As per the Latest Syllabus of Anna University, Chennai (Regulation -2017) UNCONVENTIONAL MACHINING PROCESSES For B.E. Vil Semester Mechanical Engineering Branch (Professional Elective - Il) ARS PUBLICATIONS Prof.M.VIVEKANANDHAN CHENNAIBenard UNCONVENTIONAL MACHINING PROCESSES For B.E. VII Semester Mechanical Engineering Branch (Professional Elective-II) As per the latest syllabus of Anna University, Chennai (Regulation-2017) Prof.M.VIVEKANANDHAN, B.E., M.E., PGFSM, (Ph.D), Department of Mechanical Engineering School of Engineering and Technology Surya Group of Institutions Vikiravandi ~ 605652 Villupuram (Dist) Email : vivekanandanm@suryagroup.edu.in A.R.S. PUBLICATIONS No.11, Veerabathra Nagar, Part Il, 8th Street, Medavakkam, Chennai - 600 100, Tamilnadu, India Phone: 044-48587467, Mobile: 9840025186 E-mail: arspublications@gmail.com Web : www.arspublications.comCESSES: UNCONVENTIONAL MACHINING PRO' by Prof.M.vivekanandhan First Edition : July 2024 Copyright © 2021 exclusive by the Authors dno be reproduced in any form without the ing This book or part thereof sou permission of the author Price : Rs.200/- , Dedicated ISBN : 978-93-84608-26-2 7 our Published by and copies can be had from: Beloved Students | Head Office: % A.RS, PUBLICATIONS ot, No.l, Veerabathra Nagar, Part Il, 8th Street, Medavakkam Chennai - 600 100, Tamilnadu, India Phone : 044-48587467, Mobile: 9840025186 E-mail: aspublications@gmail.com Web : www.arspublications.com Branch Office: A.RS. PUBLICATIONS O), Sikali (Taluk) ‘Nagapattinam District Tamilnadu - 609 111, india SePREFACE | am delighted and pleased to bring out our fist edition of UNCONVENTIONAL MACHINING PROCESSES” which covers comprehensively the latest Anna University Syllabus. This book will also be useful to students of ther Unversity questions have been added under each unit, which enable the students to score high marks in University ‘examinations. This book contains five units to elaborate the following titles. Unit-:Deals a Lean Unconventional machining Process, Need, classification merits, demerits and applications. Abrasive Jet Machining, Water Jet Machining, Abrasive Water Jet Machining, Ultrasonic Machining. (AJM, WJM, AWJM and USM). Working Principles, equipment used Process parameters MRR and Applications. Unit- I: Discusses about Electric Discharge Machining (EDM) Wire cut EDM Working Principle, equipment's, Process Parameters, Surface Finish and MRR electrode / Tool Power and control Circuits, Tool Wear, Dielectric, Flushing, Applications, Laser Beam machining and driling, (LBM), plasma, Arc machining (PAM) and Electron Beam Machining (EBM). Principles Equipment, Types - Beam control techniques and Applications, Unit i: Covers the Chemical machining and Electro, Chemical machining (CHM ‘and ECM) Etchants, Mask ant techniques of applying mask ants, Process Parameters, Surface finish and MRR-Applications. Principles of ECM equipment's-Surface Roughness and MRR Electrical circuit Process Parameters ECG and ECH Applications, Unit - IV: Discusses the Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, magneto rheological abrasive flow finishing their working principles, equipment’, and effect of process parameters, tions, advantages and limitations, Unit - V: Deals with Recent developments in non-traditional machining processes, their working principles, equipments, effect of process parameters, applications, advantages and limitations. Comparison of non-traditional machining processes. ‘Two marks questions and answer in addition to review questions have been provided at the end of each unit. Any errors, omission and suggestions forthe improvement of this book are most welcome and would be incorporated in the next edition with a view to make the book more valuable. Authors Prof. M. VIVEKANANDHANACKNOWLEDGEMENT grateful to our honourable founder Chai, MA, MPhil, for the immediate approyay out this book | am extremely ‘Tmt.VisalakshiPonmudi, constant encouragement to bring | am extremely grateful to our honourable Chairms Thiru.DrP.GautamaSigamani M.D., Secretary, Thiru.Dr-P.AShOkSigaman, M.D, forte immediate approval and constant encouragement to bring on ng this book. | also extend our heart felt gratitude to our Principal DrV.KalyanChakaravarthy, M.Tech, Ph.D., Surya Group of Institution {or the valuable assistance provided by him 4 | also thank Dr.M.Shankar, M.E., Ph.D. Head, Department of Mechanical Engineering, Surya Group of Institutions. | &oress our heartul thanks fo Rtn.Mr.A.Ramesh, Proprietor of AR.S.Publications, Chennaifor hi success 'maifor his involvement to make this publication Prof. M.VIVEKANANDHAN SYLLABUS ME8073 UNCONVENTIONAL MACHINING PROCESSES UNIT INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES Unconventional machining Process - Need ~ classification - merits, demerits and applications, Abrasive Jet Machining - Water Jet Machining - Abrasive Water Jet Machining - Ultrasonic Machining.(AJM, WJM, AWJM and USM). Working Principles = equipment used - Process parameters - MRR- Applications. UNIT II THERMAL AND ELECTRICAL ENERGY BASED PROCESSES iple-equipments- Electric Discharge Machining (EDM) - Wire cut EDM — Working Pri Process Parameters-Surface Finish and MRR- electrode / Tool - Power and control Circuits-Too! Wear ~ Dielectric - Flushing — Applications. Laser Beam machining and driling, (LBM), plasma, Arc machining (PAM) and Electron Beam Machining (EBM). Principles ~ Equipment ~Types - Beam control techniques ~ Applications. UNIT Ill CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES Chemical machining and Electro-Chemical machining (CHM and ECM)- Etchants ~ Maskant - techniques of applying maskants - Process Parameters ~ Surface finish and MRR-Applications. Principles of ECM- equipments-Surface Roughness and MRR Electrical circuit-Process Parameters- ECG and ECH - Applications. UNIT IV ADVANCED NANO FINISHING PROCESSES ‘Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing, magneto rheological nishing, magneto rheological abrasive flow finishing their working principles, equipments, effect of process parameters, applications, advantages and limitations. UNIT V RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES Recent developments in non-traditional machining processes, their working principles, equipments, effect of process parameters, applications, advantages and limitations. Comparison of non-traditional machining processes.CONTENTS UNIT- 1 INTRODUCTION AND MECHANICAL 11 1.2 13 14 1.5 1.6 17 18 19 1.10 1 1.12 1.13 ENERGY BASED PROCESSES.. 1.1-1.46 Introduction Types of Manufacturing Process .. Types of Material Removal Process ... Need for Unconventional Machining Processes .... Classification of UCM Processes..... Characteristics of Unconventional Machining Processes Unconventional Manufacturing Process Selection ... Conventional Machining Vs Unconventional Machining .... 1.8.1 Conventional Machining ... 1.8.2. Unconventional Machining .. ‘Advantages and Disadvantages of Unconventional Machining . 1.9.1 Advantages 1.9.2. Disadvantages. Introduction Mechanical Energy based Processes .. Abrasive Jet Machining (Ajm) 1.12.1 Construction of AJM 1.12.2 Working Principle of AIM 1.12.3 Metal Removal Rate Process Parameter (MRR)...... 1.12.4 Process Parameters and AJM Characteristics ... 1.12.5 Characteristics of AJM ....... 1.12.6 Applications of AIM 1,12.7 Advantages and Limitations of AJM .. Water Jet Machining (WJM) ....... 1.13.1, Principle ... 1.13.2 Construction of WJM ....~~ 1113.3 Working of Water Jet 1134 Advantages and dis 1.13.5 Applications of Wat 1.13.6 Process Parameters 1.13.7 Characteristics of WIM 1.14 Ultrasonic Machining (US! 1.14.1 Principle of USM... 1.14.2 Construction of USM 1.14.3 Working of Ultraso 1.14.4 Applications of USM .. 1.14.5 Advantages and Disadvantages of USM .. 1.14.6 Transducers 1.14.7 Clarifications of Transducers. 1.14.8 Magnetostriction Transducers . 1.149 Piezoelectric Transducer 1.14.10 Feed Mechanism, 1.14.11 Material Removal Process. 1.14.12 Factors Affecting Material Removal Rate... 1.14.13 Micro-Ultrasonie 1.14.14 Characteristics of USM .. ‘Abrasive Water Jet Machining (AWJM) , 1.15.1 Construction of AWIM... Las 1.15.2 Working Principle 1.15.3 Advantages and Dis 1.154 Applications of AWIM 1.15.5. Characteristics of AWIM. Review Questions... 2.1 Introduction 2.2 Electrical Discharge Machi eo Machining (WIM) advant ter Jet Machining .. M) nic Machining. Machining (MUSM) of AWM, advantages of AWJM. ining (EDM) unconventional Machining Proce, tages of Water Jet Machining (whey 3 26 2.1 Construction of EDM 2.2.2 Working Principle of Electric Discharge Machining ... 2.2.3 Application of Electric Discharge Machining, 2.2.4 Advantages of EDM . 