Ucmp Notes

SEMESTER: VI
BRANCH: Mechanical
LESSON PLAN
(Even Semester 2016)
Prepared by
Mr.N.Keerthi Varman
Mr.V.Uma Mahesh, Asst.Professor,
Department of Mechanical Engineering,
Kingston Engineering College.
ME 6004 Unconventional Machining Processs
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INSTITUTE VISION
To be a pioneer in engineering and management education by providing
amicable ambience and being a centre for learning there by perpetuating versatile
professionals in engineering and management suitable for industry, higher education
and research.
INSTITUTE MISSION
Developing, nurturing and building professionals with technical, research and
managerial expertise, intellectual proficiency, right attitude and moral ethics.
Building infrastructure that earmarks the institution to be the most preferred
educational destination and provides the right ambience for creative and innovative
teaching learning process.
Enabling learners to broaden their horizon and helping to meet global challenges.
DEPARTMENT VISION
The department of Mechanical Engineering strives to develop skilled, competent,
ethical and versatile mechanical engineers capable of designing, developing and
analyzing the complex problems and implementation of emerging engineering
technologies, to solve the real time problems.
DEPARTMENT MISSION
Imparting quality education to the students and enhancing their skills to make them
competitive mechanical engineers.
Producing graduates with an ability to identify analyze and solve technical
problems through effective teachinglearning process and emerging techniques.
Maintaining vital, state-of- the-art facilities and as well maintain and update the
same to the requirement with opportunities to create, interpret, apply and
disseminate knowledge.
Providing extension programs to assist graduates finding solutions to engineering
problems through education, consultancy and research that enable the graduate to
understand
professional,
ethical
and
social
responsibilities,
continuous
improvement and well balanced minds suitable for industry, higher education and
research.
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SYLLABUS
ME 6004 UNCONVENTIONAL MACHINING PROCESS
OBJECTIVE:
To learn about various unconventional machining processes, the various process
parameters and their influence on performance and their applications.
UNIT I INTRODUCTION
Unconventional machining Process Need classification Brief overview.

UNIT II MECHANICAL ENERGY BASED PROCESSES
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 III ELECTRICAL ENERGY BASED PROCESSES
Electric
Discharge
Machining
(EDM)-
working
9
Principle-equipments-Process
Parameters-Surface Finish and MRR- electrode / Tool Power and control Circuits-Tool
Wear Dielectric Flushing Wire cut EDM Applications.
UNIT IV CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
11
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 V THERMAL ENERGY BASED PROCESSES
10
Laser Beam machining and drilling (LBM), plasma Arc machining (PAM) and Electron
Beam Machining (EBM). Principles Equipment Types - Beam control techniques
Applications.
TOTAL: 45 PERIODS
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Year : 2015-16
Course Outcomes
Sem. : Even
Name of the Faculty
: V.Uma Mahesh
Design./Dept.
: Asst.Professor
Subject Code
: ME6004
Branch
: Mechanical
Subject Name
: Unconventional Maching Process
Year/Sem./Sec.
: III/VI/A/B
Course Outcomes:
Upon the successful completion of the course, students will be able to:
C316.1: Apply the knowledge of engineering science and identify the processes suitable
for machining of hard materials.
C316.2: Understand the principle, Mechanism of metal removal of various
unconventional machining processes.
C316.3: Identify and evaluate the various process parameters, Material removal rate
(MRR) and their effect on the component machined on various unconventional
machining processes.
C316.4: Understand the engineering applications of various un conventional machining
processes.
Contact Hours:
Lecture: 05 Hrs/week
Tutorial: -
Type of Course:
Required Course
Elective Course
Pre-requisite:
Manufacturing Technology.
Page 4
UNIT I
INTRODUCTION
Year : 2015-16
Sem. : Even
Name of the Faculty
: V.Uma Mahesh
Design./Dept.
: Asst.Professor
Subject Code
: ME6004
Branch
: Mechanical
Subject Name
: Unconventional Machining
Process
Year/Sem./Sec.
: III/VI/A
Unconventional machining Process Need classification Brief overview.

Introduction
Manufacturing processes can be broadly divided into two groups and they are primary
manufacturing processes and secondary manufacturing processes. The former ones provide
basic shape and size to the material as per designers requirement. Casting, forming, powder
metallurgy are such processes to name a few. Secondary manufacturing processes provide the
final shape and size with tighter control on dimension, surface characteristics etc. Material
removal processes are mainly the secondary manufacturing processes.
Material removal processes once again can be divided into mainly two groups and
they are Conventional Machining Processes and Non-Traditional Manufacturing
Processes.
Examples of conventional machining processes are turning, boring, milling, shaping,
broaching, slotting, grinding etc. Similarly, Abrasive Jet Machining (AJM), Ultrasonic
Machining (USM), Water Jet and Abrasive Water Jet Machining (WJM and AWJM),
Electro-discharge Machining (EDM) are some of the Non Traditional Machining (NTM)
Processes.
Classification of Non Traditional Machining Processes
To classify Non Traditional Machining Processes (NTM), one needs to understand
and analyse the differences and similar characteristics between conventional machining
processes and NTM processes.
Conventional Machining Processes mostly remove material in the form of chips by
applying forces on the work material with a wedge shaped cutting tool that is harder than the
work material under machining condition. Such forces induce plastic deformation within the
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work piece leading to shear deformation along the shear plane and chip formation. Fig. shows
depict such chip formation by shear deformation in conventional machining.
Major characteristics of conventional machining are:
Generally macroscopic chip formation by shear deformation
Material removal takes place due to application of cutting forces energy domain can
be classified as mechanical
Cutting tool is harder than work piece at room temperature as well as under
machining conditions
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Non Traditional Machining (NTM) Processes on the other hand are characterised as
follows:
Material removal may occur with chip formation or even no chip formation may take
place. For example in AJM, chips are of microscopic size and in case of
Electrochemical machining material removal occurs due to electrochemical
dissolution at atomic level
In NTM, there may not be a physical tool present. For example in laser jet machining,
machining is carried out by laser beam. However in Electrochemical Machining there
is a physical tool that is very much required for machining
In NTM, the tool need not be harder than the work piece material. For example, in
EDM, copper is used as the tool material to machine hardened steels.
Mostly NTM processes do not necessarily use mechanical energy to provide material
removal. They use different energy domains to provide machining. For example, in
USM, AJM, WJM mechanical energy is used to machine material, whereas in ECM
electrochemical dissolution constitutes material removal.
Thus classification of NTM processes is carried out depending on the nature of energy
used for material removal. The broad classification is given as follows:

