The document discusses various non-traditional machining processes such as abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). It provides details on the classification of non-traditional processes, including mechanical metal removal processes, electro-chemical processes, and thermal methods. Specific information on process parameters and applications are given for AJM, WJM, and USM. The advantages and limitations of these non-traditional machining techniques are also summarized.
Non-traditional machining processes are used to manufacture complex precision parts. They use indirect energy like sparks, lasers, heat or chemicals instead of direct tool contact. This allows machining of hard materials with complex shapes. Some common non-traditional processes include electrical discharge machining (EDM), electrochemical machining (ECM), laser beam machining, and abrasive jet machining. These processes remove material using techniques like electrical sparks, electrolysis, focused laser beams or high pressure abrasive jets. Non-traditional machining provides benefits like high accuracy, improved surface finish, less tool wear and greater design flexibility compared to traditional machining.
This document provides information on non-traditional manufacturing processes. It defines non-traditional processes as those that remove material using mechanical, thermal, electrical or chemical energy without direct tool-workpiece contact. Several non-traditional processes are described in detail, including ultrasonic machining, water jet machining, abrasive jet machining, electrochemical grinding, and chemical milling. Non-traditional processes allow hard and brittle materials to be machined without damage and with better surface finish compared to traditional processes. They find applications in industries such as aerospace, electronics, and automotive.
This document provides an overview of ultrasonic machining (USM). It explains that in USM, a tool oscillated at ultrasonic frequencies (around 20 kHz) with abrasive particles in the gap between the tool and workpiece. The abrasive particles are forced to repeatedly impact the work surface due to the ultrasonic oscillations, removing material through micro-chipping. Key advantages of USM include the ability to machine hard and brittle materials precisely without producing thermal or chemical defects, while disadvantages include low material removal rates and fast tool wear. Common abrasives used include aluminum oxide and silicon carbide in a water slurry. USM is suitable for machining intricate shapes, small holes, and hard non-conductive
The document discusses non-conventional machining processes. It begins by distinguishing between conventional machining processes, which use hard cutting tools to remove material, and non-conventional processes, which use other energies like mechanical, thermal, electrical, or chemical. Non-conventional processes are then classified based on the type of energy used, including mechanical, electrochemical, electro-thermal, and chemical processes. Examples of specific non-conventional machining techniques are provided within each classification.
Non-traditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies
Non-conventional machining techniques such as EDM, ECM, laser beam machining, electron beam machining, and plasma arc machining remove material using thermoelectric or chemical processes instead of mechanical cutting. They allow machining of hard metals and complex shapes but require specialized equipment. Conventional machining relies on mechanical forces and contact between a harder cutting tool and workpiece, while non-conventional techniques use energy sources like electrical discharge, laser, electron beam, or plasma arc along with chemical etching to remove material layer-by-layer.
The document discusses various non-traditional machining processes such as abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). It provides details on the classification of non-traditional processes, including mechanical metal removal processes, electro-chemical processes, and thermal methods. Specific information on process parameters and applications are given for AJM, WJM, and USM. The advantages and limitations of these non-traditional machining techniques are also summarized.
Non-traditional machining processes are used to manufacture complex precision parts. They use indirect energy like sparks, lasers, heat or chemicals instead of direct tool contact. This allows machining of hard materials with complex shapes. Some common non-traditional processes include electrical discharge machining (EDM), electrochemical machining (ECM), laser beam machining, and abrasive jet machining. These processes remove material using techniques like electrical sparks, electrolysis, focused laser beams or high pressure abrasive jets. Non-traditional machining provides benefits like high accuracy, improved surface finish, less tool wear and greater design flexibility compared to traditional machining.
This document provides information on non-traditional manufacturing processes. It defines non-traditional processes as those that remove material using mechanical, thermal, electrical or chemical energy without direct tool-workpiece contact. Several non-traditional processes are described in detail, including ultrasonic machining, water jet machining, abrasive jet machining, electrochemical grinding, and chemical milling. Non-traditional processes allow hard and brittle materials to be machined without damage and with better surface finish compared to traditional processes. They find applications in industries such as aerospace, electronics, and automotive.
This document provides an overview of ultrasonic machining (USM). It explains that in USM, a tool oscillated at ultrasonic frequencies (around 20 kHz) with abrasive particles in the gap between the tool and workpiece. The abrasive particles are forced to repeatedly impact the work surface due to the ultrasonic oscillations, removing material through micro-chipping. Key advantages of USM include the ability to machine hard and brittle materials precisely without producing thermal or chemical defects, while disadvantages include low material removal rates and fast tool wear. Common abrasives used include aluminum oxide and silicon carbide in a water slurry. USM is suitable for machining intricate shapes, small holes, and hard non-conductive
The document discusses non-conventional machining processes. It begins by distinguishing between conventional machining processes, which use hard cutting tools to remove material, and non-conventional processes, which use other energies like mechanical, thermal, electrical, or chemical. Non-conventional processes are then classified based on the type of energy used, including mechanical, electrochemical, electro-thermal, and chemical processes. Examples of specific non-conventional machining techniques are provided within each classification.
Non-traditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies
Non-conventional machining techniques such as EDM, ECM, laser beam machining, electron beam machining, and plasma arc machining remove material using thermoelectric or chemical processes instead of mechanical cutting. They allow machining of hard metals and complex shapes but require specialized equipment. Conventional machining relies on mechanical forces and contact between a harder cutting tool and workpiece, while non-conventional techniques use energy sources like electrical discharge, laser, electron beam, or plasma arc along with chemical etching to remove material layer-by-layer.