2.2.5 Disadvantages of EDM. 2.2.6 Dielectric Fluids of EDM 2.2.7 Requirements of EDM. 2.2.8 Electrode Materials and Tool Wear .. 2.2.9 Type of Flushing System... 2.2.10 Power Generator... Wire cut Electr Discharge Machining (Weedm) (00 ‘Travelling Wire Electro - Discharge Machining (Twedm) 2.3.1 Construction and Working. 2.3.2 Applications of Wire-Cut EDM... 2.3.3 Advantages of Wire-cut EDM... - 2.3.4 Disadvantages and Limitations of Wire-Cut EDM .. 2.3.5 Process of Material Removal in Wire-Cut EDM .. 2.3.6 Characteristics of EDM and WCEDM .. Introduction Electron Beam Machining (EBM) 2.5.1 Construction of EBM ... 2.5.2. Working of EBM ... 2.5.3 Material Removal Rate (MRR) 2.5.4 Process Parameters... 2.5.5 Applications of EBM 2.5.6 Advantages and Disadvantages of EBM ... 2.5.7 Characteristics of EBM ... Laser Beam Machining (LBM) 2.6.1 Principle of LBM... 2.6.2 Construction of LBM ..C4 21 Unit-3 3.1 Introduction 3.2. Chemical Miling (CHM) ee Unconventional Machining Pog, 2.6.3 Working of LBM 2.6.4 Material Removal Rate 2.65 Applications of LBM « 2.6.6 Advantages of LBM. 2.6.7 Disadvantages of LBM. 2.68 Characteristics of LBM Plasma Are Machining (PAM). 2.7.1 Principle of PAM 2.72 Construction of PAM... 2.7.3 Working of PAM... 2.7.4 Plasma Are... 2.75 Plasma let 2.1.6 Material Removal Rate (MRR) 2.1.7 Accuracy and Surface Quality 2.7.8 Applications of PAM (MRR) 34 2.7.9 Advantages and Disadvantages of PAM... 2.7.10 Characteristics Of PAM... REVIEW QUESTIONS ‘Chemical and Electro-Chemical Energy based Processes 3.1-3.31Unit-3 Chemical and Electro-Chemical Energy based Processes .. 32.1 Construction and Working of CHM 3.22 Process Details of CHM 3.2.3 Process Parameters... 324 Mater Removal Rte (MRR) 325 Application of CHM, 3.2.6 Advantages of CHM 41 3.2.7 Limitations of CHny 2 UNIT - 4 Advanced Nano inishing Pr Processes. Contents cs Gonmpts 433 Electrochemical Machining (ECM).... 3.9 3.3.1 Working Principle of ECM... 3.9 3.3.2 Construction of ECM 3.9 3.3.3 Power Supply.. Bul 33.4 Electrolytes. 3. 3.3.5 Tools Design..... 3.13 3.3.6 Process Characteristics 3.3.7 Material Removal Rate (MRR) .. 3.3.8 Accuracy of ECM... 3.3.9 Surface Finish.. 3.3.10 Process Control 3.3.11 Applications... 3.3.12 Advantages and Disadvantages of ECM .. Electro Chemical Grinding (ECG)... 3.4.1 Principle 3.42 Construction of ECG .. 3.4.3 Working of ECG..... 3.44 Accuracy and Surface Quality 3.45 Applications of ECG .. 3.4.6 Advantages and Disadvantages. 3.5 Electrochemical Honing (ECH) 3.5.1 Construction of ECH.... 3.5.2. Working of ECH 3.5.3 Applications... REVIEW QUESTIONS Introduction : = . 4.1.1 The different types of Nano Finishing Process Includes 42 Abrasive flow machining Process (AFM) 43 4.2.1. Introduction of AFM.142.7 Mixed in Polmerio 4.28 Classification of AFM ~ 4.29 Capabilities of AFM Process 14.210 Applicaton of AFM Pr0@#88 43. Chemie MECHANICAL POLISHING (cmp) - 431 Principle of CMP. 43.2. Chemo-Mechancal Polishing Tools 43.2 Working . 433 Material Removal Rate in CMP 433.1 Chemical Aspects of Material Removal Rate Se (MRR) 43.2 Mechanical Aspect of Material Removal... 4.34 Process Parameters 44 Magnetic Abrasive Finishing 44.1 Introduction ese 44.2 Principle of MAF... 443 Construction of MAF 44.4 Working of MAE 445 Process Parameters... 44.6 Advantages of MAF. 44. Disadvantages of MAR. 44.8 Applicaton of MA 4.5 Magneto Rheological Fi 8 OM : 4.5.1 Principle ee ates OR 45.2 Working of MRP. 45.3 Modes of Operation 454 Magneto Rbsoogcal Fug” ae cz 4.28 Contents 4.5.5 Properties for MR Fluid 4436 Material Removal Rate in Magneto Rheological Finishing. 4.5.7 Process Parameters Affecting the MRF Process ...unmesnrnnee 430 4.5.8 Advantage of MRAFF 32 4.5.9 Disadvantage of MRAFF ... 432 433 ABB 434 4.5.10. Application of MRAFF .. 46 Magneto Rheological Abrasive Flow Finishing (RAFF) 4.6.1 Working of MRAFF 4.6.2 Mechanism of MRAFF Proces 4.63 Advantages of MRAFF. 4.64 Disadvantages of MRAFF 4.37.. 4.65. Applications of MRAFF REVIEW QUESTIONS Unit-5 Recent Trends in Non-traditi nal Machining Processes .. 5.1 Introduction to Micromachining ... : 5.14 UnConvenionsl Machining in Micromachining Proce. 5.1.2. Classification of UnConventional Micromachining Processes... 5.1.3. Principle of Mechanical Advanced Micromachining... 5.14 Advantages over Other Micromachining Processes: 5.1.5 Applications Micromachining Processes... 5.2. Mechanical Micromachining... 5.3 Thermal Micromachining .....» 5.4 Chemical and Electrochemical Micromachining 5.5. Hybrid Micromachining ae 5.5.1 Types of Non-Traditional Micromachining Processes 5.6 Abrasive Flow Finishing (AFF) .. 5.7. Abrasive Assisted Micromachining... 5.8 Blectro-Discharge Micromachining 5.8.1 Working Principe... 5.8.2 Material Removal Rate (MRR)| 59 Becton 9.1 Working 59.2 Elector 539.3 Advantages 594 Limitations : $59.5, Applictins om us 5,10 Mie Laser Beam Machi (LBM). ‘i 5,101 Pringle we . $0.2 Laser Beam Cutting line) ‘5 5.10.3 Material Removal Rat (MRR) ~ 5.104 Advantages - 5.105 Limitations. 5.10.6 Applicaton... ‘11 Bletrochemical Micromachining (ECM) ~~ 11.1 Mechanism of Material Removal Rate (MRR) ..... 5:12 Bleetrochemical Grinding (ECO) 513 Blastic Emission Machining (BEM)... 5.14 Chemical Micromachining (CM) 5.14. Mechanism of Material Removal 515 Chemo Mechanical Polishing (CMP) 5.16 Laser Assisted Micromachining 5.16 Laser Assisted Micromachining 5.17 Magnetic Abrasive Finishing (MAF) 5.18 fon Beam Micromachining (IBM) SM 5.18.1 Mechanism of MRR. oe SB 5.19 Ulrasonie Micromachining (USM) see 5.19.1 Mechanism of MRR 5.20 Utrasoie Assisted Wicomatning REVIEW QUESTION Two mukqusionanl avon. Model Question Paper S30 . : itl MQ.i-Mae INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES 7a_INTRODUCTION ‘Unconventional manufacturing processes is defined as a group of processes that remove excess material by various technique involving mechanical, thermal, electrical or chemical energy or combinations ofthese energies but do not use a sharp cutting tools as, it needs to be used for conventional manufacturing processes. Extremely hard and brittle materials are difficult to machine by conventional ‘machining processes such as turning, drilling, shaping, and milling. Unconventional machining processes, also called advanced manufecturing processes, are employed where conventional machining processes are not feasible, satisfactory or economical ue to the following special reasons:- © Veryhard fragile materials dificult to clamp for traditional machining. When the workpiece is too flexible or slender. © When the shape ofthe part is too complex. Severaltypes of non-traditional machining processes have been developed to meet «xtra required machining conditions. When these processes are employed properly, they offer many advantages over non traditional machining processes. The common non traditional machining processes are described inthis section. 12 TYPES OF MANUFACTURING PROCESS Manufacturing processes can be broadly divided into two groups: 1, Primary Manufacturing Processes: Provide basi shape and size. 2. Secondary Manufacturing Processes: Provide final shape and size with tighter control on dimension, surface characteristics,yy 42 TaTvPEs OF Material renowl Machining ProeessS al Manotetsing Processes oF UTCONVEntong yy, Unconventional Machin ne x REMOVAL PROCESS SI TERIAL ws ante divided ito two group, posses one ag © 1, Comentiona 2, Non-Tradiion Process. 1, Convetionl Machining Processes: Temestly removes mat mo chips by appving forees onthe work material with a wedge Nh tanga it shrethan he workmatrial under machining cog 2. Characteristics of Conventional Machining: The major charac ofconventional mschining ae: © Generally ncrosopi chip formation by shear deformation ti, ‘© Material removal takes place due to application of cutting forces domain can be classified as mechanical, a © Cutting tools harder than workpiece at room temperature as wet der acing conditions. 