plasma arc cutting torch, the metal from the
work piece melts which results into the
machining of work piece.
• The continuous attack of electrons on the
work piece which transfer the heat energy of
plasma on the work piece causes the work
piece to melt.
 SET UP OF THE PROCESS OF PAM
• It consist of
1. Plasma cutting torch
2. Tool and work piece
3. Gas supply unit
4. Cooling system
5. Power supply
1.Plasma cutting torch
 It carries a tungsten electrode fitted in a small chamber.
 At other end of the torch is a small converging orifice
called as nozzle.
 One side of the torch provides a passage for supply of
gas into the torch.
 SET UP OF THE PROCESS OF PAM
2.Tool & work piece
 The electrode is connected to negative terminal of D.C. power
supply and therefore acts as a cathode.
 The nozzle is made anode by connecting to the positive terminal of
the power supply through a suitable resistor. This resistor limits the
current through the nozzle to about 50A.\
 The work piece to be machined is also connected to the positive
terminal of the supply.
 Anode and cathode are seperated by an insulator
3.Gas supply unit
 It consists of gas cylinder, regulator and supply hoses.
 The commonly used gases are argon or nitrogen or mixture of two, a
percentage of hydrogen may be added.
 The flow rate of gas varies directly with the thickness of the work
piece.
 SET UP OF THE PROCESS OF PAM
• 3.Cooling system
 A provision is made for circulating the water around the
torch so that the electrodes and the nozzle both remains
water cooled.
• Working
 When supply is made ON, a strong arc is struck between the
electrode and the nozzle and gas is forced into the chamber.
 When the gas molecules collide with the high velocity
electrons of the arc, plasma is formed. This plasma is forced
through the nozzle onto the work piece.
 The heat produced from this jet of plasma is directed on the
work piece surface which results into machining of work
piece.
 Controlling Parameters in PAM
• 1.Stand-off distance
 Increase in stand-off distance reduces the depth of penetration and
hence narrows the cut width at the bottom.
 The stand-off distance depends on the thickness of the metal to cut.
The typical value of the stand-off distance varies from 5 mm to 10
mm.
• 2.Cutting Speed
 Increase in the cutting speed reduces the depth of immersion of the
plasma jet, leading to narrowing of the cut in the lower portion.
 Decrease in the cutting speed will cause the opening of the cut at the
bottom of the work piece.
• 3.Gas
 The gas flow rate is directly proportional to thickness of the
material.
 The selection of a particular gas depends on the quality of cut and
the economics.
 Advantages of PAM
The rate of cutting is high.
It is used to cut any metal irrespective of its
hardness and even to non-conducting material
like concrete.
It can cut carbon steel-up to 10 times faster
than oxy-fuel cutting.
The process is finding ever increasing
applications because it gives the highest
temperature available for many practical
sources.
 Disadvantages of PAM
Protection of noise is necessary.
Heat affected zone is more.
High initial cost of the equipment.
Safety precautions are necessary for the
operator and those in the near by area.
 Applications of PAM
For removal of gates and riser from casting in
foundry.
For stock cutting, plate beveling, shape cutting
and piercing
In manufacture of automotive and rail road
components.
It can cut hot extrusions to desired length.
Electro Chemical Machining (ECM)
 Electro Chemical Machining (ECM)
• Electrical energy used in combination with chemical reactions to remove
material.
• ECM utilizes the principle of reverse of electroplating.
• In ECM, the material is removed and hence electroplating is reversed.
Here the tool is made cathode and work piece is made anode.
• The electrolyte is so that after electrolysis there is no decomposition of
metal on the tool.
• A close gap of about 0.5 mm is maintained between the tool and work
piece.
• An electrolyte is continuously pumped into the gap and D.C.voltage is
applied.
• Due to the applied voltage the current flows in the electrolyte.
• Due to this positively charged ions are attracted towards the cathode and
the negatively charged ions are attracted towards the anode.
• The metal from the anode is removed atom by atom by removing negative
charges that bind the surface atoms to their neighbors.
• The ionized atoms are then positively charged and can be attracted away
from the work piece.
• Thus, electrochemical reaction takes place in presence of the electrolyte
which results in removal of metal from the work piece.
 Set-Up of ECM (Working of ECM)
• It consists of following systems
1) D.C. power supply unit
2) Work piece and work holding system
3) Tool and tool feed system
4) Electrolyte supply system
1) D.C.power supply unit
In ECM, the current of about 40,000 A is applied
across a D.C. voltage of 5 to 30 volts.
2) Work Piece and work holding system
The work piece is made anode. The work piece is
placed on a table in a tank.
The table material is non-conductive and have good
thermal stability.
 Set-Up of ECM (Working of ECM)
3) Tool and tool feed system
• The tool is made cathode
• A small gap is maintain the gap during machining, the tool is
continuously feed towards the work piece by servo mechanism.
• The tool used is hollow to provide passage for the electrolyte.
• The tool has reverse profile of that to be produced on the work
piece.

