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UNIT-1-Introduction_to_Unconventional_Machining_Processes.pptx
- 1. UNIT- 1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES 20ME503PE Unconventional Machining Processes
- 2. DEMERITS OF CONVENTIONAL MACHINING PROCESS
- 4. Need for Unconventional Machining 4 • Greatly improved thermal, mechanical and chemical properties of modern materials – Not able to machine thru conventional methods. (Why???) • Ceramics & Composites – high cost of machining and damage caused during machining – big hurdles to use these materials. • In addition to advanced materials, more complex shapes, low rigidity structures and micro-machined components with tight tolerances and fine surface finish are often needed. • To meet these demands, new processes are developed. • Play a considerable role in aircraft, automobile, tool, die and mold making industries.
- 5. Need for Unconventional Machining 5 • Very high hardness and strength of the material. (above 400 HB.) • The work piece is too flexible or slender to support the cutting or grinding forces. • The shape of the part is complex, such as internal and external profiles, or small diameter holes. • Surface finish or tolerance better than those obtainable conventional process. • Temperature rise or residual stress in the work piece are undesirable.
- 7. 7
- 8. 8 Unconventional Machining Processes - Classification Electrical
- 9. Mechanical Based Processes 9 AJM - Abrasive Jet Machining WJM – Water Jet Machining AWJM – Abrasive Water Jet Machining USM – Ultrasonic Machining
- 10. 10 Electrical Based Processes Electrical EDM - Electrical Discharge Machining WEDM - Wire Cut Electrical Discharge Machining
- 11. 11 Chemical & Electrochemical Based Processes ECM - Electro –Chemical Machining ECD - Electro Chemical Deburring ECG – Electro –Chemical Grinding ECH – Electro – Chemical Honing
- 12. 12 Thermal Based Processes LBM - Laser Beam Machining PAM – Plasma Arc Machining EBM - Electron Beam Machining
- 13. MATERIAL – METHOD OF MACHINING 13
- 14. PROCESS SELECTION 14 Based on the following points 1. Physical Parameters 2. Shapes to be machined 3. Process Capability or Machining Characteristics 4. Economic Considerations
- 17. 17 Process Capability or Machining Characteristics 1. Material Removal rate 2. Tolerance Maintained 3. Surface Finish 4. Depth of surface Damage 5. Power required for machining
- 19. LIMITATIONS Of Un Conventional Machining 19 1. More expensive process 2. Low Material Removal Rate (MRR) 3. AJM, CHM , PAM and EBM are not commercially economical Process
- 20. ADVANTAGES of UCM 20 High Accuracy and surface finish in process Less Rejected pieces Increase productivity Tool material need not be harder than work piece material. Easy to machine harder and brittle materials There is no residual stresses in the machined material
- 21. Abrasive Jet Machining (AJM)
- 22. Arrangement of Abrasive Jet Machining (AJM) .
- 23. AJM
- 24. MRR - PARAMETERS
- 25. MASS FLOW RATE
- 27. Gas Pressure
- 28. Velocity of Abrasive particles
- 29. Mixing Ratio
- 31. .
- 32. Advantages 1. We can cut all kind of materials 2. No heat produced in process , so no thermal damage 3. Very thin and brittle material can be machined 4. Low initial investment 5. Good Surface Finish 6. Intricate holes can be cut in hard and brittle material
- 33. Dis-Advantages 1. Low MRR 2. Soft Material cannot be machined 3. Machining accuracy is poor 4. Nozzle Wear Rate is High 5. Abrasive Powder cannot be reused 6. Embedding of Abrasive particle in work piece is the high damage thing in this process 7. It requires Dust Collection System
- 34. Application
- 36. Introduction
- 37. Principle
- 39. WJM
- 41. MRR
- 42. MRR
- 43. MRR
- 44. .
- 45. .
- 46. ADVANTAGES
- 47. DIS-ADVANTAGES
- 48. APPLICATION
- 49. Hydro-dynamic jet Machining Abrasive Water jet Machining
- 52. SUITABLE
- 53. .
- 54. Abrasive Slurry
- 55. Working of USM
- 56. COMPARISON
- 57. TRANSDUCER
- 59. MAGNETOSTRICTIVE TRANSDUCER . Change in length is independent of the direction of the magnetic field But depend only on the magnitude of the field and Nature of the material
- 61. Resonance Frequency of the oscillatory circuit Frequency of Vibrating Rod = Resonance will occur when At resonance , the rod vibrates vigorously and ultrasonic waves are produced at high frequencies
- 64. PIEZOELECTRIC TRANSDUCER Its more efficient than magnetostrictive transducer The modern USM are of this type.
- 66. Definition - Piezoelectric Piezoelectric transducers are a type of electro acoustic transducer that convert the electrical charges produced by some forms of solid materials into energy. The word "piezoelectric" literally means electricity caused by pressure.
- 67. Circuit
- 68. Arrangement of the circuit
- 69. Resonance
- 70. Advantages – Piezoelectric transducer Disadvantages – Piezoelectric transducer 1. Piezoelectric quartz is high cost 2. Cutting and shaping of crystal is very complex.
- 72. STRAIGHT AND TAPER ROD AS HORN
- 73. HORN
- 75. FEED MECHANISM
- 76. . 1. Its high sensitive 2. Compact in size
- 77. . 1. Feed rate is high
- 78. MRR MRR Per unit time
- 79. Factors considered for MRR in USM
- 80. Grain size of Abrasives
- 81. Concentration of Slurry Abrasive Slurry = Abrasive Particles + Water
- 82. Amplitude of Vibration MRR increase with the increase of Amplitude of Vibration
- 83. Frequency MRR increases with the increase of Ultrasonic wave Frequency
- 85. Tool Material Lengthy tool causes overstresses So tool should be short and rigid Process Parameters
- 86. Process Parameters Wear Ratio 1.5 : 1 For Tungsten Carbide Work Pieces 100 : 1 For Glass Work Pieces 50 : 1 For Quartz Work Pieces 75 : 1 For Ceramics 1 : 1 For Hardened tool steel Work Pieces
- 87. Abrasive Material and Cutting Power Process Parameters
- 90. Applications