4 3, Non-Conventir Manufacturing Processes: It is defined as a group of processes that remove excess material by Various techniques invol mechanical, thermal, electrical or chemical energy or combinations ofthese cnergits but donot use a sharp cutting tools as it needs to be used {omation oreven no chp formation may take place; For example i. Sresstrcusperatineae ‘ofelectrochemical machining mat a ‘occurs due to electrochemical dissolution at. atomic level. SEE TORINCONVENTIONAL WACHINING PROCESSES Convention mating decades, But new exot of products and cor a ent the requirement of the industries over | a ‘aterialsas well as innovative geomettic des Nee putting lot of pressure on capabilites! ‘unconventional mac ‘lteratives to conven ce inthe industry as efficient and ecom™™ ‘ tnizoducton and Mechanical Energy based Proceses ee 413 | With development in the unconventional machining processes, currently there are often the first choice and not an alternative to ‘conventional processes for certain technical requirements. ‘The following examples are provided where unconventional machining processes are prefered over the conventional machining process: © Intricate shaped blind hole ~e.g. square hole of 15 mm x 15 mm witha depth of 30mm, Difficult to machine material e.g. same example as above in Inconel, Ti-alloys or Carbides. Low stress grinding ~ Electrochemical grinding is preferred as compared to conventional grinding. Deep hole with small hole diameter—e.g. 1.5 mmbole with Vd =20. Machining ofcomposits. Extremely hard and brite materials or dificult to machine material ae difficult to machine by traditional machining processes. ‘When the workpiece is too flexible or slender to support the cutting or grinding forces when the shape of the partis too complex. T5_CLASSIFICATION OF UCM PROCESSES. 135 CLASSIFICATION OF UCM PROCESSES © Thenon-conventional manufacturing processes are not affected by hardness, toughness or brittleness of material and can produce any intricate shape on any ‘workpiece material by suitable control over the various physical parameters of the processes. ‘The non-conventional manufacturing processes may be classified on the basi of type of energy namely, mechanical, electrical, chemical, thermal or magnetic, apply to the workpiece directly and have the desired shape transformation or material removal from the work surface by using diferent scientific mechanism. ‘Thus, these non-conventional processes can be classified into various groups according tothe following basic requirements (Fig, 1.1);45 production and Mechanical Energy based Process Unconventional Machining Uvysmorf sesseooad Bujansrvfnunu Puopuruos-uoN z°1 24n3pp saayoeu Sorurgsece Beragoent PPO BUPIEFgeungoets ‘om Surorsem weg *8zRHORIP eR yeortnaqo SUMP waryg Wesquo] one OMT ONDIT OHDOT amesqy Suoeatn t + * + t t * } woryoens Sune | gurmgpeu Supt Sorapea Seago fee : i foyer | ctuojoion, MIND FIEND solves anger IRONED sassenoug saytued | ‘Aioojen ——roetwoo——_wmypout a "T vonsoyg owORe jonas gi Tosa Teuseus —193y ie | | ‘Bou astuoy payydume ABeNOA WENA Ajpeoruioycy ALIN WBE, 00) funn svetpouran i i | I yo somos worsng ‘oResIOgeA uonse aasyqyttouiare[dsip uoy 285 stugoou | | o1seq, womssfe-oumoyy, ——feoqaay —ortuayp-on oat ‘dks A800 tes AE 2 en at sessoooid Sutamyoeynueu: feuonUaAUOS-UON, CHM ECM ECG ECH Chemical & electrochemical z ay 2 a | = ga2i 25 %.,8 i 25322 Mihi) ah . _ . oo 3 228 PCM Figure 1,1 Unconventional machining processes—oOE=EOrtti‘“Csi‘—é—‘(—‘sé 7 unconventional Machining Procese, 16 7.6 CHARACTERK PROCESSES STcS OF UNCONVENTIONAL MACHINING formation > Matralremoval ay occr whi formaionorevenn0 chip Omration maytag Jace, For example in AJM, chips are of microscopic si7= and in case of lace. For example in AIM, Tntachenial macning material reovaloccusdueto elroeetical soho, atatomic evel Tn UCM there may not bea physical tool present. For example in ase jet machining snachisng carried out by laser beam, However in letrochemical machining there is aphysial tol that is very much required for machining, In UCMB the tool need not be harder than the workpiece material. For example in EDM, coppers used as the tool material to machine hardened steels, “Mostly UCMBP processes do not necessarily se mechanical energy to provide material removal They use diferent energy domains to provide machining, For example i USM, AIM, WIM mechanical energy is used to machine material, whereas in ECM electrochemical dissolution constitutes material removal. 4.7 UNCONVENTIONAL MANUFACTURING PROCESS SELECTION = ‘& Acomparative analysis ofthe various unconventional manufacturing processes should ‘bemade so that a guideline may be drawn to find the suitability of application of Afferent processes. ‘© A particular manufacturing process found suitable under the given conditions may notbe equally efficient under other conditions, Therefore, a carefil selection ofthe ‘Process for a given manufacturing problemi, essential, The analysis has been made from the point of view of 1 2 3 Physical parameters involved in the processes, Ceosbiliy ofmaciing direst shapes of wrk materia Applicability of diferent - and non-metal, “So Various types of material, e.g, metals, ally® Operational characterises ofan Economics involved inthe varios, Processes, ee Introduction and Mechanical Energy based Processes 47 1. Physical Parameters “The physical parameters of unconventional machining processes havea direct impact ‘onthe metal removal as wel as on the energy consumed in diferent processes. Table 1.1 Physical parameters of the unconventional processes frarameter] USM | AJM | EcM | cum | EDM | eBM| LBM| PAM Potential] 220 20 10 - 45 | 15000| 4500 | 100 Ww) 0 Current | 12 1 1000 - 50} 0.001 }araveragy 500, (Amp) | (A.C) 09 (pulsed (pulsed 200 peak] (D.C) DC) | D.C) Power | 2400 | 220 |100000] - | 2700 | 150 | - | 5000 Gap | 0.25 | 0.75 | 0.20 - | 0.025} 100 | 150 | 7.5 (mm) Medium | Abrasive| Abrasive [Hestoiye| Liquid | Liquid |Vaceum| Air | Argon inwater |” in gas Cheez | dite ee open Froma comparative study of the effect of metal removal rate onthe power consumed by various unconventional machining processes shown in Fig.1.3 ECM. 104 : Power consumgt lo! aot 10 Metal removal ate mm!imin 10! 10° 10" 10° Figure 1.3 Effect of metal removal rate on power consumption——seeoao—ro—eee uncamentn MCKIE Proce con and MechanialEegy bed Process 18. mpi ine, Tus, the capital cost involved g the mean lines high whereas forthe processes consumption line consum PAM, ECG) below the mean power const the processes (EBM, ECM etc.) ingabove ; below tha line (e.g, EDM, PAM, MCG) i comparatively low. sass (@ EBM, ECM) above the mean pow | 19 “Applicability to materials Materials applications ofthe various machining methods are summarized in the ‘Tables 1.3 and 1.4. For the machining of electrically non-conducting materials, both ECM and EDMare unsuitable, whereas the mechanical methods can achieve the desired results [USM is suitable for machining of reftactory type of material while AJM are for 2. Capability to Shape e ‘The capability of diferent proceses can be analyzed onthe bass of various super alloys and refractory materials sachning operation point ofvew suchas micro ding, rig, cavity Skng, pocketing ‘Table 1.3 Applicability to materials of nonconventional (shallow and dee), contouring a surface, trough euting (shallow and deep) ee processes Table 1.2 Shape application of unconventional processes Hts Alge Toles Through cavities Tantamq| [SNe] Process [Aluminium] Steel [Super aloy]Titanium | Refractory material Precision | Standard [Doube] surface = small holes ‘ato: | of reve- hallow| Dee T [USM | Poor| Fair | Poor | Fair | Good Fewest Dix] Din | P= [D7], alangand wine] St ! 2 |AIM | Fair | Fair | Good | Fair Good | ety is |Prstin|sanaard 3_|_geM_ | Fair [Good[ Good [Fair Fair sm | mm | mm 4 | cam | Good [Good | Fair [Pair Poor Fisml = | = [ood] Poor | Good] Good | Poor | - | Poor | s_|_epm | Fair [Good] Good | Good |" Good! Fer Pe (ac de IES | _epm | Fair | Fair [Fair [Fair Good ecm] - | - [Good] Good | Fair | Good [Good] Fair | Good [Good 4_|_18M _|__Fait_[_fa_}_Fat_}_tt aut s_[ pam | Good [Gooa[ Good | Fair Poor lcuim| air] Far] - | - | Poor] Far] - | - |Gooal - fEDM| = | - [Good] Fair | Good] Gooa] Fax | | Poor | - anal rae Non-Metals [LBM |Goodl Good] Fair | Poor | Poor | Poor |. | = [Good | Fat Ceramics | Plastic [Glass pam] = | = [Fait] - [Poor |p F = boa 1 USM Good Fair Good or | = |_ Poor: | Gaod oo 2 AIM Good Fair Good Formicrodrling operation the 3_| ECM : - = the only proc . a ao 288 which has good capability to mist 4 CHM Poor Poor Fair the process USM, ECM and EDM wi Shapes having slenderness ratio, L/D <201 5 EDM - - = Ive nd ay ake eee sible, EDM and ECM prose 6 EBM Good Fair Fair contouring operation, ECM procesic gee Shallow or deep). For sure 1 LBM Good Fair Fair 'Smiost suitable but other processes except EDM 8 PAM : Poor, : ‘ave no application for contouring opera io eeUnconventional Machining Process, 1.40 tnuroduction and Mechanical Energy based Processes 144 3. Machining Characteristics sonalprocessescanbeanalyag}_ Es2nomies of the Processes : ventional ‘The machining characteristics of different uncom on ‘The economics of the various processes are analyzed on the basis of following with respect fo: factors and given in Table: 1.5 1. Metal emovalrate. Calta coe 2. Tolerance maintained 5 oA 3. Surfice ith obtained 