Mechanical Processes
Abrasive Jet Machining (AJM)
Ultrasonic Machining (USM)
Water Jet Machining (WJM)
Abrasive Water Jet Machining (AWJM)
Electrochemical Processes
Electrochemical Machining (ECM)
Electro Chemical Grinding (ECG)
Electro Jet Drilling (EJD)
Electro-Thermal Processes
Electro-discharge machining (EDM)
Laser Jet Machining (LJM)
Electron Beam Machining (EBM)
Chemical Processes
Chemical Milling (CHM)
Photochemical Milling (PCM) etc.
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Need for Non Traditional Machining

Conventional machining sufficed the requirement of the industries over the decades. But
new exotic work materials as well as innovative geometric design of products and
omponents were putting lot of pressure on capabilities of conventional machining processes
to manufacture the components with desired tolerances economically. This led to the
development and establishment of NTM processes in the industry as efficient and economic
alternatives to conventional ones. With development in the NTM 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 NTM processes are preferred over
the conventional machining process:
Intricate shaped blind hole e.g. square hole of 15 mmx15 mm with a depth of 30
mm
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 mm hole with l/d = 20
Machining of composites.
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UNIT II
MECHANICAL ENERGY BASED PROCESSES
Year : 2015-16
Sem. : Even
Name of the Faculty
: V.Uma Mahesh
Design./Dept.
: Asst.Professor
Subject Code
: ME6004
Branch
: Mechanical
Subject Name
Process
Year/Sem./Sec.
: III/VI/A
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.
Abrasive Jet Machining

Introduction
In abrasive jet machining (AJM) a focused stream of abrasive grains of Al2O3 or SiC
carried by high-pressure gas or air at a high velocity is made to impinge on the work surface
through a nozzle of 0.3- to 0.5-mm diameter. The process differs from sandblasting (SB) in
that AJM has smaller diameter abrasives and a more finely controlled delivery system. The
work piece material is removed by the mechanical abrasion (MA) action of the high-velocity
abrasive particles. AJM machining is best suited for machining holes in superhard materials.
It is typically used to cut, clean, peen, deburr, deflash, and etch glass, ceramics, or hard
metals.
Machining system
In the machining system shown in Fig. Shows, a gas (nitrogen, CO2, or air) is
supplied under a pressure of 2 to 8 kg/cm2. Oxygen should never be used because it causes a
violent chemical reaction with work piece chips or abrasives. After filtration and regulation,
the gas is passed through a mixing chamber that contains abrasive particles and vibrates at 50
Hz. From the mixing chamber, the gas, along with the entrained abrasive particles (1040
m), passes through a 0.45-mm-diameter tungsten carbide nozzle at a speed of 150 to 300
m/s. Aluminium oxide (Al2O3) and silicon carbide powders are used for heavy cleaning,
cutting, and deburring. Magnesium carbonate is recommended for use in light cleaning and
etching, while sodium bicarbonate is used for fine cleaning and the cutting of soft materials.
Commercial-grade powders are not suitable because their sizes are not well classified. They
may contain silica dust, which can be a health hazard. It is not practical to reuse the abrasive
powder because contaminations and worn grit will cause a decline of the machining rate. The
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abrasive powder feed rate is controlled by the amplitude of vibrations in the mixing chamber.
The nozzle standoff distance is 0.81 mm. The relative motion between the work piece 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.
Process Parameters and Machining Characteristics.
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The process parameters are listed below:

Abrasive
Material Al2O3 / SiC / glass beads
Shape irregular / spherical

Size 10 ~ 50 m
Mass flow rate 2 ~ 20 gm/min
Carrier gas
Composition Air, CO2, N2
Density Air ~ 1.3 kg/m
Velocity 500 ~ 700 m/s

Pressure 2 ~ 10 bar
Flow rate 5 ~ 30 lpm
Abrasive Jet
Velocity 100 ~ 300 m/s
Mixing ratio mass flow ratio of abrasive to gas
Stand-off distance 0.5 ~ 5 mm
0
0
Impingement Angle 60 ~ 90
Nozzle
Material WC / sapphire
Diameter (Internal) 0.2 ~ 0.8 mm
Life 10 ~ 300 hours
The important machining characteristics in AJM are
3
The material removal rate (MRR) mm /min or gm/min
The machining accuracy
The life of the nozzle
Applications
1. Drilling holes, cutting slots, cleaning hard surfaces, deburring, polishing, and
radiusing
2. Deburring of cross holes, slots, and threads in small precision parts that require a
burr-free finish, such as hydraulic valves, aircraft fuel systems, and medical
appliances
3. Machining intricate shapes or holes in sensitive, brittle, thin, or difficult-to-machine
materials
4. Insulation stripping and wire cleaning without affecting the conductor
5. Micro-deburring of hypodermic needles
6. Frosting glass and trimming of circuit boards, hybrid circuit resistors, capacitors,
silicon, and gallium
7. Removal of films and delicate cleaning of irregular surfaces because the abrasive
stream is able to follow contours
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Advantages and limitations of AJM

Advantages
Because AJM is a cool machining process, it is best suited for machining brittle and
heat-sensitive materials like glass, quartz, sapphire, and ceramics.
The process is used for machining superalloys and refractory materials.
It is not reactive with any workpiece material.
No tool changes are required.
Intricate parts of sharp corners can be machined.
The machined materials do not experience hardening.
No initial hole is required for starting the operation as required by wire EDM.
Material utilization is high.
It can machine thin materials.
Limitations
The removal rate is slow.
Stray cutting cant 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 cant be machined by the process.
Silica dust may be a health hazard.
Ordinary shop air should be filtered to remove moisture and oil.
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Water Jet Machining

Introduction
The key element in water jet machining (WJM) is a water jet, which travels at
velocities as high as 900 m/s (approximately Mach 3). When the stream strikes a work piece
surface, the erosive force of water removes the material rapidly. The water, in this case, acts
like a saw and cuts a narrow groove in the work piece material.
The Machining System