This document provides an overview of 4 unconventional machining processes: abrasive jet machining, water jet machining, abrasive water jet machining, and ultrasonic machining. For each process, it describes the basic working principles, key process parameters, advantages, disadvantages, and applications. The processes remove material using abrasive particles accelerated by air, water, or ultrasonic vibration rather than traditional cutting tools. Water jet machining can cut a variety of materials with no heat effect, while adding abrasives allows cutting stronger metals. Ultrasonic machining uses tool vibration to erode material with abrasives and can machine hard, brittle materials.
Unconventional manufacturing processes remove material using mechanical, thermal, electrical or chemical energy rather than sharp cutting tools. They are used for very hard, brittle materials that cannot be easily machined through traditional processes. There are several types of unconventional processes including abrasive jet machining (AJM), electrochemical machining (ECM), and laser beam machining (LBM). AJM works by using a high velocity stream of abrasive particles to remove material through micro-cutting or brittle fracture. Water jet machining (WJM) uses high pressure water to cut softer materials while abrasive water jet machining (AWJM) adds abrasive particles to the water jet to cut harder materials. Both WJM
This document provides information on various machining processes, both traditional and non-traditional. It begins by defining machining and categorizing different machining methods such as cutting, abrasive processes, and nontraditional processes using electrical, chemical or optical energy. Specific nontraditional processes discussed include abrasive jet machining (AJM), water jet machining (WJM), ultrasonic machining (USM), chemical machining (CM), and electrochemical machining (ECM). The document explains the basic working principles, construction details, advantages, and applications of these nontraditional machining processes.
Conventional machining involves physically removing material from a workpiece using a harder cutting tool, typically through mechanical forces. Non-conventional machining utilizes other forms of energy like thermal, chemical, or electrical instead of mechanical forces and may not require physical contact or chip formation. While conventional machining can be used for most materials economically, non-conventional machining allows for higher precision machining of hard metals and complex parts but requires more advanced equipment and skilled operators.
This document discusses conventional and non-conventional machining methods. It begins by defining conventional machining as using a sharp cutting tool for removal of metal. Non-conventional machining does not require physical contact between tool and workpiece and instead uses tools like laser beams or water jets. The document then covers several non-conventional machining processes in more detail like ultrasonic machining, abrasive jet machining, and water jet machining. It concludes by comparing characteristics of conventional and non-conventional machining.
The document discusses abrasive waterjet machining (AWJM). It begins by explaining that AWJM uses a high pressure water jet mixed with abrasive particles to cut materials. It then discusses the history and development of AWJM, the types of water jets (pure water jet and abrasive water jet), how AWJM works, its applications in cutting a wide variety of materials, advantages like lack of heat affected zones and ability to cut complex shapes, and comparisons to other machining methods. The document provides examples of materials cut with AWJM and concludes by discussing trends in using more environmentally friendly methods like cryogenic abrasive jet machining.
Nontraditional machining processes like waterjet machining (WJM) and abrasive waterjet machining (AWJM) use mechanical energy from water and abrasives for material removal. WJM is used for softer materials while AWJM can machine harder materials. AWJM has advantages over traditional machining like fast setup, low heat generation, and ability to machine complex shapes. Parameters like orifice size, water pressure, abrasive type and flow rate, and traverse speed need to be optimized for effective AWJM.
This document is a seminar report on non-conventional machining processes submitted by Rahul Solanki for their master's degree. It discusses several non-traditional machining techniques including abrasive jet machining, ultrasonic machining, water jet cutting, abrasive water jet cutting, and electrical discharge machining. For each technique, it describes the basic working principles, applications, advantages, and limitations. The report provides an overview of different options for machining hard materials and complex shapes that are difficult with traditional methods.
Non conventional machining process - me III - 116010319119Satish Patel
This document discusses non-conventional machining processes and abrasive water jet cutting. It classifies non-conventional processes into thermal and electro-thermal, mechanical, and chemical and electro-chemical processes. It then describes abrasive water jet cutting, where a high pressure water jet mixed with abrasive particles is used to cut materials. Advantages include the ability to cut hard and brittle materials without generating heat, while disadvantages include low material removal rates and abrasive particles embedding in the workpiece.
Non Traditional Machining is playing vital role in now a days in mechanical Industries so student it should be need sound knowledge in this particular subject due to impact of this subject i am prepare in this materials it is most useful for my students...
All The Best ...
By: Author-Prof.S.Sathishkumar
Advantages and limitation of non traditional machiningMrunal Mohadikar
The document provides an overview of several non-traditional machining processes including Electrical Discharge Machining (EDM), Electrochemical Machining (ECM), Ultrasonic Machining (USM), Laser Beam Machining (LBM), Water Jet Cutting, and Abrasive Water Jet Cutting. For each process, the document discusses the basic technique, key advantages such as ability to machine hard materials and produce complex shapes, and limitations such as low material removal rates or inability to machine non-conductive materials. The document serves to educate readers on alternative manufacturing methods beyond traditional cutting tools and their various applications and constraints.
- Traditional machining processes have limitations like generating unwanted chips and heat that cause issues. Non-traditional machining (NTM) methods were developed to address these limitations.
- NTM methods use different energy sources like mechanical, electrical, chemical, or thermal energy for material removal rather than traditional cutting. They can machine complex geometries, delicate parts, and hard/brittle materials.