3, Consumed power cost. 4, Depthofsurface damage. ae wal rate efficiene 5. Power requiced for machining Se a Table 1.4 The process capabilities of unconventional manufacturing Se roo wen processes have been compared Table 1.5 The processes economics of unconventional processes [SNe] — Process] MRR] Teerance | Sarace | Depihat | Foner rata) SNo Process [Capital | Tooling] Power | Material] Toot omnis) | w_ | ycta | damage ad |_surtace cost. | cost [consumption| removal rate wear i{ um | | 7s | oaos | 200 cost_| efficiency 2 [am [08 | 9 | 03-12 | 25 250 1 [usm | L L H M 3) eon | oon [9 [ons ts ooo 2_|_aM_| vo L 1 H L + [om [os 3% | os-25 | # : 3 [ecm [va_[ Mt L ve ES 0 «| ciM_[M L c M Vo eM | 16 : 25] 08-25] 250 —} 1s (avenany Salamone iT ro i i yo a Fan —[ 50} “is | eash | a f 7 [tem [7 5 rE VEL VL 7] Coven sy @ [Pam | VE L c VE VE machining 2 | o5-so | 25 3000 9 [mco_[ L L VE L © Themetal ote: + Indicates cost of chemicals ‘The metal removal rates by ECM and PAM are respectively one-fourth and 1.25 times that of conventional whereas others are only smal fractions oft nd Peet requirement ofECM and PAM is alo very high when compared with oe oy other unconventional machin _ : the nc entonal machining processes, This involves higher capital costo, Ho High Processes. ECM bas very low tool wear ate i VEE = Veryhigh eee ut thas certain fil serious y aminati : of machine pars ‘ation ofthe electrolyte used and the corrosion M__= Medium ° The capital cost of ECM is very high when compared with traditional mechanical Contour grinding and other non-conventional machining processes whereas capital costs for AJM and PAM are comparatively low.Unconventional Machining Processes 4412 EDM as ot higher toting cost than other machining process. PoWer Consumption isverylow for PAM and LBM processes wheeasit i greater inc ofECM. The meta} rexmoval elicincys ver high for EBM and LBM than fr othe processes Tnconcusion, the suitability of application of any of the processes is dependent ‘upon various factorsand must be considered allor some ofthem before applying non. conventional processes. conventional OSS nL ACHING. 7 CONVENTIONAL MACHINING VS UNCONVENTIONAL MACHINING 78 CONVENTIONAL NACHINNG Sor 4.8.4 Conventional Machining Conventional machining usually involves changing the shape of a workpiece using animplement made ofa harder material. Using conventional methods to machine hard ‘metal and alloys means increased demand of time and energy and therefore increases in costs; in some cases conventional machining may not be feasible Conventional machining also costs in terms oftool wear and in loss of quality in the product owing to induced residual stresses during manufacture. With ever increasing demand for manufactured goods ofhard alloy and metals, such as Inconel! 718 ot Titanium, more interest has gravitated to non-conventional machining methods. 1.8.2 UnConventional Machining ‘Unconventional machining utilises other forms of energy. The three main forms of nergy used in unconventional machining processes areas follows: 1, Thermal energy. 2. Chemical energy 3. Blecrical energy Inconel 718, itanium and other hard metals and alloys have a very high melting | Point, Using thermal methods will require high energy input for these materials. Concentrating heat onto any material greatly affects its microstructure and will ‘normally cause cracking, which ‘may not be desirable. Safety requirements fr thermal methods, a especially laser, are demanding in terms Machining large areas or many surfaces at the isnot nomally ossbe ame time using thermal methods Introduction and Mechanical Energy based Processes 1.13 segpociction ak erm Dose Proce TS 7 ADVANTAGES AND DISADVANTAGES OF UNCONVENTIONAL SEE MAGHINING 1.9.4 Advantages High accuracy and surface finish, No direct contact of tool and workpiece, so there is less/no wear. Tool life is more. 1. Quieter operation. 41.9.2 Disadvantages 1. Highcost 2. Complex set-up. 3. Skilled operator require. 740 INTRODUCTION. Inthese processes unwanted material inthe workpiece is removed by mechanical erosion. ‘The mechanical erosion can be faciitated by using any medium. For example in abrasive jet machining high velocity abrasive jet is used fr eroding material from the workpiece. In water jet machining high velocity water jets used for cutting the work piece material. 1:11 MECHANICAL ENERGY BASED PROCESSES 1, Abrasive Jet Machining (AJM). 2. Ultrasonic Machining (USM). 3, Water Jet Machining (WJM). 4, Abrasive Water Jet Machining (AWIM). 2 ABRASIVE JET MACHINING (AJM) ‘© Inabrasive jet machining (AJM) a focused stream of abrasive grains of AhO3 oF SiC cartied by high-pressure gas or ai at a high velocity is made to impinge on the work surface through a nozzle of0.-to0.5-mm diameter. © Theprocess dfs from sandblasting (SB) in that AJM has smaller diameter abrasives ‘and a more finely controlled delivery system. The workpiece materialis removed by ‘the mechanical abrasion (MA) action ofthe high-velocity abrasive particles.Unconventional Machining Procesey 444 = AJM machinings best suite typically used to cu, clean, Pee, hard metals Gor machining olesin superbard materials 1 debut, defiash, and etch glass, ceramics, gy Airand abrasives stream \y* diameter (0.3-0.5 mm) Stand-off distance (0.8 mm) Sapphire nozzle ° Jet velocity (150-300 mis) } @ eo Workpiece Figure 14 AJM terminology 4.12.4 Construction of AJM © In the machining system as shown in Fig. 1.5 a gas (nitrogen, CO or ait) is ‘Supplied under a pressure of 2-8 kg/cm?, Oxygen should never be used because itcauses a violent chemical reaction with workpiece chips or abrasives. contains abrasive particles and vibrates at 50 Hz. From the: ‘mixing chamber, the’ 22s, along with the entrained abrasive particles (10-40 Y4 m), passes through 0.45-mm-diameter tungsten carbide nozzle ‘at a speed of 150-300 mis. Introduction and Mechanical Energy based Processes 4.15 © Theabrasive powder feed rate is controlled by the amplitude of vibrations in the mixing chamber. The nozzle stand off distance is 0,81 mm, The relative motion ‘between the workpiece and the nozzle is manually or automatically controlled using cam drives, pantographs, tracer mechanisms, or using computer control according to the cut geometry required, & Masks of copper, glass, or rubber may be used to concentrate the jet stream of abrasive particles to a confined location on the workpiece. Intricate and precise shapes can be produced by using masks with corresponding contours. Dust removal equipment is incorporated to protect the environment. Pressure gauge Mixing chamber [ Gas LS supply Filter Regulator Wyn ‘Vibratory source eset if Workpiece Figure 1.5 AJM systems 1.12.2. Working Principle of AJM & Inthis process gas propulsion system, high pressure gas (air, nitrogen, or CO:) is supplied either by a compressor or a cylinder to propel the abrasive particles to the mixing chamber. ‘The gas should be dry and clean. In case of a compressor, ar filter cum drier is used to avoid water/il contamination of abrasive particles. ‘The amplitude of vibration of the mixing chamber controls the feed rate ofthe abrasive powder.6 Unconventional Machining Procesey 41 © Thesizeand shape of cut tobe controlled by using pantograph. © AJMnozze is usuelly made of tungsten carbide or sapphire (usual ife= 300 fy) with citeular or rectangular cross-section. © Thenozzle material should have high resistance to wear, The nozzle pressure i generally maintained from 2 to 8.5 kgf/cm? depending upon the workpiece material, desired accuracy, ete. ‘The material removal rate, geometric of cut, surface roughness and nozzle wear rate are influenced by the size and distance of nozzle, composition, strength, sz and shape of abrasive. 1.12.3 Metal Removal Rate Process Parameter (MRR) ‘The various parameter that afect the material removal rate ae a follows: 1, Abrasive Mass Flow Rate, 2. Velocity of Particles. 3. MixingRatio, 4. Nozzle TipDistance 5. Gas Pressure. 1. Abrasive Mass Flow Rate Zs sbeasve Dow rte Figure 1.6 Abrasive mass flow rate ‘The metal removal ate is found to ass flow rate (sec Fig 1,6) Increase steadily with an increase in abrasi Introduction and Mechanical Energy based Processes 4.47 2, Velocity of Particles Constant ‘mixing ratio MRR velocity flow ratio Figure 1.7 Velocity of particles ‘& The metal removal rate (MRR) is directly proportional to velocity of abrasive particles (see Fig.1.7). 3. Mixing Ratio ‘Minina ratio Figure 1.8 Mixing ratio ‘&‘Themetal removalrate (MRR) is found to increase with mixing ratio til saturation point and thereafter the MRR decrease with increasing mixing rato (see Fig. 1.8). 