4) Electrolyte supply system

An electrolyte is continuously pumped into the gap between the tool
and the work piece.
The electrolyte is selected is such that it will not plate material on the
tool.
When a D.C. voltage is applied, current flows through the equipment
and electrochemical reaction takes place.
This results in removal of material from the work piece.
 Tool Material for ECM
The general requirements of ECM tool material
1) It should be a good conductor of electricity.
2) It should have good machinability.
3) It should be chemically inert to the
electrolyte (i.e. it should not react with the
electrolyte.)
4) It should have high thermal conductivity.
5) It should be anti-corrosive in nature.
The commonly used tool materials are copper,
brass, stainless steel, aluminum, graphite,
bronze,tungsten.
 Functions of Electrolyte
• It should carry current between the tool and
work piece.
• It should dissipate the heat produced in the
process.
• It should carry away the products of reaction
away from the machining area.
• It should flow with high velocity.
• It should allow the electrochemical reaction to
occur.
• The commonly used electrolyte are sodium
nitrate, sodium chloride, sodium hydroxide,
sodium sulphate, sodium fluoride,potassium
nitrate,potassium chloride etc.
 Properties of Electrolyte
• High electrical conductivity
• Non-corrosive and non-toxic in nature
• Low viscosity and high specific heat
• Chemically stable
• Inexpensive and readily available.
 Advantages of ECM
• The process has no tool wear so tool life is
high
• It generates a burr free surface
• The metal removal rate is high
• It is used for profiling and contouring of
complex shapes.
 Disadvantages of ECM
• Heavy initial investment
• High power consumption
• It cannot produce sharp corner and edges
• Only electrically conductive material can be
machined
• Floor space area required is more
 Applications ECM
• It can be suede for die-sinking operations
• Drilling a jet engine turbine blades
• Multiple hole drilling
• Steam turbine blades can be machined within
close limits.
Abrasive Jet Machining
Abrasive Jet Machining
 Abrasive Jet Machining