- NTM processes are classified based on the energy source and material removal mechanism used. Some common types are abrasive jet machining (AJM), electrochemical machining (ECM), and electric discharge machining (EDM).
This document provides an overview of various advanced machining processes, including chemical milling, photochemical blanking, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, plasma arc cutting, water jet machining, abrasive water jet machining, and abrasive jet machining. Each process is described along with considerations for its application. These non-traditional machining methods allow complex shapes to be cut in hard materials and offer alternatives to conventional processes for difficult-to-machine materials.
This document discusses advanced machining processes, which utilize chemical, electrical, or high-energy beams to machine materials that cannot be processed through traditional machining methods. It describes 10 common types of advanced machining, including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, plasma arc cutting, ultrasonic machining, water jet machining, abrasive jet machining, and nanofabrication methods. The document explains the need for these advanced processes and provides examples of typical parts machined through these methods.
1. The document discusses advanced machining processes and provides an overview of conventional and non-conventional machining.
2. Non-conventional machining uses techniques other than traditional cutting tools, such as thermal, electrical, chemical energies. Examples covered include abrasive jet machining, electrochemical machining, and electron beam machining.
3. Key characteristics of non-conventional machining are that material can be removed without chip formation, there may not be a physical tool, and the tool need not be harder than the workpiece.
Water jet machining uses a high-pressure jet of water to cut materials. Key components include an intensifier that increases water pressure to 3800 bar, an accumulator that maintains uniform pressure, and a sapphire nozzle that forms the jet. It can cut a variety of materials with few limitations and without heat or tool wear. Advantages are flexibility, accuracy, minimal kerf and burrs, and no heat affected zones.
This document provides information on various advanced manufacturing processes including abrasive jet machining, water jet machining, ultrasonic machining, and electric discharge machining. It describes the basic working principles, key components, process parameters, advantages, disadvantages, and applications of each process. For abrasive jet machining, it discusses the arrangement, construction details, abrasive particles used, nozzle types, and factors affecting material removal rate. For water jet machining, it outlines the main parts, operating principle, and process parameters that influence material removal. For ultrasonic machining, it explains how ultrasonic waves are generated using different transducer types, and how the machining occurs between the vibrating tool and workpiece with an abrasive
This document provides an introduction to non-traditional machining processes. It defines non-traditional machining as processes that remove material using mechanical, thermal, electrical or chemical energy without using sharp cutting tools. The need for developing such processes is discussed, such as difficulties in machining new hard materials and complex geometries. A comparison is provided between traditional and non-traditional machining. The document outlines the classification and selection of various non-traditional machining processes and provides examples of when they may be preferable to traditional processes. It introduces several specific non-traditional machining techniques that will be covered in more depth later in the document.
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.
This document discusses electrochemical honing, which combines electrochemical dissolution and mechanical abrasion to machine conductive materials. It removes metal through an electrochemical process using an electrolyte and cathodic tool, while also using abrasive stones for mechanical material removal and surface finishing. This hybrid process allows for higher material removal rates than conventional honing or grinding. Electrochemical honing can achieve tight tolerances, good surface finishes, and shape and finish workpieces in a single process with minimal heat and stresses on the material.
The document describes the process of electrical discharge machining (EDM). It discusses how EDM works by using electrical sparks to erode metal between an electrode tool and a workpiece separated by a dielectric fluid. Key points include:
- EDM uses high frequency electrical pulses to create sparks that melt and vaporize small amounts of metal.
- The sparks shape the workpiece by progressively lowering the electrode as material is removed.
- Process parameters like voltage, current, polarity, and dielectric fluid properties control the material removal rate and surface finish.
The document describes the electrical discharge machining (EDM) process. EDM involves using electrical sparks to erode material from a conductive workpiece. A tool shaped to the desired cavity or hole acts as an electrode and is placed near the workpiece in a dielectric fluid. High-frequency pulses of voltage are applied, causing sparks that melt and evaporate small amounts of material. The process is repeated until the cavity is shaped. Key aspects of EDM include the dielectric fluid, gap size, electrode material, and operating parameters which control the machining rate and surface finish.
This document provides an overview of 4 unconventional machining processes: abrasive jet machining, water jet machining, abrasive water jet machining, and ultrasonic machining. For each process, it describes the basic working principles, key process parameters, advantages, disadvantages, and applications. The processes remove material using abrasive particles accelerated by air, water, or ultrasonic vibration rather than traditional cutting tools. Water jet machining can cut a variety of materials with no heat effect, while adding abrasives allows cutting stronger metals. Ultrasonic machining uses tool vibration to erode material with abrasives and can machine hard, brittle materials.
Unconventional manufacturing processes remove material using mechanical, thermal, electrical or chemical energy rather than sharp cutting tools. They are used for very hard, brittle materials that cannot be easily machined through traditional processes. There are several types of unconventional processes including abrasive jet machining (AJM), electrochemical machining (ECM), and laser beam machining (LBM). AJM works by using a high velocity stream of abrasive particles to remove material through micro-cutting or brittle fracture. Water jet machining (WJM) uses high pressure water to cut softer materials while abrasive water jet machining (AWJM) adds abrasive particles to the water jet to cut harder materials. Both WJM
This document provides information on various machining processes, both traditional and non-traditional. It begins by defining machining and categorizing different machining methods such as cutting, abrasive processes, and nontraditional processes using electrical, chemical or optical energy. Specific nontraditional processes discussed include abrasive jet machining (AJM), water jet machining (WJM), ultrasonic machining (USM), chemical machining (CM), and electrochemical machining (ECM). The document explains the basic working principles, construction details, advantages, and applications of these nontraditional machining processes.