4. Nozale Tip Distance & The nozzle geometry, material, stand-off distance (SOD), fedrate, inclination to work. © Thenozle tip distance varies fom 0.25 to 15 mm. 0D 6 w Figure 1.9 Nozzle tip distance_—"—-—srh—tt—ts—~— ventional Machining Proce j gag odction and Mech > The MRR is found to crease with neexsing nozze top distance and then remaing constant fora period oftime despite the increase inthe nozzle tip distance andi gradually decrease after certain value. Energy based Processes 4.42.5 Characteristics of AJM 1. Abrasive Material—Al,O, / SiC/ glass beads Shape — irregular / spherical Size~ 10-50 wm 5, Gas Pressure Mass flow rate~2~20 gm/min gas flow rate MR | 2. Carrer Gas for constant agate ‘Composition Air, CO,,N, Density—Air—1.3 kg/m® Gas Pressure Velocity ~ 500-700 m/s Figure 1.10 Gas pressure Pressure -2~10 bar = The Gas: composition, pressure and velocity. 5-30 pm © The metal removal ate (MRR) is found to increase and is directly proportional ee to the gas pressure 3. Abrasive Jet 1.12.4 Process Parameters and AJM Characteristics Velocity — 100-300 m/s © Process parameters M, Mixing ratio - mass flow rato of abrasive to gas | “2% WORK MATERIAL = NOZZLE Mees ‘Types Material Stand-off distance — 0.5 —5 mm Fe 7 Geometry Impingement Angle ~ 600 - 900 4. Nozzle sop. Material —WC / sapphire 7 Performance of| Diameter — (Internal) 0.2 -0.8 mm Velocity 4 Pressure paca! pune Life — 10-300 hours, a — it | ae Composition S#® ‘Composition 5, The important machining characteristics in AJM are /_Con ‘ Strength, /—Type ‘The material removal rate (MRR) mn?’/in (or) r/min. GAS ‘The machining accuracy. The life ofthe nozzle. ABRASIVE Figure 1.1 Process parameters of AJM—— ET ll 1.20 4.12.6 Applications of AJM 1 4.42.7 Advantages and Limitations of AJM Advantages:- L unconventional Machining Processeg Drling holes, cutting slots cleaning hard surfaces, deburring, polishing, ang radiusing. Deburrng of eoss hoes, slots and threads in small precision parts that require a burr-ftee finish, such as hydraulic valves, ireraft fuel systems, and medical appliances. Machining intricate shapes or holes in sensitive, brite, thin, or diffcult-to-machine materials Insulation stripping and wire cleaning without affecting the conductor. “Micro-deburring of hypodermic needles. Frosting glass and trimming of circuit boards, hybrid circuit resistors, capacitors, silicon and gallium, Removal of films and delicate cleaning of irregular surfaces because the abrasive! streams ableto follow contours. Because AIM is cool machining process, itis best suited for ‘machining brittle and heat-Sensitive material like glass, quartz, sapphire, and ceramics. The processis used for ‘Proves fused for machining super alloys and refractory materials. Ttisnot reactive with any workpiece material, No toot changes are required Intricate parts of sharp comers ‘can be machined, ‘The machined, ‘materials do not, experience hardening No initial hole is required f ied fo ating th ae * operation as required by wire EDM: Ikcan machine thin material tneroduction and Mechanical Energy based Proceses 4124 Limitations: The removal rate is slow. Stray cutting can’t be avoided (low accuracy of + 0.1 mm). ‘The tapering effect may occur especially when drilling in metals. ‘The abrasive may get impeded in the work surface. Suitable dust-collecting systems should be provided. ‘Soft materials can’t be machined by the process. 2. 3. 4 5. 6 1. Silica dust may be a health hazard. 8. Ordinary shop air should be filtered to remove moisture and oil. 113 WATER JET MACHINING (WJM) ‘The key clement in waterjet machining (WIM) is a waterjet, which travels at velocities as high as 900 m/s (approximately Mach 3). When the stream strikes a workpiece surface, the erosive force of water removes the material rapidly. The water, inthis case, acts ike asaw and cutsa narrow groove in the workpiece material. 1.43.1 Principle Water jet technology uses the principle of pressurizing water to extremely high pressures, and allowing the water to escape through very small opening called “orifice” or “jewel”. Water jet cutting uses the beam of water exiting the orifice to cut soft materials. ‘This method isnot suitable for cutting hard materials. The inlet water is typically pressurized ‘between 13004000 bars. This high pressure is forced through a tiny hole in the jewel, ‘hich is typically 0.18 — 0.4 mm in diameter. 1.13.2 Construction of WJM ‘The apparatus of waterjet machining consists ofthe following components: 1. Reservoir It is used for storing water that is to be used in the machining operation. 2.Pump It pumps the water from the reservoir.12 Unconventional Machining Processe, 3.Intensifier It isconnected to the pump. It pressurizes the water acquired from the pump to a desired level. 4. Accumulator It is used for temporarily storing the pressurized water. It is connected to the flo regulator through a control valve 5. Control Valve It controls the direction and pressure of pressurized water that is to be supplied t the nozzle. 6. Flow Regulator Itisused to regulate the flow of water. 7. Nozle Itrenders the pressurized water as a water jet at high velocity (see Fig. 1.12). Accumulator |____J_ Control valve Flow Intensifier Regulator Pump Fa Nozzle Introduction and Mechanical Energy based Processes 4.23 Working of Water Jet Machining (WJM) ‘= Water fromthe reservoir is pamped to the ntensifer using a hydraulic pump. The intensifier inereases the pressure ofthe water tothe required level. Usually, the water is pressurized to 200 from 400 MPa. ‘7 Pressurized wateris then sent to the accumulator. The accumulator temporarily stores the pressurized water, ‘& Pressurized water then enters the nozzle by passing through the control valve and flow regulator. & Control valve controls the direction of water and limits the pressure of water under permissible limits. & Flow regulator regulates and controls the flow rate of water. Water Nozzle feed Sapphire nozzle Jet velocity | YW Figure 1.13 WIM terminology ‘> Pressurized water finally enters the nozzle, Here, it expands witha tremendous increase ints kinetic energy, High velocity water ets produced by the nozzle. & When this waterjet strikes the workpiece, tresses are induced. These stresses are used to remove material from the workpiece. © The water used in water jet machining may or may not be used with stabilizers. Stabilizers are substances that improve the quality of water jet by preventing its fragmentation,__~—S ets Unconventional Machining Processe, 424 4.43.4 Advantage Advantages:- © Waterjet machining isa relatively fast process Iepreventsthe formation ofhea affected zones onthe workpiece. © automatically cleans the surface ofthe workpiece. © WIM has excellent precision. Tolerances of the order of + 0.0053 can obtained. © Iedoes not produce any hazardous gas. = Itiseco-iendly. Disadvantages:- ‘& Only soft materials can be machined. & Very thick materials cannot be easily machined. © Initial investments high 1.13.5 Appli ions of Water Jet Machining ‘Waterjet machining i used to cut thin non-metallic sheets, tis used to cu rubber, wood, ceramics and many other soft materials, tis used for machining circuit boards tis usedin food industry 1.13.6 Process Parameters rtroduction and Mechanical Energy based Processes 41.25 2. Jet Fluid = Typical pressures reported are 150 ~ 1000 MPa, which provide 8 ~ 80 kW of power. Fora given nozzle diameter, the increase in pressure allows more power to be used in the machining process, which in turn increases the depth of the cut. Jet velocities range between 540 and 1400 mis. ‘Material removal rate Surface quality Accuracy Jetnozzle ie ce Wai Stand oft Thickness isance © Feed rate Jet uid © Type © Velocity © Flow rate © Pressure ® Viscosity Figure 1.14 Factors affecting WIM performance ‘The quality of cutting improves at higher pressures by widening the diameter of the jet and by lowering the traverse speed. Under such conditions, materials of greater thicknesses and densities can be cut. Moreover, the larger the pump pressure, the greater will be the depth of the cut. ‘The fluid used must possess low viscosity to minimize the energy losses and be ‘non corrosive, non toxic, common, and inexpensive, ‘Water is commonly used for cutting alloy steels. Alcohol is used for cutting meat, while cooking oils are recommended for cutting frozen foods. Figure 2.11 summarizes different parameters affecting the performance of WIM,OE unconventional Machining Processy 1.26, 3, Target Material &Biritle materi ranges from0.8 to 25 mor uote ones willeut well Materia thickness sutting rates for differeny will fracture, while ee ‘Table 1,6shows thee more. ates for various materials material thicknesses = Table 