WJM system and the main parts of which it is composed.
Hydraulic pump. The hydraulic pump is powered from a 30- kilowatt (kW) electric motor
and supplies oil at pressures as high as 117 bars in order to drive a reciprocating plunger
pump termed an intensifier. The hydraulic pump offers complete flexibility for water jet
cutting and cleaning applications. It also supports single or multiple cutting stations for
increased machining productivity.
Intensifier. The intensifier accepts the water at low pressure (typically 4 bar) and expels it,
through an accumulator, at higher pressures of 3800 bar. The intensifier converts the energy
from the low-pressure hydraulic fluid into ultrahigh-pressure water. The hydraulic system
provides fluid power to a reciprocating piston in the intensifier centre section. A limit switch,
located at each end of the piston travel, signals the electronic controls to shift the directional
control valve and reverses the piston direction. The intensifier assembly, with a plunger on
each side of the piston, generates pressure in both directions. As one side of the intensifier is
in the inlet stroke, the opposite side is generating ultrahigh-pressure output. During the
plunger inlet stroke, filtered water enters the high-pressure cylinder through the check value
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assembly. After the plunger reverses direction, the water is compressed and exits at ultrahigh
pressure.
Accumulator. The accumulator maintains the continuous flow of the high-pressure water and
eliminates pressure fluctuations. It relies on the compressibility of water (12 percent at 3800
bar) in order to maintain a uniform discharge pressure and water jet velocity, when the
intensifier piston changes its direction.
High-pressure tubing. High-pressure tubing transports pressurized water to the cutting head.
Typical tube diameters are 6 to 14 mm. The equipment allows for flexible movement of the
cutting head. The cutting action is controlled either manually or through a remote-control
valve specially designed for this purpose.
Jet cutting nozzle. The nozzle provides a coherent water jet stream for optimum cutting of
low-density, soft material that is considered unmachinable by conventional methods. Nozzles
are normally made from synthetic sapphire. About 200 h of operation are expected from a
nozzle, which becomes damaged by particles of dirt and the accumulation of mineral deposits
on the orifice due to erosive water hardness. A longer nozzle life can be obtained through
multistage filtration, which removes undesired solids of size greater than 0.45 m. The
compact design of the water jet cutting head promotes integration with motion control
systems ranging from two-axis (XY) tables to sophisticated multi axis robotic installations.
Catcher. The catcher acts as a reservoir for collecting the machining debris entrained in the
water jet. Moreover, it reduces the noise levels [105 decibels (dB)] associated with the
reduction in the velocity of the water jet from Mach 3 to subsonic levels.
Process parameters
Jet nozzle.
The standoff distance, shown in Fig. 2.20, is the gap between the jet nozzle (0.10.3
mm diameter) and the work piece (2.56 mm). However for materials used in printed circuit
boards, it may be increased to 13 to 19 mm. For a nozzle of 0.12-mm diameter and cutting
rate of 1.1 milli meters per second (mm/s), McGeough (1988) reported the decrease of the
depth of cut at a larger standoff distance. When cutting fiber-reinforced plastics, reports
showed that the increase in machining rate and use of the small nozzle diameter increased the
width of the damaged layer.
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Jet fluid.
Typical pressures reported by McGeough (1988) are 150 to 1000 MPa, which provide
8 to 80 kW of power. For a 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 to 1400 m/s. 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 noncorrosive, nontoxic, 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 summarizes
different parameters affecting the performance of WJM.
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WJM-Process Parameters
Work piece:
Brittle materials will fracture, while ductile ones will cut well.
Material thicknesses range from 0.8 to 25 mm or more.
Table below shows the cutting rates for different material thicknesses
Material
Thickness(m
m)
Feed rate, m/min
Leather
2.2
20
Vinyl chloride
3.0
0.5
Polyester
2.0
150
Kelvar
3.0
Graphite
2.3
Gypsum board
10
Corrugated board
200
Pulp sheet
120
Plywood
WJM-Applications
WJM is used on metals, paper, cloth, leather, rubber, plastics, food, and ceramics.
It is a versatile and cost-effective cutting process that can be used as an alternative to

traditional machining methods.
It completely eliminates heat-affected zones, toxic fumes, recast layers, work

hardening and thermal stresses.
It is the most flexible and effective cleaning solution available for a variety of
industrial needs.
In general the cut surface has a sandblast appearance.
Moreover, harder materials exhibit a better edge finish.
Typical surface finishes ranges from 1.6 m root mean square (RMS) to very coarse
depending on the application.
Tolerances are in the range of 25 m on thin material.
Both the produced surface roughness and tolerance depend on the machining speed.
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Cutting
WJM is limited to fibreglass and corrugated wood.
Typical example of water jet cutting of
Drilling
The process drills precision-angled and shaped holes in a variety of materials for which other
processes such as EDM or EBM are too expensive or too slow.
Cutting of PCBs
Using a small-diameter water jet, a printed circuit board (PCB) can be cut at a speed
that exceeds 8 m/min, to the accuracy of 0.13 mm.
Boards of various shapes for use in portable radios and cassette players can be cut
using computer numerical control (CNC) technology.
Surface Treatment
Removing deposits and residues without toxic chemicals, which eliminates costly
cleanup and disposal problems.
Surface cleaning of pipes and castings, decorative finishing, nuclear decontamination,

food utensil cleaning, degreasing, polishing, preparation for precise inspection, and
surface texturing.
Economical surface preparation and coating removal.
Removing corrosion, spray residue, soluble salts, chemicals, and surface damage prior
to recoating or painting.
Wire Stripping
Can remove the wire insulating material without damaging the metal or removing the
tinning on the copper wire.
Processing time can be decreased to about 20 % of the manual stripping method.
WJM-Advantages
It has multidirectional cutting capacity.
No heat is produced.
Cuts can be started at any location without the need for predrilled holes.
Wetting of the work piece material is minimal.
There is no deflection to the rest of the work piece.
The burr produced is minimal.
The tool does not wear and, therefore, does not need sharpening.
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The process is environmentally safe.
Hazardous airborne dust contamination and waste disposal problems that are common
when using other cleaning methods are eliminated.
There is multiple head processing.
Simple fixturing eliminates costly and complicated tooling, which reduces turnaround
time and lowers the cost.
Grinding and polishing are eliminated, reducing secondary operation costs.
The narrow kerf allows tight nesting when multiple parts are cut from a single blank.
It is ideal for roughing out material for near net shape.
It is ideal for laser reflective materials such as copper and aluminum.
WJM-Disadvantages
Hourly rates are relatively high.
It is not suitable for mass production because of high maintenance requirements.
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Abrasive Water Jet Machining