Conventional machining involves physically removing material from a workpiece using a harder cutting tool, typically through mechanical forces. Non-conventional machining utilizes other forms of energy like thermal, chemical, or electrical instead of mechanical forces and may not require physical contact or chip formation. While conventional machining can be used for most materials economically, non-conventional machining allows for higher precision machining of hard metals and complex parts but requires more advanced equipment and skilled operators.
This document discusses conventional and non-conventional machining methods. It begins by defining conventional machining as using a sharp cutting tool for removal of metal. Non-conventional machining does not require physical contact between tool and workpiece and instead uses tools like laser beams or water jets. The document then covers several non-conventional machining processes in more detail like ultrasonic machining, abrasive jet machining, and water jet machining. It concludes by comparing characteristics of conventional and non-conventional machining.
The document discusses abrasive waterjet machining (AWJM). It begins by explaining that AWJM uses a high pressure water jet mixed with abrasive particles to cut materials. It then discusses the history and development of AWJM, the types of water jets (pure water jet and abrasive water jet), how AWJM works, its applications in cutting a wide variety of materials, advantages like lack of heat affected zones and ability to cut complex shapes, and comparisons to other machining methods. The document provides examples of materials cut with AWJM and concludes by discussing trends in using more environmentally friendly methods like cryogenic abrasive jet machining.
Nontraditional machining processes like waterjet machining (WJM) and abrasive waterjet machining (AWJM) use mechanical energy from water and abrasives for material removal. WJM is used for softer materials while AWJM can machine harder materials. AWJM has advantages over traditional machining like fast setup, low heat generation, and ability to machine complex shapes. Parameters like orifice size, water pressure, abrasive type and flow rate, and traverse speed need to be optimized for effective AWJM.
This document is a seminar report on non-conventional machining processes submitted by Rahul Solanki for their master's degree. It discusses several non-traditional machining techniques including abrasive jet machining, ultrasonic machining, water jet cutting, abrasive water jet cutting, and electrical discharge machining. For each technique, it describes the basic working principles, applications, advantages, and limitations. The report provides an overview of different options for machining hard materials and complex shapes that are difficult with traditional methods.
Non conventional machining process - me III - 116010319119Satish Patel
This document discusses non-conventional machining processes and abrasive water jet cutting. It classifies non-conventional processes into thermal and electro-thermal, mechanical, and chemical and electro-chemical processes. It then describes abrasive water jet cutting, where a high pressure water jet mixed with abrasive particles is used to cut materials. Advantages include the ability to cut hard and brittle materials without generating heat, while disadvantages include low material removal rates and abrasive particles embedding in the workpiece.
Non Traditional Machining is playing vital role in now a days in mechanical Industries so student it should be need sound knowledge in this particular subject due to impact of this subject i am prepare in this materials it is most useful for my students...
All The Best ...
By: Author-Prof.S.Sathishkumar
Advantages and limitation of non traditional machiningMrunal Mohadikar
The document provides an overview of several non-traditional machining processes including Electrical Discharge Machining (EDM), Electrochemical Machining (ECM), Ultrasonic Machining (USM), Laser Beam Machining (LBM), Water Jet Cutting, and Abrasive Water Jet Cutting. For each process, the document discusses the basic technique, key advantages such as ability to machine hard materials and produce complex shapes, and limitations such as low material removal rates or inability to machine non-conductive materials. The document serves to educate readers on alternative manufacturing methods beyond traditional cutting tools and their various applications and constraints.
- Traditional machining processes have limitations like generating unwanted chips and heat that cause issues. Non-traditional machining (NTM) methods were developed to address these limitations.
- NTM methods use different energy sources like mechanical, electrical, chemical, or thermal energy for material removal rather than traditional cutting. They can machine complex geometries, delicate parts, and hard/brittle materials.
- NTM processes are classified based on the energy source and material removal mechanism used. Some common types are abrasive jet machining (AJM), electrochemical machining (ECM), and electric discharge machining (EDM).
This document provides an overview of various advanced machining processes, including chemical milling, photochemical blanking, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, plasma arc cutting, water jet machining, abrasive water jet machining, and abrasive jet machining. Each process is described along with considerations for its application. These non-traditional machining methods allow complex shapes to be cut in hard materials and offer alternatives to conventional processes for difficult-to-machine materials.
This document discusses advanced machining processes, which utilize chemical, electrical, or high-energy beams to machine materials that cannot be processed through traditional machining methods. It describes 10 common types of advanced machining, including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, plasma arc cutting, ultrasonic machining, water jet machining, abrasive jet machining, and nanofabrication methods. The document explains the need for these advanced processes and provides examples of typical parts machined through these methods.
1. The document discusses advanced machining processes and provides an overview of conventional and non-conventional machining.
2. Non-conventional machining uses techniques other than traditional cutting tools, such as thermal, electrical, chemical energies. Examples covered include abrasive jet machining, electrochemical machining, and electron beam machining.
3. Key characteristics of non-conventional machining are that material can be removed without chip formation, there may not be a physical tool, and the tool need not be harder than the workpiece.
Water jet machining uses a high-pressure jet of water to cut materials. Key components include an intensifier that increases water pressure to 3800 bar, an accumulator that maintains uniform pressure, and a sapphire nozzle that forms the jet. It can cut a variety of materials with few limitations and without heat or tool wear. Advantages are flexibility, accuracy, minimal kerf and burrs, and no heat affected zones.