Abrasive jet machining is a process that removes material from a work piece with the
help of abrasive particles.
The process consists of mixture of fine abrasive particles and gas at high pressure.
This stream of mixture is directed through a nozzle on to the surface of the work piece
as shown in fig.
The abrasive particles impinge on the work piece at high speed.
As the particles impacts the surface, it causes a small fracture of the work surface which
results in removal of metal.
The gas stream carries both the abrasive particles and the fractured (wear) particles
away.
 Abrasive Jet Machining
• ABRASIVE- Abrasive material used is aluminum
oxide or silicon carbide or sodium bicarbonate
etc.
• The grains should have sharp edges
• The grain size should be of 10-50 micron
• Grains should not be reused as the sharp edges
are worn down.
• GAS- Typically used gas is air or nitrogen or
carbon-di-oxide.
• Gas pressure typically ranges from 0.2N/mm2 to
1 N/mm2
 Process Set-up
• A typical set up of abrasive jet machining as shown in fig.
• The abrasive particles are held in hopper through which it is fed into
the mixing chamber.
• A regulator controls the flow of abrasive particles.
• Gas at high pressure is supplied to the mixing chamber through a pipe
line.
• A pressure gauge and a regulator is incorporated in the pipeline to
control the gas flow and its pressure.
• The mixing chamber carrying the abrasive particles is vibrated by the
device and the amplitude of these vibrations controls the flow of
abrasive particles.
• These abrasive particles travels through the hose and enter into the
nozzle.
• The control valve and pressure gauge controls the flow of abrasive
particles.
• This outgoing high speed stream that comes out of the nozzle is known
as abrasive jet.
• When such jet impinges on the work piece, the erosion caused by their
impact enable the removal of metal.
 Advantages of AJM
• Intricate cavities and holes of any shapes can be
easily machine.
• Brittle material of thin section can be easily
machined.
• Low initial investment is required
• No direct contact of tool and work piece.
• Amount of heat generated is not appreciable.
 Disadvantages of AJM
• Low metal removal rate
• Once used, abrasive particles cannot be reused
• Not suitable for machining of ductile material
• Relatively poor machining accuracy
 Applications of AJM
• Fine drilling and micro welding
• Machining of semi conductors
• Frosting and abrading of glass articles
• Machining of intricate profile on hard and fragile
materials
• Cleaning and cutting operations on material like
germanium, silican,quartz,mica
• Machining of brittle materials like glass, ceramics,
refractories etc.
Ultrasonic Machining (USM)
 Ultrasonic Machining (USM)
• The term ultrasonic refers to waves of high
frequency, general above the hearing range of a
normal human ear i.e. generally above 20 kHz.
• In this process, cutting tool is given mechanical
vibration so that it oscillates at high frequency in
abrasive slurry against the stationary work piece.
• The tool has the same shape as the shape to be
machined. The impact of the abrasive causes the
metal removal from the work piece. This method
is generally used to machine hard and brittle
materials.
 Ultrasonic Machining (USM)
• Every abrasive grain is hammered into the work surface
by a high-frequency oscillating tool that cause chipping
of fine particles from the work piece resulting in the
removal of material.
• The electronics oscillator and amplifier also known as
generator, convert the electrical energy at low
frequency to high frequency.
• The vibrations thus produced are focused on the
cutting point by means of a horn or a tuned vibration
concentrator.
• The abrasive used in the process is supplied in the form
of slurry suspended in a carrier fluid and the tool feed
is achieved by means of static loading of the vibrator
head that transmits vibrations to the tool.
 Process set-up
• The elements of process are
1) Transducer
2) Tool
3) Abrasive slurry
4) Tool feed mechanism
1) Transducer – The transducer is made of magnetostrictive material
like nickel, iron-cobalt, iron-Al etc. A generator converts the available
electrical energy of low frequency to high frequency and is supplied to
transducer.
Due to this the longitudinal strains are produced in the transducer.
2) Tool – it consists of two parts i.e. the tool holder and tool tip. The
tool holder is connected to the transducer and it transmits the
vibratory energy from the transducer to the tool tip.
This causes linear oscillatory motion of the tool when the work piece
comes in contact with the tool.
 Process set-up
3) Abrasive slurry – The mixture of abrasive
particles and water is used as abrasive slurry. This
slurry is continuously fed at the tool work piece
contact.
When the supply is made ON, the abrasive grains
are hammered by the high frequency oscillatory
tool into the work piece. This results in removal of
material from the work piece.
4) Tool feed mechanism – As the tool machines the
work piece, the gap between the two increases.
Thus, for machining action the tool must be fed
continuously into the work piece.
 Advantages of USM
1) Any known hard material can be easily machined
2) It can be used for machining of both conductive and
non-conductive material
3) The process is noiseless
4) Complex shapes with good accuracy and reasonable
surface finish can be obtained.
5) No heat generated in the process, so physical
properties of the work piece remain unchanged.
6) Abrasive slurry
7) Tool feed mechanism
 Disadvantages of USM
1) The abrasive slurry has to be periodically
replaced
2) The metal removal rate is low
3) It is not suitable for heavy stock removal
4) The initial equipment cost and the tooling
cost is high
5) Power consumption is quite high
 Applications of USM
1) Cutting internal threads in ceramics and
glasses by rotating the wor4kpiece
2) Cutting of industrial diamonds
3) Manufacturing of wire drawing, punching
and blanking dies
4) In making holes of any shape for which the
tool can be made
5) Coining of glass and ceramics.
Electron Beam Machining
Principle of Working of Electron Beam Machining
• When a high velocity of electron is focused on
a work piece, the electrons strikes on the work
piece and their kinetic energy is converted
into heat energy.
• This heat results in removal of material from
the work piece by vaporization and melting.
 Set-up of Electron Beam Machining
• The set up of EBM consists of six basic units as
shown in fig.
1) Electron gun
2) Magnetic lens
3) Magnetic deflection coil
4) Movable table
5) Monitoring instrument
6) Vacuum chamber
 Set-up of Electron Beam Machining
1) Electron gun – It consist of a cathode, grid cup and an anode.
• A cathode is a tungsten filament which is heated by a low voltage
current.
• A grid cup is negatively biased with respect to the filament.
• An anode is in the form of a ring. It is kept at a ground potential.
• When the cathode is heated it emits electrons by thermionic
emission.
• As there is a high potential difference between anode and cathode,
the electrons are accelerated towards the anode by a high velocity.
• The grid helps in narrowing the beam.

