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Non Conventional machining processes
This document provides an overview of non-conventional machining processes including ultrasonic machining, water jet machining, electro-chemical machining, electro-chemical grinding, and electrical discharge machining. The objective is to make audiences aware of the merits of these non-conventional processes over traditional machining for machining complex, less machinable, or brittle materials in a faster and more economical way using computer-controlled processes with minimal human intervention. An outline and brief description is given for each non-conventional machining technique.
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Non Conventional machining processes
- 1. Machining… with adifference!! That’s what Non-conventional Machining is all about…!!!!
- 2. Objective of Presentation Atthe end of this presentation, audience will be aware of merits of Non conventional machining processes over their traditional counter-parts.
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- 4. Why NCM? • In-Housemachining of complex and less machinable jobs. • Economical and Faster than purchasing readymade job. • Processes are computer-controlled, so negligible human intervention during machining,
- 5. Outline – Ultrasonic Machining –Water Jet Machining – Electro-chemical Machining – Electro-chemical Grinding – Electrodischarge Machining – Conclusion
- 6. Ultrasonic Machining • Ultrasonicvibration (20,000 Hz) of very small amplitudes (0.04-0.08 mm) drive the form tool of ductile material (usually soft steel) • An abrasive slurry is flowed through the work area • Used for brittle materials like glass.
- 7. Water Jet Machining •High pressure water (20,000-60,000 psi) • Induct abrasive into stream • Tight tolerances achievable • Can cut extremely thick parts (5-10 inches possible)
- 8. Water Jet MachiningProducts
- 9. Electro-Chemical Machining (ECM) •Works on the principle of electrolysis • Die is progressively lowered into workpiece as workpiece is dissociated into ions by electrolysis • Low DC voltage, very High current (700 amps) • Used to machine Dies, easily deformable and bittle materials.
- 10. Electrochemical grinding • Combineselectrochemical machining with conventional grinding • Grinding wheel is the cathode • Metal bonded wheel with diamond or Al2O3 abrasive • Majority of material removal from electrolytic action (95%) therefore very low wheel wear • Much faster than conventional grinding • Used to grind brittle and thin jobs.
- 11. Electrical Discharge Machining(EDM) • The tool acts as a cathode (typically copper and graphite) is immersed in a Dielectric fluid with conductive workpiece • DC voltage 40-400V is applied. • Sparking at around 12,000 deg F. • Cycle repeated at 200,000-500,000 Hz • Dielectric: – Acts as an insulator – Cools tool and workpiece – Flushes out debris from work area
- 12. Die Sinker vs.Wire EDM • Die sinker EDM – The die sinks into the part as it sparks away the workpiece – Most common Injection molding die process • Wire EDM – The electrode is a wire that traverses through the part – Common for Extrusion Dies
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- 15. Conclusion Non Conventional machiningprocesses are used when required attributes are impossible to achieve with traditional machining processes.
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