Considerations in Process

Selection & Materials Applications

Lecture-2
Considerations in Process Selection
• To make efficient use of modern machining, it is
necessary to know the exact nature of machining
problem
• For a given machining problem, the aspects to be
studied in selecting a machining process are:
i) Physical Parameters
ii) Properties of the work material and the shape to be
machined
iii) Process capability
iv) Economic Considerations
 Physical parameters
Parame USM AJM ECM CHM EDM EBM LBM PAM
ter
Potenti 220 220 10 - 45 1,50, 000 4500 100
al (V)
Current 12 (AC) 1 10,000 - 50 0.001 2 500
(Amp) (Pulsed (Pulsed (Avg.) (DC)
DC) DC) 200
(Peak)
Power 2400 220 100000 - 2700 150 (avg.) - 50000
(Watt) 200 (peak)
Gap 0.25 0.75 0.20 - 0.025 100 150 7.5
(mm)
Mediu Abrasive Abrasive Electro Liquid Liquid Vacuum Air Argon
m in water in gas lyte chemic dielectri or
al c Hydro
gen
 Shape applications of modern
machining processes
Proce Holes Through Cavities Surfacing Through Cutting
ss
Precision holes Standard Precision Standard Double Surf. Shallow Deep
Contou Of rev.
ring
D<0.025 D>0.025 L<20D L>20D

USM - - A C A A C - C -

AJM - - B C C B - - A -

ECM - - A A B A A B A A

CHM B B - - C B - - A -

EDM - - A B A A B - C -

LBM A A B C C C - - A B

PAM - - B - C C - C A A

A-Good, B-Fair, C-Poor

 Process Capability
Process MRR Tolerance Surface Surface Corner radii,
(mm3/min.) (µm) finish, CLA, damage mm
µm depth , µm
USM 300 7.5 0.2 - 0.5 25 0.025
AJM 0.8 50 0.5 – 1.2 2.5 0.100
ECM 1500 50 0.1 – 2.5 5.0 0.025
CHM 15.0 50 0.4 – 2.5 50 0.125
EDM 800 15 0.2 – 12.5 125 0.025
EBM 1.6 25 0.4 – 2.5 250 2.50
LBM 0.1 25 0.4 – 1.25 125 2.50
PAM 75000 125 rough 500 -
Conv. Milling 50000 50 0.4 – 5.0 25 0.050
of steel
 Economic considerations
Process Capital Tooling & Power Efficiency Tool
investment Fixtures requiremen consumptio
t n
USM B B B D C
AJM A B B D B
ECM E C C B A
CHM C B D C A
EDM C D B D D
EBM D B B E A
LBM C B A E A
PAM A B A A A
Conv. Milling B B B A B
of steel
A-Very low, B-Low, C-Medium, D-High, E-Very high
Comparison of some modern
machining processes
 Materials Applications
Process Material
Al Steel Super Titaniu Refract Plastics Cerami Glass
Alloys m ories cs
USM C B C B A B A A
AJM B B A B A B A A
ECM B A A B B D D D
CHM A A B B C C C B
EDM B A A A A D D D
EBM B B B B C B A B
LBM B B B B C B A B
PAM A A A B C C D D

A – Good Application B – Fair C-Poor D-Not Applicable