1.6 Typical water jet cuttin a Material Thickness, (mm) | Feed se (wn) 1 | Leather 2.2 7 | Vinyl chloride 3.0 2 3 | Polyester 2.0 Ee 4 Kevlar 3.0 3 5 Graphite 23 2 =} Gypsumboard 10 6 7_|_Comugated board 200 8 Pulp sheet 120 9 Plywood 1 1.13.7 Characteristics of WJM Table 1.7 Characteristics of WIM [SNe Material Specification 1_| Nozzle material Sapphire, tungsten, carbide 2. Nozzle life 300-500 hours 3. Jet diameter 0.1-0.3 mm 4. | Stand distance 3-25 mm se | 2 salen rate O.6mmi/sco 9. | Toot 14mns 10" | Wetter Water/water with additives i. | Additives Glass, tungsten carbide 12. | Power Giyeerin, polyethylene oxide _— a ——— production and Mechanlcal Enery based Proceses 4.27 ULTRASONIC MACHINING (USM) 744 sitrasonic machining (USM) is one of the unconventional machining process. Working principle ofthis process resembles with conventional and metal cutting asin his process vyasives contained in slurry are driven at high velocity against the workpiece by a tool ‘ioratng at low amplitude and high frequency. “Amplitude is kept ofthe order of 0.07 mmand frequency is maintained at approximately 20,000 Hz. The workpiece material is removed inthe form ofeextremely small chips. Normally very hard particle dust is included in the sturry ike, Al,O,, silicon carbide, boron carbide or diamond dust. 4.14.1 Principle of USM © Working principle of USM is same as that of conventional machining that is material of workpiece is removed by continuous abrasive action of hard particles vibrating in the slurry. Abrasive shurry acts as a multipoint cutting tool and does the similar action as done by a cutting edge. 1.14.2 Construction of USM USM process is indicated inline diagram shown in Fig, 1.15. Details of the process are discussed below. tH Power supply Electro magnetic transducer (Converting clectrical energy to ‘mechanical vibrations) b> Connecting body Tool holder Tool motion| | > Abrasive slurry ‘Tank Figure 1.15 Details of USM Process——— unconventional Machining Processey 128 | 1. Abrasive Slurry ' “Abrasive surry consists of dust cof very hard particles. zone. ten be rezyled wit the elp of Pum ts filed into the machining ‘Ultrasonic head (@) Jet flow Figure 1.16 Slurry injection methods 2, Workpiece ‘Workpiece of hard and brittle material can be machined by USM. Workpiece i clamped on the fixture Ithe setup 3. Cutting Too! ‘Tool oF USM does not do the cutting directly but it vibrates with small amplitude and hgh frequency. So itis suitable to name the tool as vibrating tool rather than cutting} tool. Te toolis made of relatively soft material and used to vibrate abrasive slurry to cut the workpiece material. The tool is attached to the arbor (tool holder) by brazing or ‘mechanical means, Sometimes hollow tols are also used which feed the slurry focusing ‘machining zone. 4. Ultrasonic Oscillator This operation ees ‘lectric current which passes to an ultrasoni coe mucaneaten sara function of the transducer is to convert electr® By developing vibrations into t 5. Feed Mechanism be tool into 4.14.3 Working of Ultrasonic Machi | omen ction and Mechanical Energy based Processes ing @ Ultrasonic machining (USM) is a mechanical material removal process. Itisusedto ‘erode material in the form of fine holes and cavities in hard or brittle workpiece through the use of formed tools, vibrations of high frequency along withthe use ofa suitable abrasive surry-mi. & Theultrasonic machining (USM) process is suitable for machining britle materials such as glass, ceramics and semiconductors for increasingly complex operations to provide intricate shapes and workpiece profiles. © The USMis a non-thermal and non-chemical process which creates no change in the chemical, physical or metallurgical properties of the workpiece. It is therefore being widely used in the manufacturing of hard and brittle materials ‘which are normally unfeasible to machine by the traditional methods. © The cutting is actually performed by the abrasive particles which are suspended in the slurry (fuid). Ultrasonic machining accomplishes the material removal through the abrading action of the grit-loaded slurry which circulates between the tool and the workpiece. Small amplitudes and high frequency of vibrations are given to the tool, typically in the range of 10-20 um at 20-40 kHz. © ‘The hard abrasive particles in the slurry are accelerated towards the workpiece surface by the oscillating action ofthe tool - through repeated abrasions, the tool further machines a cavity of cross-section identical to its own. The material removal takes place is the form of fine grains by shear deformation. © Different mechanisms could be attributed to this material process such as brittle fracturing of the work material, impact action of abrasives, capitations and chemical reaction due to the slurry. The workpiece shape and dimensional accuracy is directly dependent on the geometry of the tool ‘The schematic of ultrasonic material removal process and the schematic of “ultrasonic machine ae shown n Fig 1.15a wide range of brittle materials, including lass, ceramics and diamond can be effectively machined by USM process.Unconventional Machining Procese, 1.30 4.44.4 Applications of USM (1) Thispocessis general apple forthe machining of ard and brite mater lik carbides glass, ceramies, precious stones, titanium, et. It is used for tog) making and punch and die making, (2) The workpeiee materials nomally removed in the form of very find chips ‘generated surface quality is extremely good. (3) Itiswidely used for severalmachining operations ike turing, grinding, tre and milling, etc, It can make hole of round shape and other shapes. 1.14.5 Advantages and Disadvantages of USM _ (1) High accuracy and good surface finish, () Nobest generation during machining @) Capability of driling circular and non-circular holes in very hard materials, (4) No thermal effects on mechanical workpiece (5) Non-conductive materials can be machined. Dleadentge: () Toolwee (2) Frequent tumingis required ©) Lownateiaremovalrat, | (8) Not economical for sof materials, (6) Not suitable for heavy tock removal 1.44.6 Transducers ‘nergy. Inuitrasonic, machining process ectical energy converte, into mechanical ener} 4.14.7 Clarifications of Transducers 1-Based on the physical phenomenon (2) Primary transducer (©) Secondary transducer snsoduction and Mechanical Energy based Proeses 2, Based on the Power Transducer (@) Active transducer () Passive transducer ased on the Type of Output Transducer (@) Analog transducer (©) Digital transducer |, Based on the Electrical Transducer (@) Resistive transducer (b) Capacitive transducer (© Inductive transducer (@ Photoelectric transducer (© Photovoltaic transducer 5. Based on the Non-electrical Transducer (@) Linear displacement (©) Rotary displacement 6. Based on the transduction phenomenon, (a) Transducer (©) Inverse transducer 1.14.8 Magnetostriction Transducers ‘A magnetostriction transducer is a device that is used to convert mechanical energy into magnetic energy and vice versa, Such device can be used asa sensor and also for ‘actuation as the transducer characteristics in very high due tothe bi-directional coupling ‘between mechanical and magneto states ofthe material, This device can also be called as an electro-magneto mechanical device as the Thenociingrte ie veeayeto the problemofadequtely distributing the set of transducer, hom, and cone. decreases the aching = slurry over the enie machining zone. ¢ In addition, the complete system is much more simple and compact than ae sue macknabily ratings or some materials bY USM conventional USM (Fig 1.24), able 18 Relative machin nme ive Removal Rate% suchamethod microholes ofS-rm diameter on quart, glas, and silicon WorkWaverat Relat o Using ee 100 have been produced using tungsten carbide (WC) alloy microtools. However | ce 66 the high wear resistance of sintered diamond (SD) tools made it possible to : = ia ‘machine multiple holes using a single tool oj 40 4.44.44 Characteristics of USM | teri : sea a5 Table 1.9 Characteristics of USM | 6 | Come see! 14 | [SNo [Material Specification | 1 ‘Too! material Brass, mild steel ‘ero : | 4.14.13 Micro-Ultrasonic Machining (MUSM) | Te nasa “Hard and brittle material 3. Abrasive used ‘A 1202, silicon carbide, boron Tool oa | , * — | carbide or diamond dust fet | [4_[ Grinsze 100-800 microns | [5 [een 02-06 mm Microtoo! | 6 Material removal Fracture of work material | 2 Power 500-1200 watts | 8 Hole tolerance Sum | 9. | Surface finish 0.2-0.7 um | 10. |” Amplitude ofoscillation mit | 0.04-0.08 mm i— Workpiece ; oL eee us vin] 1.45 ABRASIVE WATER JET MACHINING (AWJM) ‘Transducer WIMis suitable forcuting plastics foods, rubber insulation, automotive carpeting ‘nd headliners, and most textiles. Harder materials such as glass, ceramics, concrete, Figure 1.24 Mlero-ulrason and tough composites can be cut by adding abrasives to the waterjet during abrasive *mackining Waterjet machini (AWIM).ee Unconventional Machining Proce, 142 ey “The addition of abrasives tothe water jet enhanced the material removal rate a produced cutting speeds between 51 and 460 mm/min. Generally, AWIM CUts 10 tim, faster than the conventional machining methods of composite materials. 