This document provides information on various advanced manufacturing processes including abrasive jet machining, water jet machining, ultrasonic machining, and electric discharge machining. It describes the basic working principles, key components, process parameters, advantages, disadvantages, and applications of each process. For abrasive jet machining, it discusses the arrangement, construction details, abrasive particles used, nozzle types, and factors affecting material removal rate. For water jet machining, it outlines the main parts, operating principle, and process parameters that influence material removal. For ultrasonic machining, it explains how ultrasonic waves are generated using different transducer types, and how the machining occurs between the vibrating tool and workpiece with an abrasive
This document provides an introduction to non-traditional machining processes. It defines non-traditional machining as processes that remove material using mechanical, thermal, electrical or chemical energy without using sharp cutting tools. The need for developing such processes is discussed, such as difficulties in machining new hard materials and complex geometries. A comparison is provided between traditional and non-traditional machining. The document outlines the classification and selection of various non-traditional machining processes and provides examples of when they may be preferable to traditional processes. It introduces several specific non-traditional machining techniques that will be covered in more depth later in the document.
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.
This document discusses electrochemical honing, which combines electrochemical dissolution and mechanical abrasion to machine conductive materials. It removes metal through an electrochemical process using an electrolyte and cathodic tool, while also using abrasive stones for mechanical material removal and surface finishing. This hybrid process allows for higher material removal rates than conventional honing or grinding. Electrochemical honing can achieve tight tolerances, good surface finishes, and shape and finish workpieces in a single process with minimal heat and stresses on the material.
The document describes the process of electrical discharge machining (EDM). It discusses how EDM works by using electrical sparks to erode metal between an electrode tool and a workpiece separated by a dielectric fluid. Key points include:
- EDM uses high frequency electrical pulses to create sparks that melt and vaporize small amounts of metal.
- The sparks shape the workpiece by progressively lowering the electrode as material is removed.
- Process parameters like voltage, current, polarity, and dielectric fluid properties control the material removal rate and surface finish.
The document describes the electrical discharge machining (EDM) process. EDM involves using electrical sparks to erode material from a conductive workpiece. A tool shaped to the desired cavity or hole acts as an electrode and is placed near the workpiece in a dielectric fluid. High-frequency pulses of voltage are applied, causing sparks that melt and evaporate small amounts of material. The process is repeated until the cavity is shaped. Key aspects of EDM include the dielectric fluid, gap size, electrode material, and operating parameters which control the machining rate and surface finish.
Electrical discharge machining (EDM) involves using electrical sparks to erode metal surfaces. Key aspects include:
1) An electrode is used to shape electrical discharges that melt and vaporize small amounts of material from the workpiece. Common electrode materials include copper, tungsten, and graphite.
2) A dielectric fluid is used to separate the electrode and workpiece and to flush away debris. Typical fluids include oil-based fluids like kerosene.
3) An electrical charge creates sparks that momentarily melt and vaporize metal. Process parameters like voltage, gap size, and flush rate must be optimized to control the erosion process.
Electric discharge machining (EDM) is a machining process that uses electrical discharges to remove material from a conductive workpiece. There are two main EDM processes - die sinking and wire cutting. Die sinking involves an electrode progressively eroding a workpiece cavity to its shape. Wire cutting uses a continuously fed wire electrode to cut complex profiles. EDM can machine all conductive materials regardless of hardness and produces parts with good accuracy and surface finish.
The document discusses Electrical Discharge Machining (EDM) and Wire Cut Electrical Discharge Machining (WC EDM). EDM uses electric sparks to remove small amounts of conductive material from the workpiece. Key aspects covered include the principles, characteristics, parameters, processes, advantages/disadvantages and applications of EDM and WC EDM. WC EDM uses a thin wire as the electrode to cut complex 2D profiles, while EDM uses solid electrodes and submerges the entire workpiece. Both processes precisely machine hard conductive materials like tungsten carbide.
ECM is an electrochemical machining process that removes metal by electrolysis rather than mechanical forces. It involves passing electrical current between an electrode tool and a metal workpiece separated by an electrolyte. This causes metal ions from the workpiece to dissolve into the electrolyte, machining the workpiece without physical contact. ECM can machine very hard metals, produces high accuracy parts, and leaves a good surface finish. However, it also requires high energy and can only machine electrically conductive materials.
This document contains information about a student named Sourabh Tailor with roll number 2013btechme041. It discusses unconventional machining processes including electrochemical machining (ECM) and electric discharge machining (EDM). For ECM, it describes the principles, equipment, electrolyte, tools, advantages, disadvantages and applications. For EDM, it discusses the physical principles, characteristics, tools, dielectric fluid, advantages, disadvantages and applications such as wire EDM and electric discharge grinding.
Two Russian scientists invented electrical discharge machining in 1943 while trying to prevent erosion of tungsten contacts from sparking. EDM works by using electrical sparks to erode metal by melting and vaporizing small amounts of material. Key components of EDM include electrodes, dielectric fluid, and a power supply that provides pulsed voltage. EDM can machine hard metals and complex shapes and is especially useful for dies and molds due to its ability to machine without affecting heat treatment of the workpiece material.
The document summarizes electrodischarge machining (EDM). EDM uses electrical sparks to erode material from a workpiece and tool electrode separated by a dielectric liquid. Key points:
- Material is removed through high-temperature melting and evaporation caused by electrical discharges between the electrodes.
- Process advantages include ability to machine hard materials and produce complex geometries without mechanical forces.