Harder materials such as glass, ceramics, concrete, and tough composites can be cut
by adding abrasives to the water jet.
The addition of abrasives to the water jet enhanced MRR and produced cutting speeds
between 51 and 460 mm/min.
Generally, AWJM cuts 10 times faster than the conventional machining methods of
composite materials.
In AWJM, abrasive particles are added to the water jet to enhance its cutting ability
by many folds.
In entrained type AWJM, the abrasive particles are allowed to entrain in water jet to
form abrasive water jet wit sufficient velocity of as high as 800 m/s.
Such high velocity abrasive jet can machine almost any material.
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AWJM accelerates a jet of water (70 percent) and abrasive (30 percent) from 4.2 bar
up to a velocity of 30 m/s.
Silicon carbides, sand (SiO2), corundum, and glass beads of grain size 10 to 150 m
are often used as abrasive materials.
Using such a method, burrs of 0.35 mm height and 0.02 mm width left in steel
component after grinding are removed by the erosive effect of the abrasives while
water acts as an abrasive carrier.
The introduction of compressed air to the water jet enhances the deburring action.
Typical Parameters in Entrained AWJM

Orifice Sapphires 0.1 to 0.3 mm
Focussing Tube WC 0.8 to 2.4 mm
Pressure 2500 to 4000 bar
Abrasive garnet and olivine - #125 to #60
Abrasive flow rate - 0.1 to 1.0 kg/min
Stand off distance 1 to 2 mm
Machine Impact Angle 60o to 900
Traverse Speed 100 mm/min to 5 m/min
Depth of Cut 1 mm to 250 mm
AWJM - Applications
Steels & Non-ferrous alloys
Ti alloys, Ni- alloys
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Polymers
Honeycombs
Metal Matrix Composite & Ceramic Matrix Composite
Concrete
Stone Granite
Wood
Reinforced plastics
Metal Polymer Laminates
Glass Fibre Metal Laminates
AWJM - Advantages
Simple fixturing eliminates costly and complicated tooling, which reduces
turnaround time and lowers the cost.
Grinding and polishing are eliminated, reducing secondary operation costs.
The narrow kerf allows tight nesting when multiple parts are cut from a single
blank.
It is ideal for roughing out material for near net shape.
It is ideal for laser reflective materials such as copper and aluminum.
It allows for more accurate cutting of soft material.
It cuts through very thick material such as 383 mm in titanium and 307 mm in
Inconel.
AWJM - Disvantages
Hourly rates are relatively high.
It is not suitable for mass production because of high maintenance requirements
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ULTRASONIC MACHINING (USM)

Introduction
USM is mechanical material removal process or an abrasive process used to erode
holes or cavities on hard or brittle work piece by using shaped tools, high frequency
mechanical motion and an abrasive slurry. USM offers a solution to the expanding need for
machining brittle materials such as single crystals, glasses and polycrystalline ceramics, and
increasing complex operations to provide intricate shapes and work piece profiles. It is
therefore used extensively in machining hard and brittle materials that are difficult to
machine by traditional manufacturing processes. The hard particles in slurry are accelerated
toward the surface of the work piece by a tool oscillating at a frequency up to 100 KHz through repeated abrasions, the tool machines a cavity of a cross section identical to its own.
USM is primarily targeted for the machining of hard and brittle materials (dielectric
or conductive) such as boron carbide, ceramics, titanium carbides, rubies, quartz etc. USM is
a versatile machining process as far as properties of materials are concerned. This process is
able to effectively machine all materials whether they are electrically conductive or insulator.
For an effective cutting operation, the following parameters need to be carefully considered:
The machining tool must be selected to be highly wear resistant, such as high-carbon
steels.
The abrasives (25-60 m in dia.) in the (water-based, up to 40% solid volume) slurry
includes: Boron carbide, silicon carbide and aluminum oxide.
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The magnetostrictor. The magnetostrictor used in USM, shown in Fig. 2.4, has a highfrequency winding wound on a magnetostrictor core and a special polarizing winding around
an armature. The magnetostrictor effect was first discovered by Joule at Manchester in 1874.
Accordingly, a magnetic field undergoing ultrasonic frequencies causes
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Abrasive slurry. Abrasive slurry is usually composed of 50 percent (by volume) fine
abrasive grains (100800 grit number) of boron carbide (B4C), aluminum oxide (Al2O3), or
silicon carbide (SiC) in 50 percent water. The abrasive slurry is circulated between the
oscillating tool and workpiece.
Under the effect of the static feed force and the ultrasonic vibration, the abrasive
particles are hammered into the workpiece surface causing mechanical chipping of minute
particles. The slurry is pumped through a nozzle close to the tool-workpiece interface at a rate
of 25 liters per minute (L/min). As machining progresses, the slurry becomes less effective as
the particles wear and break down. The expected life ranges from 150 to 200 hours (h) of
ultrasonic exposure (Metals Handbook, 1989). The slurry is continuously fed to the
machining zone in order to ensure efficient flushing of debris and keeps the suspension cool
during machining. The performance of USM depends on the manner in which the slurry is
fed to the cutting zone. Figure shows the different slurry feeding arrangements.
Material removal process

Figure shows the complete material removal mechanism of USM, which involves three
distinct actions:
1. Mechanical abrasion by localized direct hammering of the abrasive grains stuck between
the vibrating tool and adjacent work surface.
2. The micro chipping by free impacts of particles that fly across the machining gap and
strike the workpiece at random locations.
3. The work surface erosion by cavitation in the slurry stream.
The relative contribution of the cavitation effect is reported to be less than 5 percent
of the total material emoved. The dominant mechanism involved in USM of all materials is
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direct hammering. Soft and elastic materials like mild steel are often plastically deformed
first and are later removed at a lower rate.
Applications
The beauty of USM is that it can make non round shapes in hard and brittle materials.
Ultrasonically machined non round-hole part is shown in Figure
Advantage of USM
USM process is a non-thermal, non-chemical, creates no changes in the
microstructures, chemical or physical properties of the workpiece and offers virtually stress
free machined surfaces.
Any materials can be machined regardless of their electrical conductivity
Especially suitable for machining of brittle materials
Machined parts by USM possess better surface finish and higher structural integrity.
USM does not produce thermal, electrical and chemical abnormal surface
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Some disadvantages of USM