2) Magnetic Lens – A magnetic lens further converges the beam into a

narrow spot on the work piece.

3) Magnetic Deflection coil – is used to deflect the beam onto a

different spot on the work piece or for moving it along a contour.
 Set-up of Electron Beam Machining
4) Movable Table – A table which is used to mount the work piece is
kept in the vacuum chamber.
The table is numerically controlled to move under the beam. Thus, the
machining the work piece is done either by moving the table or by
deflecting the beam.

5) Monitoring Instrument – A light microscope is kept to monitor the

complete process. The operator can adjust the position the work piece
as per the requirement and observe the actual machining process.
Generally the beam remains stationary and the work piece is moved.

6) Vacuum Chamber – The vacuum helps in the following

• The beam retains its narrow configuration over a long distance
• The electrons do not lose energy by collision with air molecules
• The electrons emitted from the gun maintain their high velocity
until they strike the work piece.
 Working of Electron Beam Machining
The electrons which comes out of the electron
gun and pass through the magnetic lens posses
a very high energy.
When this narrow stream of electrons strike the
work piece, the kinetic energy of electrons is
converted into the heat energy and this heat
melts the work piece.
 Advantages of Electron Beam Machining
As beam is used as a tool, there is no wear of
the tool.
Drilling of tapered holes is possible
High speed perforation of any kind of material
The process is suitable for automatic
machining
Holes, slots, orifices etc. which cannot be
made by any other method can be produced
by EBM.
Through cutting of any material
 Disadvantages of Electron Beam Machining
 Very high cost of equipment
 Size of work piece is limited to the size of the
vacuum.
 The process results in X-ray emission which
retards the production rate and limits the size of
the parts to be machined.
 Skilled operators are required to operate the
process.
 Exact straight edges or right angles or corners
cannot be cut.
 The process can be operated only in vacuum
 Metal removal rate is low.
 Applications of Electron Beam Machining
The process is mainly used for welding
Micromachining operations on thin materials
like drilling etc.
Engraving of metals and ceramics
Drilling of micro holes in turbine blades.
Producing metering holes in injector nozzles
of diesel engines.
To remove small broken taps from holes.
 Controlling Parameters of Electron Beam Machining

Beam current – The beam current depends on

the grid voltage. If the grid voltage is more
negative with respect to the cathode, then the
more it restricts the emission of electrons.
Beam diameter – the beam diameter depends
on the beam current, the accelerating voltage,
the magnetic lens and distance between gun
and the work piece.
 Difference between EBM and LBM
Sr. Parameters EBM LBM
NO
.
1 Working When a high velocity When the excited atoms releases
principle beam of electrons photon in the form of chain, a laser
strikes the work piece beam is generated which when strikes
its kinetic energy is on the work piece melts it.
converted into heat
energy
2. Tools used Electron gun is used as Laser material is used as a tool
a tool
3. Accuracy Accuracy is good Accuracy is comparatively more
4. Metal Metal removal rate is Metal removal rate is high
removal rate low
5. Environment The complete process Vacuum is required between flash
or process should be kept in lamp and ruby rod
requirement vacuum
6. Work piece Usually only metals Any material, but not very suitable for
material plastics