- Factors like pulse characteristics, electrode material properties, dielectric properties influence material removal rate and surface finish.
- EDM leaves a recast layer and heat-affected zone in the workpiece due to high temperatures from sparking.
Electric discharge machining is an electrothermal machining process that can machine hard conductive materials using electric sparks. It works by applying a potential difference between a tool electrode and workpiece submerged in a dielectric fluid, causing electric sparks that erode away material. Key factors that affect the process include the electric current, pulse duration and frequency, electrode and workpiece gap distance, and dielectric fluid. EDM enables precision machining of complex shapes without mechanical forces and is useful for brittle materials. Applications include drilling micro holes, cutting intricate cavities, and machining hard alloys like turbine blades.
The document discusses various thermal energy-based material removal techniques, including electrical discharge machining (EDM) and laser beam machining (LBM). It provides details on the EDM process, including how it works using electric sparks to erode metals. Wire EDM and micro EDM are also examined. The document then covers the LBM process, the types of lasers used for different applications like cutting, drilling, and marking. It discusses key laser beam parameters such as beam waist, intensity, and depth of focus. In summary, the document provides an in-depth overview of EDM and LBM processes for removing material using thermal energy.
Electrochemical machining (ECM) is a non-traditional machining process that removes metal by electrolysis rather than mechanical forces. In ECM, a tool acts as a cathode and the workpiece as an anode, and an electric current is passed through an electrolyte in the gap between them, chemically dissolving metal from the workpiece. ECM can machine hard metals and complex shapes more accurately than traditional machining. It provides a smooth surface finish with no mechanical forces or heat affecting the workpiece material. However, ECM requires an electrolyte solution, specialized equipment, and produces chemical waste, making it more expensive and less environmentally friendly than other processes.
Electro Discharge Machining
Introduction
Process
Process Parameters
Dielectric
Advantages of EDM
APPLICATIONS
Power generator
Wire EDM
ELECTRIC DISCHARGE GRINDING (EDG)
This document discusses electrical discharge machining (EDM) and wire cut EDM. It begins with a brief history of EDM and an overview of the EDM process, including its working principle, important characteristics, and applications. It then focuses on wire cut EDM, explaining its working principle, major components of the process, advantages, and disadvantages. The document concludes by outlining the scope and plan for investigating the effects of process parameters on material removal rate, surface finish, and kerf width in wire cut EDM.
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
The document discusses various advanced manufacturing processes that use thermal energy or electrical discharges to remove material from a workpiece. It focuses on electrical discharge machining (EDM) and wire EDM. EDM works by sparking electrical discharges between an electrode and workpiece submerged in dielectric fluid to erode away material. Key advantages of EDM are its ability to machine hard metals and create complex shapes. The document also covers laser beam machining which uses a focused laser beam to melt, vaporize, or ablate material from the workpiece.
Introduction to Electric Discharge MachiningDignesh Parmar
The document provides information about electric discharge machining (EDM). It discusses the history of EDM, which began in the 18th century with observations of erosion from electric discharge. EDM was developed in the 1940s and commercialized in the 1950s. The document describes the basic working principles of EDM, including how material is removed through electric sparks between electrodes. It also covers aspects like power generators, material removal rates, surface roughness, electrode materials and movement.
Electrical discharge machining (EDM) is a non-traditional machining process that uses electrical sparks to remove metal. The document discusses the history and development of EDM, including key components like the electrode, workpiece, dielectric fluid, and power supply. It describes the basic EDM process and different EDM methods like conventional EDM, wire EDM, and hole drilling EDM. The document also covers EDM applications, innovations like dry EDM and powder-mixed EDM, and concludes with a list of references.
This document discusses parameters that affect the surface roughness of electrochemically machined surfaces. It outlines several key parameters including: the type of power supply used, duty cycle, voltage, inter-electrode gap, electrolyte concentration, temperature and flow rate, the type of tool used, and the micro-tool feed rate. Maintaining an optimal inter-electrode gap of 15-20 micrometers and using a duty cycle of 0.3 were found to produce the best surface roughness. The concentration of the electrolyte and keeping the temperature below 50 degrees Celsius also impacted surface quality.
Resistance welding is described as an electric welding process where heat is generated by resistance of the workpieces to electric current in a circuit. Pressure is applied simultaneously with current to produce coalescence. Common resistance welding techniques include spot welding, seam welding, projection welding, and flash butt welding. Spot welding involves passing current through overlapping metal sheets held between electrodes to create nugget welds. Seam and projection welding can continuously weld moving sheets using arrays of electrodes.
The presentation discusses research and publication ethics as well as scientific misconduct. It defines scientific misconduct as fabrication, falsification, or plagiarism in research. The three elements of scientific misconduct are then defined: fabrication is making up false data, falsification is manipulating research materials/processes to misrepresent results, and plagiarism is using other's work without credit. Potential reasons for misconduct are then outlined along with consequences such as career ending and blacklisting. Methods to prevent misconduct through policy, supervision, and research integrity offices are also presented.
This document discusses research methodology and data collection and presentation. It outlines primary and secondary data collection methods. Primary data collection methods discussed include observation, personal interviews, telephone interviews, and mail surveys. Secondary data sources include internal sources like sales records and external sources like government publications. The document also discusses presenting collected data through tools like frequency distribution, charts and other visualization methods.