USM has higher power consumption and lower material-removal rates than traditional
fabrication processes.
Tool wears fast in USM.
Machining area and depth is restraint in USM.
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UNIT III
ELECTRICAL ENERGY BASED PROCESSES
Year : 2015-16
Sem. : Even
Name of the Faculty
: V.Uma Mahesh
Design./Dept.
: Asst.Professor
Subject Code
: ME6004
Branch
: Mechanical
Subject Name
Process
Year/Sem./Sec.
: III/VI/A
Electric Discharge Machining (EDM)- working Principle-equipments-Process ParametersSurface Finish and MRR- electrode / Tool Power and control Circuits-Tool Wear
Dielectric Flushing Wire cut EDM Applications.
Electrical Discharge Machining (EDM)
Electrical discharge machining (EDM) is one of the most widely used nontraditional
machining processes. The main attraction of EDM over traditional 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 by a series of discrete electrical
sparks between the workpiece and the electrode. A picture of EDM machine in operation.
The traditional machining processes rely on harder tool or abrasive material to remove
the softer material whereas non-traditional machining processes such as EDM uses electrical
spark or thermal energy to erode unwanted material in order to create desired shape. So, the
hardness of the material is no longer a dominating factor for EDM process. A schematic of an
EDM process is shown in Figure, where the tool and the workpiece are immersed in a
dielectric fluid.
Page 28
EDM removes material by discharging an electrical current, normally stored in a capacitor

bank, across a small gap between the tool (cathode) and the workpiece (anode) typically
inorder
Application of EDM
The EDM process has the ability to machine hard, difficult-to-machine materials.
Parts with complex, precise and irregular shapes for forging, press tools, extrusion dies,
difficult internal shapes for aerospace and medical applications can be made by EDM
process. Some of the shapes made by EDM process are shown in Figure.
Working principle of EDM

As shown in Figure at the beginning of EDM operation, a high voltage is applied
across the narrow gap between the electrode and the workpiece. This high voltage induces an
electric field in the insulating dielectric that is present in narrow gap between electrode and
workpiece. This cause conducting particles suspended in the dielectric to concentrate at the
points of strongest electrical field. When the potential difference between the electrode and
the workpiece is sufficiently high, the dielectric breaks down and a transient spark discharges
through the dielectric fluid, removing small amount of material from the workpiece surface.
Advantages of EDM
The main advantages of DM are:
By this process, materials of any hardness can be machined;
No burrs are left in machined surface;
One of the main advantages of this process is that thin and fragile/brittle components
can be machined without distortion;
Complex internal shapes can be machined
Page 29
Limitations of EDM
The main limitations of this process are:
This process can only be employed in electrically conductive materials;
Material removal rate is low and the process overall is slow compared to
conventional
machining processes;
Unwanted erosion and over cutting of material can occur;
Rough surface finish when at high rates of material removal.
Dielectric fluids
Dielectric fluids used in EDM process are hydrocarbon oils, kerosene and deionised water.
The functions of the dielectric fluid are to:
Act as an insulator between the tool and the workpiece.
Act as coolant.
Act as a flushing medium for the removal of the chips.
The electrodes for EDM process usually are made of graphite, brass, copper and coppertungsten alloys.
Design considerations for EDM process are as follows:
Deep slots and narrow openings should be avoided.
The surface smoothness value should not be specified too fine.
Rough cut should be done by other machining process. Only finishing operation
should be done in this process as MRR for this process is low.
Page 30
Wire Cut Electrical Discharge Machining(WCEDM)

EDM, primarily, exists commercially in the form of die-sinking machines and wire
cutting machines (Wire EDM). The concept of wire EDM is shown in Figure. In this process,
a slowly moving wire travels along a prescribed path and removes material from the
workpiece. Wire EDM uses electro-thermal mechanisms to cut electrically conductive
materials. The material is removed by a series of discrete discharges between the wire
electrode and the workpiece in the presence of dielectirc fluid, which creates a path for each
discharge as the fluid becomes ionized in the gap. The area where discharge takes place is
heated to extremely high temperature, so that the surface is melted and removed. The
removed particles are flushed away by the flowing dielectric fluids.
The wire EDM process can cut intricate components for the electric and aerospace
industries. This non-traditional machining process is widely used to pattern tool steel for die
manufacturing.
The wires for wire EDM is made of brass, copper, tungsten, molybdenum. Zinc or brass
coated wires are also used extensively in this process. The wire used in this process should
posses high tensile strength and good electrical conductivity. Wire EDM can also employ to
cut cylindrical objects with high precision. The sparked eroded extrusion dies are presented in
Figure
Page 31
This process is usually used in conjunction with CNC and will only work when a part
is to be cut completely through. The melting temperature of the parts to be machined is an
important parameter for this process rather than strength or hardness. The surface quality and
MRR of the machined surface by wire EDM will depend on different machining parameters
such as applied peak current, and wire materials.
Applications of Wire-Cut EDM