1.15.1 Construction of AWJM & AWIM uses low pressure of 4.2 bar to aceclerate a large Volume of a wate, (70%) and abrasive (30%) mixture up oa velocity of 30 mvs, Silicon carbide, corundum, and glass beads of gain size 10-50 jum are often used as abrasiye materials (Fig. 1.25). | Using such method, buts of 0.35 mm height and 0.02 mm width lef in ste) ‘component after grinding arc removed by the erosive effect of the abrasives whig| ater acts asan abrasive carir that dampens its impact effect on the surface, ‘& The introduction of compressed arto the water jet enhances the deburring action Abrasives 30% Jet inzodueion and Mechanical Enery based Proceues Siiecuaes ‘he following elements: Abrasive hopper and feeder, Intensifir, Filters, Mixing chamber, Cutting nozzles, Catcher Weer Woe Pressure gneation [5 Abrasive reservoir ‘Water: unconventional Machining Process, yin and Mechanical Energy based Processes 1.45 64 i 14 sr anges bern 3.8 and 64H, whi vivantoge = Te pried inte Repeiy f8 a Sane a cannot cut materials which degrades quickly with moisture. : are te eo oe aes of 5 am pe iste oP Higher cutting speeds are frequently used for rough cutting purposes which oe ots andes HOWere Btn, ade the surface finish, ety sed oreo oan ‘ deg “ Fa sense a ce Thereisastrong possibility of cracking in brittle materials and only few varieties ee ang scuting te of164mmiminis achieved, which sg of materials could be cut economically. During = WJM process, thick parts cannot be cut accurately and economically. totes tat fore oe WihWIMp terial, grit size, and ty ° Scr aers pl wcrm peel Inthicker materials the taper generated is also a problem. hes, abrasives. Amateral with a high removal rat fe gin arwsed for machining soft metals to obtain the same The equipment used are quite expensive, Fortis, re © There are safely concerns due to noise and high pressures. . ya, atasmaler grain size isrelated tothe reduce, 4,45.4 Applications of AWJM depth of cut and the undeformed chip cross section. In addition the larger the) ‘The water jet cutting (WJC) process is mainly made used in cutting low strength ‘numberof grains per unit shury volume, the more that fall ona unit surface aca, materials like plastics, wood and aluminum. With the addition of abrasives, the AWJM 1.15.3 Advantages and Disadvantages of AWJM process can be used for stronger materials like tool steels. Advantages 1.155 Characteristics of AWJM |Iincases whee the excessive heat generated can cause changes in the material Table 1.9 Characteristics of AVIM ‘Properties, AWIM are very sf processes fr hard metals like cutting tool tects, [so | Material Spciacaee * evar hese dosnt pany ds oc uchparices whi i Curing specds “‘eOmaaias © ‘Nofniersndayer — Smsssedgining Ce 2. AW JMusesalow pressure | 4.2 bar epee: Perinsaerequred inmost cases, = Velocity Some eTown 7 rested onwripsces are typically Zz Riera Silicon carbides, © Typical surtice corundum and glass beads ° fais cette 0f125-250 microns Ra, 3 Grain size 10-150 pm © Theres heat, done, we osmaller kerf sizes, 6. ‘Surface roughness ranges 3.8 and 6.5 ym, . ment li contanination 7, Tolerances £0.13 mm © Therese ra 8 Repeatability £0.04mm > Renee 9. Straightness 0.05 mm Os conposiy, cota 10. Glass a cutting rate 16.4mm'/min ceramics and rubber. |tncanvenonal Machining Proceay 148 REVIEW QUESTIONS energy processes in terms of physic lctrical tpnical and electrical and process economy. rocess capability, rent ofunconventional machining Proce, ded in selection ofthese processes. 1. Compare the mect : parameters. Shape capitis ‘explain the reasons fr the develo” Discuss about the criteria recommen cen traditional and unconventional machining time, advantages and limitations i machinng processe| ‘Make a comparison betwe +, application, copes in terms of cost conventional processes, present in the form of atable, varioy| For different non-< process parameters recommended Jain the principle ofAIM. Mention some ofthe sP deailbout the AJM process variables that influence the rate of materi cific applications. Expl Discuss in removal and accuracy inthe machining. Explain the method of AIM with help of schematic diagram. Mention the advantages and limitations of AIM, Explain the process parameters in WIM processes. With neat sketch explain the process of AJM. List its application and limitations, Explain the process parameters that influence WIM. List the app and limitations of wim Briefly discuss the application and limitation of WIM. Explain the USM machine setup an discuss various feed mechanisms. Discuss the in uence process parameters and applications of USM Give anote the various types of transducers, (2 \THERMAL AND ELECTRICEL ENERGY BASED PROCESSES ZAINTRODUCTION Inthis category of Unconventional machining electrical energy is used in the form of electrochemical energy or electro-heat energy to erode the material or to melt and ‘vapourized itrespectively. Electrochemical machining, electroplating or electro discharge machining are the examples work on this principle. 1. Electrical Discharge Machining (EDM). 2. Wire Cut Electrical Discharge Machining (WC EDM). 22 ELECTRICAL DISCHARGE MACHINING (EDM) It is also known as spark erosion machining or spark machining. Material of workpiece removed due to erosion caused by electric spark. Electrical discharge machining (EDM) is one of the most widely used unconventional machining processes. The main attraction of EDM over conventional machining processes such as metal cutting using different tools and grinding is that this technique utilises thermoelectric process to erode undesired materials from the workpiece bya series of discrete electrical sparks between the workpiece and the electrode 2.2.1 Construction Of EDM ‘The working principle and process of EDM is explained with the help of line diagram in Fig. 2.1. The process details and components are explained below serially. 1. Base and Container ‘& Acontainer of non-conducting, transparent material is used for carrying out EDM The container is filled with dielectric solution. A base to keep workpiece is installed at the bottom of container.ik ing Pr | Energy based Proc unconventional Machining Procesy, aa along lect esses 22. 2. Tool © Toolisgiven ey brass copper or tungsten. bigh wear resistant. Toolsmade siglo ‘machining. Toolis design chine. 3, Dieletrie lution © Dickectriesoitonis gu which should zcgatve polar. ismade of eto provides wo min fnctions, stl itdrive away the chs and prevents ther sticking to workpiece ad t00 © Itenhances the intensity of discharge after getting ionized and so accelerates ‘neta removal ate. 4.Power Supply & ADCpower supply is used, 50-450 V is applied. Due to ionization of dielectric soltonancloctrical breakdown occurs. The electric discharge so caused directly) impinges on the surface of workpiece. © Ittakes onlya few micro seconds to complete the cycle and remove the material. ‘The circuit can be adjusted for auto off after pre-decided time interval. 5. Tool Feed Mechanism Servo sysem senses the chang in COmecsitby moving th toa 84? deo metal removal and immediately | 9.005 t00.50, “ordngly The spa : mn, Spark gap normally varies from secrially conducting material lng material selected should be easy £0 maching der sve foriasde maining and over sized for cut sige i manufactured according tothe geometry to by be electrically conductive. This solution : alll 23 woraplee and Machined Geometry jo ‘The important point for workpiece i that any material whichis electrical conductor é ‘can be machined through this process, whatever be the hardness of the same. The geometry which isto be machined into the workpiece decides the shape and size ofthe tool. | Rack Pinion Gear box ss — Tote tein dt ides Desciof gem GP ea aay Se, vot Tool+Ve = - terminal ete lspoly piese a ne 2 fet sess. = Yc roving pro Figure 2.1 Line diagram indicating working principle and process details of EDM 2.22 Working Principle of Electric Discharge Machining Electric discharge machining process is carried out in presence of dielectric fluid which creates path for discharge. ‘When potential difference is created across the two surfaces of die electric fluid, it gets ionized. Anelectric spark/discharge is generated across the two terminals. The potential difference is developed by a pulsating direct current power supply connected across the two terminals. One of the terminal is positive terminal given to workpiece and tools made negative ‘terminal, ‘Two third of the total heat generated is generated at positive terminal so workpiece is generally given positive polarity ‘The discharge develops atthe location, where two terminals are very close. So tool helps in focusing the discharge or intensity of generated heat at the point of metal removal Application of focused heat raise the temperature of workpiece locally at a point, these way two metals is melted and evaporated,unconventional Machining Process, 24 2.2.3 Applicatio & Thisprocesishiehy independent ofhardnesso Its © tiserywefilintoolnanutiiag 80% ‘edb sight or curved axcs, and for making reed bycooventional macning pean MI src remaking complecavesarefo Bema nthe dy © aap However tiscapalto doalloperatontiat canbe done by convention rmactining. 