introduction

1. UNIT I INTRODUCTION

2. Syllabus
•
•
•
•
Unconventional machining Process
Need
Classification
Brief overview

3. WHAT IS UCM?

4. Conventional Machining
Process
• Metal Removal ?
• Nature of Contact ?
• Scrap ?

5. Demerits
• Disposal of Waste
• By products of chips
• Work holding Devices for larger cutting
force
• Heat Generation
• Not possible without chips

6. Unconventional Manufacturing
process
• Unconventional Manufacturing process
1. Unconventional Machining process
or
Non Traditional Machining Process
2. Unconventional Forming process

7. Unconventional
Manufacturing process
Machining process
Forming process
• Metal Removal
• Metals are formed
• No Direct Contact b/w
• Releases large amount of
tool and work piece
Energy in very short time
interval

8. NEED FOR UCM

9. Need
• Machining – produces finished products with high degree of
accuracy
• Conventional machining
• Utilizes cutting tools (harder than workpiece material).
• Needs a contact between the tool and workpiece.
• Needs a relative motion between the tool and workpiece.

10. Need
• The need for higher productivity, accuracy and surface quality
• Improve the capability of automation system and decreasing their
sophistication (decreasing the investment cost) requirements
• Very hard fragile materials difficult to clamp for traditional
machining
• When the work piece is too flexible or slender
• When the shape of the part is too complex
• Internal and external profiles, or small diameter holes.

11. CLASSIFICATION

12. Unconventional Machining Processes –
Based on Energy
12

13. Unconventional Machining Processes –
Based Mechanism
13

14. Unconventional Machining Processes –
Based on Energy used for Removal
14

15. Unconventional Machining Processes –
Based on Transfer of Energy
15

16. Mechanical Based Processes
1. Working principles
2. Equipment used
AJM
3. Process parameters
WJM
4. MRR
AWJM
5. Variation in techniques used
USM
6. Applications
16

17. Electrical Based Processes
1.
Working principle
2.
Equipment used
3.
Process parameters
4.
Surface finish & MRR
5.
Electrode/Tool
EDM
6.
Power & Control circuits
WEDM
7.
Tool wear
8.
Dielectric
9.
Flushing
Electrical
10. Applications
17

18. Chemical & Electrochemical Based
Processes
1.
Working principles
2.
Etchants & Maskants
3.
Techniques of applying maskants
CHM
4.
Process parameters
ECM
5.
Surface finish & MRR
ECG
6.
Electrical circuits in case of ECM
ECH
7.
Applications
18

19. Thermal Based Processes
1.
2.
LBM
PAM
EBM
Working principles
Equipment used
3.
Types
4.
Beam control techniques
5.
Applications
19

20. SELECTION PROCESS

21. Selection Process
• Selection Process is based of following
parameters
– Physical Parameter
– Shapes to be Machined
– Process Capability
– Economic consideration

22. Physical Parameter
Parameter
ECM
EDM
EBM
Potential, V
5- 30
50-500
Current, A
40,000
15-500
0.001
Power, kW
100
2.70
Gap, mm
0.5
Medium
Work
Material
LBM
PAM
USM
AJM
250
220
220
2
600
12
1.0
0.15
20
220
2.4
0.22
0.05
100
150
7.5
0.25
0.75
Electrolyte
Die electric
fluid
Vacuum
Air
Argon
Nitrogen
Abrasive
grains
M/C diff
Tungsten
carbide
All Mtl
All Mtl
All Mtl
Tungsten
carbide
HSS
200 x 103 4.5 x 103

23. Shapes to be Machined
Process
Holes ( Micro, Small,
deep,Shallow)
Precision Work
Machines
LBM, EBM,ECM, USM & EDM
USM & EDM
Horning
ECM
Etching
ECM & EDM
Grinding
AJM & EDM
Deburring
USM & AJM
Threading
EDM
Profile Cut
PAM

24. Process Capability or Machining
Characteristics
Process
MRR
( mm3/s )
Surface Finish
(μm)
Accuracy
(μm)
Power (kW/
cm3/ min
LBM
0.10
0.4 – 6.0
25
2700
EBM
0.15 - 40
0.4 – 6.0
25
450
EDM
15 - 80
0.25
10
1.8
ECM
27
0.2 -0.8
50
7.5
PAM
2500
Rough
250
0.90
USM
14
0.2 – 0.7
7.5
9.0
AJM
0.014
0.5- 1.2
50
312.5

25. Process Economy
Process
Capital Cost
Tool & Fixtures
Power
Requirement
Efficiency
EDM
Medium
High
Low
High
CHM
Medium
Low
High
Medium
ECM
V. High
Medium
Medium
V. Low
AJM
V. Low
Low
Low
Low
USM
High
High
Low
Medium
EBM
High
Low
Low
V. High
LBM
Medium
Low
V. Low
V. High
PAM
V. Low
Low
V. Low
V. Low
Convention
al
V. Low
Low
Low
V. Low

26. Limitation
• More Expensive
• Slow Process
• Commercial

27. Compiled By
D.Vasanth kumar