Wire EDM is used for cutting aluminium, brass, copper, carbides, graphite, steels and
titanium. A schematic of the cutting through wire EDM is shown in Fig. 3.11.2. The wire
material varies with the application requirements. Example: for quicker cutting action, zinccoated brass wires are used while for more accurate applications, molybdenum wires
are used.
The process is used in the following areas:
Aerospace, Medical, Electronics and Semiconductor applications
Tool & Die making industries.
For cutting the hard Extrusion Dies
In making Fixtures, Gauges & Cams
Cutting of Gears, Strippers, Punches and Dies
Manufacturing hard Electrodes.
Manufacturing micro-tooling for Micro-EDM, Micro-USM and such other micromachining applications.
Page 32
UNIT IV
CHEMICAL AND ELECTRO-CHEMICAL
ENERGY BASED PROCESSES
Year : 2015-16
Sem. : Even
Name of the Faculty
: V.Uma Mahesh
Design./Dept.
: Asst.Professor
Subject Code
: ME6004
Branch
: Mechanical
Subject Name
Process
Year/Sem./Sec.
: III/VI/A
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.
CHEMICAL MACHINING (CHM)
Introduction
Chemical machining (CM) is the controlled dissolution of work piece material
(etching) by means of a strong chemical reagent (etchant). In CM material is removed from
selected areas of work piece by immersing it in a chemical reagents or etchants; such as acids
and alkaline solutions. Material is removed by microscopic electrochemical cell action, as
occurs in corrosion or chemical dissolution of a metal. This controlled chemical dissolution
will simultaneously etch all exposed surfaces even though the penetration rates of the
material removal may be only 0.00250.1 mm/min. The basic process takes many forms:
chemical milling of pockets, contours, overall metal removal, chemical blanking for etching
through thin sheets; photochemical machining (pcm) for etching by using of photosensitive
resists in microelectronics; chemical or electrochemical polishing where weak chemical
reagents are used (sometimes with remote electric assist) for polishing or deburring and
chemical jet machining where a single chemically active jet is used. A schematic of chemical
machining process is shown in Figure.
Page 33
Figure: (a) Schematic of chemical machining process (b) Stages in producing a profiled
cavity by chemical machining (Kalpakjain & Schmid)
Chemical milling
In chemical milling, shallow cavities are produced on plates, sheets, forgings and
extrusions.The two key materials used in chemical milling process are etchant and maskant.
Etchants are acid or alkaline solutions maintained within controlled ranges of chemical
composition and temperature. Maskants are specially designed elastomeric products that are
hand strippable and chemically resistant to the harsh etchants.
Steps in chemical milling
Residual stress relieving: If the part to be machined has residual stresses from the previous
processing, these stresses first should be relieved in order to prevent warping
after chemical milling.
Preparing: The surfaces are degreased and cleaned thoroughly to ensure both good adhesion
of the masking material and the uniform material removal.
Masking: Masking material is applied (coating or protecting areas not to be etched).
Etching: The exposed surfaces are machined chemically with etchants.
Demasking: After machining, the parts should be washed thoroughly to prevent further
reactions with or exposure to any etchant residues. Then the rest of the masking material is
removed and the part is cleaned and inspected.
Page 34
Applications:
Chemical milling is used in the aerospace industry to remove shallow layers of material from
large aircraft components missile skin panels (Figure), extruded parts for airframes.
Figure : Missile skin-panel section contoured by chemical milling to improve the stiffnessto- weight ratio of the part (Kalpakjain & Schmid)
Electrochemical Machining (ECM)
Introduction
Electrochemical machining (ECM) is a metal-removal process based on the principle
of reverse electroplating. In this process, particles travel from the anodic material (workpiece)
toward the cathodic material (machining tool). A current of electrolyte fluid carries away the
deplated material before it has a chance to reach the machining tool. The cavity produced is
the female mating image of the tool shape.
Page 35
Figure shows the main components of the ECM machine: the feed control system,
electrolyte supply system, power supply unit, and workpiece holding device. As shown in
Fig. 4.3, the feed control system is responsible for feeding the tool at a constant rate during
equilibrium machining. The power supply drives the machining current at a constant dc
(continuous or pulsed) voltage. The electrolyte-feeding unit supplies the electrolyte solution
at a given rate, pressure, and temperature. Facilities for electrolyte filtration, temperature
control, and sludge removal are also included. ECM machines are capable of performing a
wide range of operations such as duplicating, sinking, and drilling. Semiautomatic and fully
automated facilities are used for large-size machining, such as deburring in the automotive
industry. ECM machines, in contrast to conventional machine tools, are designed to stand up
to corrosion attack by using nonmetallic materials. For high strength or rigidity, metals with
nonmetallic coatings are recommended.
Power supply. The dc power supply for ECM has the following features:
1. Voltage of 2 to 30 volts (V) (pulsed or continuous)
2. Current ranges from 50 to 10,000 amperes (A), which allow current densities of 5 to 500
A/cm2
3. Continuous adjustment of the gap voltage
4. Control of the machining current in case of emergency
5. Short circuit protection in a matter of 0.001 s
6. High power factor, high efficiency, small size and weight, and low cost
Page 36
Electrolytes. The main functions of the electrolytes in ECM are to

1. Create conditions for anodic dissolution of workpiece material
2. Conduct the machining current
3. Remove the debris of the electrochemical reactions from the gap
4. Carry away the heat generated by the machining process
5. Maintain a constant temperature in the machining region.
Process characteristics
As shown in Fig. ECM relies mainly on the ECD phase that occurs by the movement of ions
between the cathodic tool and the anodic workpiece.
Accuracy of ECM. A small gap width represents a high degree of process accuracy. As can
be seen in Fig., the accuracy of machined parts depends on the current density, which is
affected by
1. Material equivalent and gap voltage
2. Feed rate and gap phenomena including passivation
3. Electrolyte properties including rate, pH, temperature, concentration, pressure, type, and
velocity
For high process accuracy, machining conditions leading to narrow machining gaps are
recommended. These include use of
1. A high feed rate
2. High-conductivity electrolytes
Page 37
3. Passivating electrolytes, such as NaNO3, that have a low throwing power

4. Tool insulation that limits the side-machining action.
Advantages and disadvantages of ECM
Advantages
There is no wear in the tool because there is no contact between the tool and the
workpiece.
Machining is done at low voltages, compared to other processes, with high metal
removal rates.
Very small dimensions up to 0.05 mm can be controlled.
Complicated profiles can be machined easily in a single operation.
Because of the low temperature developed, no thermal damage occurs to the
workpiece structure.
Hard conductive materials can be machined.
The surface finish can be maintained at 0.1 to 1.25 m Ra.
Because of its high capital cost, ECM is only suitable for mass production work.
Labour requirements are low.
Disadvantages
A huge amount of energy is consumed (about 100 times that required for turning
or drilling steel).
Metal removal rates are slow compared with conventional methods.
ECM can only be applied to electrically conductive workpiece materials.
There are difficulties in safely removing and disposing of the explosive hydrogen
gas generated during machining.
The workpiece needs to be cleaned and oiled immediately after machining.
There are difficulties with handling and containing the electrolyte, which may
attack the equipment.
It is not easy to duplicate the shape of the tool electrode in the workpiece with a
high degree of accuracy because of the side machining effect.
The process cant produce sharp internal or external edges.
The pumping of high-pressure electrolyte into the narrow machining gap gives
rise to large forces acting on the tool and the workpiece.
Page 38
UNIT V
THERMAL ENERGY BASED PROCESSES
: V.Uma Mahesh
: ME6004
Name of the Faculty

Subject Code
Process
Subject Name
Design./Dept.
Branch
Year/Sem./Sec
.
Year : 2015-16
Sem. : Even
: Asst.Professor
: Mechanical
: III/VI/A
Laser Beam machining and drilling (LBM), plasma Arc machining (PAM) and
Electron Beam Machining (EBM). Principles Equipment Types - Beam control techniques
Applications.
LaserBeam Machining (LBM)
Introduction
Laser-beam machining is a thermal material-removal process that utilizes a highenergy, coherent light beam to melt and vaporize particles on the surface of metallic and nonmetallic work pieces. Lasers can be used to cut, drill, weld and mark. LBM is particularly
suitable for making accurately placed holes. A schematic of laser beam machining is shown
in Figure.
Different types of lasers are available for manufacturing operations which are as follows:
o CO2 (pulsed or continuous wave): It is a gas laser that emits light in the
infrared region. It can provide up to 25 kW in continuous-wave mode.
o Nd:YAG: Neodymium-doped Yttrium-Aluminum-Garnet (Y3Al5O12) laser is
a solid- state laser which can deliver light through a fibre-optic cable. It can
provide up to 50 kW power in pulsed mode and 1 kW in continuous-wave
mode.
Page 39
Applications
LBM can make very accurate holes as small as 0.005 mm in refractory metals
ceramics, and composite material without warping the workpieces. This process is
used widely for drilling
Laser beam cutting (drilling)