2.2.4 Advantages of EDM (@) Thisprocesisvery ch economia for machining very hard material (8). Mains igh degre of dimensional accuacyso its recommended for tool and di aking. (©) Compiicated geometries canbe produced which re very difficult otherwise, (@ Highly deticate sections and weak materials can also be processed without any oftheir distortion, because inthis process tool never applies direct pressure on workpiece, (©) Fineboles canbe dried easily and accurately (© Appreciably hgh vale of MRRR can be achieved as compared to other nor} ‘conventional machining processes. 2.25 Disadvantages of EDM ‘There are some limitations of EDM processas listed below: (©) Thisprocesscamot be applied on orkpie verylage sized workpieces is constrained the sie ofset up. ” Machining ic Discharge n of Electric ofveryhard material as tool Weary workpiece material eee ao wed or beach making making bo plicated cavities which cannot by assize of workpiec very high temperature atthe ‘machining zone, there at workpiece incase ofthis section Pableto produce tarp comers M process is cons yr aj and Electrical Energy based Processes 3s 79 pielectric Fluids of EDM 21 In EDM, ashas been discussed cater, material removal mainly occurs due to thermal evaporation and melting, As thermal processing is required to be caried out in absence cof oxygenso that the process can be controlled and oxidation avoided. o ‘Oxidation often leads to poor surface conductivity electrical) ofthe workpiece hindering further machining, Hence, dielectric fluid should provide an oxygen ‘ree machining environment, Further it should have enough strong dielectric resistance so that it does not breakdown electrically too easily but at the same time ionise when electrons with its molecule ‘Moreover, during sparking it should be thermally resistant as well. Generally kerosene and deionised water is used as dielectric fluid in EDM. Tap ‘water cannot be used as it ionises too early and thus breakdown due to presence of salts as impurities occur, Dielectric mediums generally flushed around the spark zone. Itis also applied through the tool to achieve efficient removal of molten material. 2.2.7 Requirements of EDM (@)_ Thepprocess canbe used to machine any work material ft is electrically conductive. (6) Material removal depends on mainly thermal properties of the work material rather than its strength, hardness ete. (© InEDM there is aphysicaltool and geometry of the tools the positive impression ofthe hole or geometric feature machined, (@ The tool has to be electrically conductive as well. The tool wear once again depends on the thermal properties ofthe tool material. (©) Though the local temperature rise is rather high, still due to very small pulse on time, there is not enough time for the heat to diffuse and thus almost no increase 7 siderably | | ining proces ly lower than the MRR in case 0! Iacinngocesesatay tbe all 88 analtemative to conventions) in bulk temperature takes place. Thus the heat affected zone is limited to 2-4 im ofthe spark.-- Unconventional Machining Proc 26 Sy (0. However rapid heating and cooling and local high temperature leads to surf, hardening which may be desirable in some applications. (@) Thouphthereis possibilty oftaper cut and overcutin EDM, they canbe controig and compensated. | 2.2.8 Electrode Materials and Tool Wear | Electrode material should be such that it would not undergo much tool wear Whey itis impinged by positive ions. Thus the localised temperature rise has to be less y tailoring or properly choosing its properties or even when temperature increases, they, would be less melting, Further, the tol shouldbe easily workable as intricate shape ‘eometri features are machined in EDM. Thus the basic characteristics of electrodg materials are ‘& High electrical conductivity — electrons are cold emitted more easily and theres less bulk electrical heating | ‘High thermal conductivity for the same heat load, the local temperature ris ‘would be less due to faster heat conducted to the bulk of the tool and thus less tool wear. ‘Higher density forthe same heat load and same tool wear by weight there would be less volume removal or tool wea and thus less dimensional loss or inaccuracy © High melting point—high melting point leads to less tool wear due to less tool ‘material melting for the same heat load, ‘& Easymanufacturability = Cost— cheap. The followings are the different lectrode materials which are used. commonly in) the industry; © Graphite, Electrolytic oxygen fee copper Tellurium copper 99% Cu +9 594 tellurium, > Brass, Se ermal and Electrical Energy based Processes 329 Type of Flushing System an "the various methods of flushing are;- 1, Pressure Flushing Suction Flushing 3, Jet Flushing 1. Pressure Flushing Pressure fusing also called injection fushng tis the most common and prefered rthod for flushing, One great advantage of pressure using is that the operator can visually see the amount ofolthat being used for fushing with pressure gauges, tis method of fushing is simple to learn and use. Pressure flushing Blectrode (. a, Secondary Machining ‘es |<—Workpicce Figure 2.2 Pressure flushing 2. Suetion Flushing zap particles, Suction Suction or vacuum flushing can be used to ee a hee eoriplceat ‘lushing can be done through the electrode as shown in Fig, inFig.23._ | Lnconvenonal Machining Procege J and Electrical Energy based Processes ae B | aio Power Generator Figure 2.5 depicted general nature of voltage pulses used in electro-discharge ‘Suction Flushing pachining- Different power generators are used in EDM and some are listed below: 7h Resistance-capacitance type (RC type) Relaxation generator, oe © Rotary impulse type generator, @ Electronic pulse generator, © Hybrid EDM generator, —Workpiece with stud | v . vy, Figure 2.3 Suction flushing 3.fet Flushing ‘Jet or side flushing is done by tubes or flushing nozzles which direct the dielectric) Iidintteppasstown aig. 24. Dashing usally used alongwith jt fusing | Electrode Jet Flushing <—Workpiece Few 24 Je flushing Figure 2.5 Waveform used in EDM ‘The waveform is characterised by the ‘The open circuit voltage- V, ‘The working voltage- V, ‘The maximum current -I, ‘The pulse on time — the duration for which the voltage pulse is applied -ton The pulse off time - off Q 9 0 9. 9 ‘The gap between the workpiece and the tool — spark gap § ° ‘The polarity — straight polarity -tool(-ve) The dielectric medium, a4 9 Extemal flushing through the spark gap.Unconventional Machining Process, 2.10 t Re fol sy & RC type Relaxation generator Reclifer E | Rotary impulse generator with rectifier = | "LY Lye Electronic pulse generator t Cian | Migure 2.6 Basic circuits for different types of EDM gen. tor Se. a ermal and Electrical Energy based Processes 244 Variable resistor DC power a y Capacites | bath: Time Figure 2.7 Resistance - capacitance circuits IL Rotary Impulse Type Generator ‘The introduction of pulse generator as overcomes the drawbacks R-C and R¢C-L. circuits, R-C and R-C-L circuits yield low metal removal rate, Therefore, the rotary pulse generator is used for spark generation Iti yeld high ‘etalremoval rate, low tool wear and precise control of parameter. In ths circuit, the “Spscitors(C) are discharged through the diode during the first half cycle. The next half ‘ele, the sum of the voltages generated by the generator the charged capacitor is applied {othe workpiece-tool gap, This arrangement gives more metal removal ratebut the surface faishing is poor, Motor Generator ul Toot Work Rotary Impulse Generator for EMD Figure 2.8 Rotary impulse type generator circuits