This document discusses project selection and portfolio management. It begins by outlining various analysis tools used for project selection like PEST analysis, SWOT analysis, and Porter's Five Forces model. It then discusses strategic planning processes like defining a vision, mission, strategic objectives, and aligning project portfolios to strategic goals. Various frameworks for analyzing markets and industries are presented, including using PEST, SWOT, and Porter's Five Forces to evaluate opportunities and threats. The importance of assessing an organization's ability to successfully perform projects is also highlighted.
While there are some common qualities needed for a project manager in any industry, there are also some differences depending on the specific industry or type of project.
For both construction and software companies, strong communication skills, ability to manage budgets/schedules, and leadership skills are important. However:
- In construction, safety oversight is a bigger responsibility due to worksite hazards. Technical knowledge of building materials/processes is also more important.
- In software, the PM needs to deeply understand programming languages/platforms to effectively manage developers. Technical troubleshooting abilities are more vital.
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Project management involves planning, organizing, and managing resources to successfully complete projects within defined objectives and constraints. It has five main stages: initiation, planning, execution, monitoring and controlling, and closing. Key aspects of project management include defining project scope and objectives, developing a work breakdown structure and schedule, managing risks and issues, monitoring progress, and ensuring project closure. Effective project management requires integrating various technical and human factors to deliver projects on time, within budget and meeting specified requirements.
3D printing can be used to create customized prosthetics and implants directly from patient scan data, allowing for a better fit. It is also used in the aerospace and automotive industries to create detailed physical models for design verification before manufacturing. For example, a generator company used 3D printing to create internal component models to check fit and identify issues early. A car company also used it to build a complex gearbox housing model quickly to verify their CAD design.
3D PRINTING- POWDER BASED ADDITIVE MANUFACTURING S. Sathishkumar
The document discusses three powder-based additive manufacturing systems: selective laser sintering (SLS), three dimensional printing (3DP), and laser engineered net shaping (LENS). SLS uses a laser to sinter powdered materials like plastic and metal together layer by layer. 3DP uses inkjet printheads to apply a binder to layers of powder to build parts. LENS uses a laser to melt metal powder as it is deposited, building parts layer by layer. Each system uses a different technique but all use lasers or binders to fuse powdered materials together to build 3D parts additively.
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The document discusses reverse engineering techniques. It describes reverse engineering as generating a CAD model from an existing physical part to reconstruct it. There are contact-based methods like coordinate measuring machines and non-contact methods like 3D scanners. 3D scanners use light or lasers to scan objects and generate CAD designs without contact. Reverse engineering is used to manufacture replacement parts, redesign products lacking documentation, or create cheaper alternatives.
This document provides an overview of rapid prototyping (RP) and additive manufacturing. It defines RP as a group of techniques used to quickly fabricate a scale model of a physical part using 3D CAD data. It then covers the history and development of RP, categorizing RP systems as liquid-based, solid-based, or powder-based. The roles of prototypes in product development are discussed, including experimentation, testing, communication, synthesis, and scheduling. Additive manufacturing is introduced as a process of joining materials layer by layer from a 3D model. Popular additive manufacturing materials and applications are briefly outlined.
Reverse engineering is the process of analyzing an existing system or product to identify its components and design in order to extract design details without prior documentation. It involves digitizing a physical object using 3D scanning techniques like contact methods, non-contact active methods, and non-contact passive methods to obtain point cloud data. This point cloud data is then processed to generate CAD models through techniques like polygonization and refinement. The final CAD models can then be used for applications like redesign, quality control, and rapid prototyping.
The document discusses reverse engineering, which involves duplicating an existing part without documentation by working backwards from the finished product. There are two main types of engineering: forward engineering, which moves from design to implementation, and reverse engineering. Reverse engineering has various applications and involves a three-phase process of scanning the object, processing the scan data, and developing a geometric model. Common scanning techniques include contact methods using probes and non-contact methods like laser scanning.
This document provides an overview of 3D printing and tooling. It begins by stating the educational objectives and outcomes of the course, which are to understand the principles, methods, materials, possibilities, limitations and environmental effects of additive manufacturing technologies.
The document then covers the different units that will be taught, with the first unit providing an introduction to additive manufacturing. It discusses the history and need for additive manufacturing, provides a classification of the different technologies, and discusses how additive manufacturing is used in product development. It also introduces the different materials that can be used for additive manufacturing.
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This document discusses hydraulic accumulator components. It describes different types of accumulators including spring loaded, gas charged, weight loaded, and hydraulically counter loaded. Spring loaded accumulators can use sealed pistons, compound springs, diaphragms, or springs with bellows. Gas charged accumulators commonly use nitrogen and can have bladder, diaphragm, sealed piston, or metal bellows designs. The accumulators store energy, stabilize pump pulsation and load shocks, and store volume under pressure for high demands.
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3. The tool (electrode) usually acts as a cathode and is
immersed in a dielectric fluid.
DC voltage (~300V) is applied in modulated pulses
(200-500K Hz).
The dielectric breaks down (sparking at around
12,000 deg F) when gap is small.
The sparks erodes the work piece in the shape of the tool.
The tool is progressively lowered as the work piece erodes.
Material removal rate is typically 300 mm3
/min
Tool wear ratio 3:1 with metallic electrodes, 3:1-100:1
with graphite electrodes
4. • Pulsed power supply (Pulsed generator)
• Electrode (tool, work piece) shape must match
• Electric discharge (spark)
• Dielectric
• Gap
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5. 1. Charge up an electrode
2. Bring the electrode near a metal work piece (oppositely charged).
3. As the two conductors get close enough a spark will arc across a
dielectric fluid. This spark will "burn" a small hole in the electrode
and work piece.