In drilling, energy transferred (e.g., via a Nd:YAG laser) into the workpiece melts the
material at the point of contact, which subsequently changes into a plasma and leaves
the region.
A gas jet (typically, oxygen) can further facilitate this phase transformation and
departure of material removed.
Laser drilling should be targeted for hard materials and hole geometries that are
difficult to achieve with other methods.
A typical SEM micrograph hole drilled by laser beam machining process employed in
making a hole is shown in Figure
SEM micrograph hole drilled in 250 micro meter thick Silicon Nitride with 3rd harmonic Nd:
YAG laser
Laser beam cutting (milling)
A laser spot reflected onto the surface of a workpiece travels along a prescribed
trajectory and cuts into the material.
Continuous-wave mode (CO2) gas lasers are very suitable for laser cutting providing
high-average power, yielding high material-removal rates, and smooth cutting
surfaces.
Advantage of laser cutting
No limit to cutting path as the laser point can move any path.
The process is stress less allowing very fragile materials to be laser cut without any support.
Very hard and abrasive material can be cut.
Page 40
Sticky materials are also can be cut by this process.

It is a cost effective and flexible process.
High accuracy parts can be machined.
No cutting lubricants required
No tool wear
Narrow heat effected zone
Limitations of laser cutting
Uneconomic on high volumes compared to stamping
Limitations on thickness due to taper
High capital cost
High maintenance cost
Assist or cover gas required
ELECTRON BEAM MACHINING (EBM)

INTRODUCTION
As has already been mentioned in EBM the gun is operated in pulse mode. This is
achieved by appropriately biasing the biased grid located just after the cathode. Switching
pulses are given to the bias grid so as to achieve pulse duration of as low as 50 s to as long
as 15 ms. Beam current is directly related to the number of electrons emitted by the cathode
or available in the beam. Beam current once again can be as low as 200 amp to 1 amp.
Increasing the beam current directly increases the energy per pulse. Similarly increase in
pulse duration also enhances energy per pulse. High-energy pulses (in excess of 100 J/pulse)
can machine larger holes on thicker plates. The energy density and power density is governed
by energy per pulse duration and spot size. Spot size, on the other hand is controlled by the
degree of focusing achieved by the electromagnetic lenses. A higher energy density, i.e., for a
lower spot size, the material removal would be faster though the size of the hole would be
smaller. The plane of focusing would be on the surface of the work piece or just below the
surface of the work piece.
1. Electrons generated in a vacuum chamber
2. Similar to cathode ray tube
3. 10-4 torr
4. Electron gun
Page 41
5. Cathode - tungsten filament at 2500 3000 degC

6. Emission current between 25 and 100mA (a measure of electron beam density)
MRR:
In the region where the beam of electrons meet the workpiece, their energy is
converted into heat Workpiece surface is melted by a combination of electron pressure and
surface tension Melted liquid is rapidly ejected and vaporized to effect material removal
Temperature of the workpiece specimen outside the region being machined is reduced by
pulsing the electron beam (10kHz or less)
Material Volumetric removal rate (mm3 s-1)
Tungsten 1.5
Aluminium 3.9
Page 42
ADVANTAGES OF EBM:
Large depth-to-width ratio of material penetrated by the beam with applications of
very fine hole drilling becoming feasible.
There are a minimum number of pulses ne associated with an optimum accelerating
voltage. In practice the number of pulses to produce a given hole depth is usually
found to decrease with increase in accelerating voltage.
Plasma Arc Machining (PAM):
Plasma-arc machining (PAM) employs a high-velocity jet of high-temperature gas to
melt and displace material in its path called PAM, this is a method of cutting metal with a
plasma-arc, or tungsten inert-gas-arc, torch. The torch produces a high velocity jet of hightemperature ionized gas called plasma that cuts by melting and removing material from the
work piece.
Temperatures in the plasma zone range from 20,000 to 50,000 F (11,000 to
28,000 C). It is used as an alternative to oxyfuel-gas cutting, employing an electric arc at
very high temperatures to melt and vaporize the metal.
Equipment:
A plasma arc cutting torch has four components:
1. The electrode carries the negative charge from the power supply.
2. The swirl ring spins the plasma gas to create a swirling flow pattern.
3. The nozzle constricts the gas flow and increases the arc energy density.
4. The shield channels the flow of shielding gas and protects the nozzle from metal spatter.
Principle of operation:
PAM is a thermal cutting process that uses a constricted jet of high-temperature
plasma gas to melt and separate metal. The plasma arc is formed between a negatively
charged electrode inside the torch and a positively charged work piece. Heat from the
transferred arc rapidly melts the metal, and the high-velocity gas jet expels the molten
material from the cut.
Applications:
The materials cut by PAM are generally those that are difficult to cut by any other
means, such as stainless steels and aluminum alloys. It has an accuracy of about 0.008".
Conclusion:
Page 43
In the latest field of technology respect to welding and machining, plasma arc welding
and machining have a huge success. Due to its improved weld quality and increased weld
output it is been used for precision welding of surgical instruments, to automatic repair of jet
engine blades to the manual welding for repair of components in the tool, die and mold
industry. But due to its high equipment expense and high production of ozone, its been
outnumbered by other advance welding equipment like laser beam welding and electro beam
welding. To overcome the mentioned problem, it is been expected that soon it will fetch with
its minimum cons.
`
PLASMA ARC Welding (PAW)

Introduction:
The plasma welding process was introduced to the welding industry in 1964 as a
method of bringing better control to the arc welding process in lower current ranges. Today,
plasma retains the original advantages it brought to industry by providing an advanced level
of control and accuracy to produce high quality welds in miniature or precision applications
and to provide long electrode life for high production requirements. The plasma process is
equally suited to manual and automatic applications. It has been used in a variety of
operations ranging from high volume welding of strip metal, to precision welding of surgical
Page 44
instruments, to automatic repair of jet engine blades, to the manual welding of kitchen
equipment for the food and dairy industry.
Plasma arc welding (PAW):
Plasma arc welding (PAW) is a process of joining of metals, produced by heating
with a constricted arc between an electrode and the work piece (transfer arc) or the electrode
and the constricting nozzle (non transfer arc). Shielding is obtained from the hot ionized gas
issuing from the orifice, which may be supplemented by an auxiliary source of shielding gas.
Transferred arc process produces plasma jet of high energy density and may be used for high
speed welding and cutting of Ceramics, steels, Aluminum alloys, Copper alloys, Titanium
alloys, Nickel alloys.
Non-transferred arc process produces plasma of relatively low energy density. It is
used for welding of various metals and for plasma spraying (coating).
Equipment:
(1) Power source. A constant current drooping characteristic power source supplying the
dcwelding current is required. It should have an open circuit voltage of 80 volts and have a
duty cycle of 60 percent.
(2) Welding torch. The welding torch for plasma arc welding is similar in appearance to a gas
tungsten arc torch but it is more complex.
(a) All plasma torches are water cooled, even the lowest-current range torch. This is
because the arc is contained inside a chamber in the torch where it generates
considerable heat. During the non transferred period, the arc will be struck between
the nozzle or tip with the orifice and the tungsten electrode.
(b) The torch utilizes the 2 percent thoriated tungsten electrode similar to that used for
gas tungsten welding.
(3) Control console. A control console is required for plasma arc welding. The plasma arc
torches are designed to connect to the control console rather than the power source. The
console includes a power source for the pilot arc, delay timing systems for transferring from
the pilot arc to the transferred arc, and water and gas valves and separate flow meters for the
plasma gas and the shielding gas. The console is usually connected to the power source. The
high-frequency generator is used to initiate the pilot arc.
Principles of Operation:
The plasma arc welding process is normally compared to the gas tungsten arc process.
But in the TIG-process, the arc is burning free and unchanneled, whereas in the plasma-arc
Page 45
system, the arc is necked by an additional water-cooled plasma-nozzle. A plasma gas

almost always 100 % argon flows between the tungsten electrode and the plasma nozzle.
The welding process involves heating a gas called plasma to an extremely high temperature
and then ionizing it such that it becomes electrically conductive. The plasma is used to
transfer an electric arc called pilot arc to a work piece which burns between the tungsten
electrode and the plasma nozzle. By forcing the plasma gas and arc through a constricted
orifice the metal, which is to be welded is melted by the extreme heat of the arc. The weld
pool is protected by the shielding gas, flowing between the outer shielding gas nozzle and the
plasma nozzle. As shielding gas pure argon-rich gas-mixtures with hydrogen or helium are
used.
The high temperature of the plasma or constricted arc and the high velocity plasma jet
provide an increased heat transfer rate over gas tungsten arc welding when using the same
current. This results in faster welding speeds and deeper weld penetration. This method of
operation is used for welding extremely thin material and for welding multi pass groove and
welds and fillet welds.
Uses & Applications:
Plasma arc welding machine is used for several purposes and in various fields. The
common application areas of the machine are:
1. Single runs autogenous and multi-run circumferential pipe welding.

2. In tube mill applications.
3. Welding cryogenic, aerospace and high temperature corrosion resistant alloys.
4. Nuclear submarine pipe system (non-nuclear sections, sub assemblies).
5. Welding steel rocket motor cases.
6. Welding of stainless steel tubes (thickness 2.6 to 6.3 mm).
7. Welding of carbon steel, stainless steel, nickel, copper, brass, monel, inconel, aluminium,
titanium, etc.
8. Welding titanium plates up to 8 mm thickness.
9. Welding nickel and high nickel alloys.
10. or melting, high melting point metals.
11. Plasma torch can be applied to spraying, welding and cutting of difficult to cut metals and
alloys.
Page 46

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SEMESTER: VI

(Even Semester 2016)

Unconventional machining Process Need classification Brief overview.

Chemical machining and Electro-Chemical machining (CHM and ECM)-Etchants

ME 6004 Unconventional Machining Processs

Name of the Faculty

: Unconventional Maching Process

ME 6004 Unconventional Machining Processs

Name of the Faculty

Unconventional machining Process Need classification Brief overview.

ME 6004 Unconventional Machining Processs

Major characteristics of conventional machining are:

Generally macroscopic chip formation by shear deformation

ME 6004 Unconventional Machining Processs

used for material removal. The broad classification is given as follows:

Need for Non Traditional Machining

Difficult to machine material e.g. same example as above in Inconel, Ti-alloys or

Low Stress Grinding Electrochemical Grinding is preferred as compared to

ME 6004 Unconventional Machining Processs

Name of the Faculty

Abrasive Jet Machining

Process Parameters and Machining Characteristics.

ME 6004 Unconventional Machining Processs

The process parameters are listed below:

Shape irregular / spherical

Density Air ~ 1.3 kg/m

Velocity 500 ~ 700 m/s

Advantages and limitations of AJM

The process is used for machining superalloys and refractory materials.

It is not reactive with any workpiece material.

No tool changes are required.

Intricate parts of sharp corners can be machined.

The machined materials do not experience hardening.

Material utilization is high.

It can machine thin materials.

The removal rate is slow.

Stray cutting cant 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 cant be machined by the process.

Silica dust may be a health hazard.

Ordinary shop air should be filtered to remove moisture and oil.

ME 6004 Unconventional Machining Processs

Water Jet Machining

The Machining System

ME 6004 Unconventional Machining Processs

ME 6004 Unconventional Machining Processs

ME 6004 Unconventional Machining Processs

Material thicknesses range from 0.8 to 25 mm or more.

Feed rate, m/min

It is a versatile and cost-effective cutting process that can be used as an alternative to

It completely eliminates heat-affected zones, toxic fumes, recast layers, work

In general the cut surface has a sandblast appearance.

Moreover, harder materials exhibit a better edge finish.

Tolerances are in the range of 25 m on thin material.

ME 6004 Unconventional Machining Processs

WJM is limited to fibreglass and corrugated wood.

Typical example of water jet cutting of

Surface cleaning of pipes and castings, decorative finishing, nuclear decontamination,

Economical surface preparation and coating removal.

Processing time can be decreased to about 20 % of the manual stripping method.

It has multidirectional cutting capacity.

Wetting of the work piece material is minimal.