4. Continue steps 1-3 until a hole the shape of the electrode is formed.
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6. • The removal of metal from the workpiece is obtained by
means of energy released by repetitive spark discharges
• Take place between two conductors (tool, workpiece)
• The removal of metal from the workpiece is obtained by
means of energy released by repetitive spark discharges
• Take place between two conductors (tool, workpiece)
8. • An electrically conductive electrode
• Shaped to match the dimensions of the desired cavity or hole
• Connected to the pole of the supply
- copper
- tungsten
- graphite
9. • Dielectric---insulating fluid
• Gap --- workpiece and tool are separated by a
small gap flooded by dielectric to provide
a controlled electrical resistant
10. An increasing voltage is applied to the electrodes, resulting
in an increasing stress on the fluid between them until it is
ionized, and the gap becomes conductive, allowing current to
flow from one electrode to the other in the form of a spark
discharge .
11. The spark channel in the first few microseconds has a very
small cross-sectional area resulting in a correspondingly high
current density calculated to be on the order of l04
~l06
A /cm2
.
12. • Because of these extreme densities, the temperature in the
channel is very high, (5,000-l0,000 ),℃ resulting in the
melting and vaporization of a small amount of material from
the surfaces of both the electrode and the workpiece at the
points of spark contact, a rapidly expanding bubble is created
in the dielectric fluid around the spark channel.
13. • When the electrical pulse is terminated, both the spark channel
and the vapor bubble collapse.
• The violent inrush of cool dielectric fluid results in an explosive
expulsion of molten metal from both the electrode and
workpiece surfaces, resulting in the formation of a small crater
in the surfaces of the two conductors, solidifying hollow balls
of material, which are removed from the gap by the fluid.
14. • Suitable choice of polarity
• Suitable choice of electrode material
• Suitable choice of the operating parameters
15. • In EDM, therefore, the cathode-electrode is made the
workpiece
• The anode becomes the tool
• The erosion of metal from the cathode can be as high as
99.5%
• The wear of the anode being kept as low as 0.5%.
16. - Electrode material
- Electrode polarity +/-
- pulse current If(A)
- pulse duration ti (micro s)
- pulse off time to (micro s)
- average voltage U (V)
- average current I (A)
- working current density Id (A/cm2
)
- open gap voltage Vo (V)
- Dielectric
- flushing mode
17. - Metal removal rate Vw (mm3
/min)
- Relative electrode wear θ (% or a fraction)
- Surface finish R (peak to valley micro m)
- Thickness of recast layer
- Gap between electrode and workpiece
- Corner and edge radii
06/03/19
18. - Fluid is used to act as a dielectric, and to help carry
away debris.
- If the fluid is pumped through and out the end of the
electrode, particles will push out, and mainly collect at
the edges. They will lower the dielectric resistance,
resulting in more arcs. As a result the holes will be
conical.
- If fluid is vacuum pumped into the electrode tip,
straight holes will result.
20. • Quite often kerosene-based oil.
• Paraffin and light oils, (cheap, low viscosity, and a flash point
high enough to make them safe to work
• The fluid must be cleaned, recycled, and returned to the
cutting gap by means of pumps and filters.
21. • The electrode workpiece gap is in the range of 10 micro m to <100
micro m.
• Uses a voltage discharge of 60 to 300 V to give a transient arc
lasting from 0.1 micro s to 8 ms.
• Typical cycle time is 20 ms or less, up to millions of cycles may be
required for completion of the part.
22. • High temperature, but easy to machine, allowing easy
manufacture of complex shapes.
• Low wear rate, be electrically conductive, provide good surface
finishes on the work piece, and be readily available.
23. - Energy density (lower to higher)
- Amount machined (less to more)
- Machining speed (slower to faster)
- Clearance (less to more)
- Surface roughness (fine to rough)
28. • Machine speed (mm2
/min)
= machine speed feed (mm/min) * work piece thickness (mm)
• Higher currents, and lower rest times increase the speed of this
process.
06/03/19
29. - Mechanism of material removal - melting and evaporation
aided by cavitation
- Medium - dielectric fluid
- Tool materials - Cu, Brass, Cu-W alloy, Ag-W alloy, graphite
- Material/tool wear = 0.1 to 10
- Gap = 10 to 125 micro m - maximum mrr = 5*103
mm3
/min
- Specific power consumption 1.8 W/mm3
/min
- Critical parameters - voltage, capacitance, spark gap,
dielectric circulation, melting
temperature
- Materials application - all conducting metals and alloys
- Shape application - blind complex cavities, microholes for
nozzles, through cutting of non-circular
holes, narrow slots
30. • High specific energy consumption (about 50 times that in
conventional machining);
• When forced circulation of dielectric is not possible, removal
rate is quite low;
• Surface tends to be rough for larger removal rates;
• Not applicable to Non conducting materials.
31. 1. We try an EDM process where the copper tool has a mass
of 200g before beginning and 180g after. The iron
workpiece drops from 3.125kg to 3.096kg, but has rounded
corners.
a) What is the tool wear factor?
b) If the tool was cylindrical to begin with, draw
sketches of the electrode before and after.
32. 2. What are the selection criteria for choosing between
machining and EDM?
Answer : EDM is particularly useful when dealing with internal
cuts that are hard to get tools into. Machining tends
to work best with external cuts. EDM is suitable for
removal of smaller amounts of material at a much
slower rate.
33. Thank you
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