Electro chemical machining
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Laser beam machining pdf
principle of laser beam machining,working of laser beam machining, neat sketch,advantages of laser beam machining, disadvantages of laser beam machining,applications of laser beam machining
Electron Beam Machining
Electron beam machining (EBM) involves directing a high-velocity beam of electrons in a vacuum chamber to melt or vaporize material from a workpiece. The electron beam is generated in a gun and focused onto a small spot on the workpiece using magnetic coils. This localized heating allows for precise material removal with minimal heat effects. EBM can machine nearly any material and produces close tolerances, but requires expensive equipment and vacuum systems. Common applications include machining wire drawing dies and manufacturing semiconductor and optical components.
THERMAL ENERGY BASED PROCESSES
This document discusses electron beam machining (EBM), a thermal energy-based machining process. EBM works by accelerating electrons in a vacuum and focusing them into a beam that strikes and vaporizes small amounts of workpiece material. Key components of an EBM system include an electron gun, focusing lens, and deflector coil. Process parameters like beam current and spot size are controlled. EBM allows for precise micro-machining of hard, brittle, and electrically conductive materials but has high equipment costs and a slow material removal rate. Applications include drilling small holes in parts for industries like aerospace, electronics, and diesel engines.
Electrochemical Machining
Electro-chemical machining (ECM) is a non-traditional machining process that removes metal by dissolving it in an electrolyte with the use of electric current. In ECM, the workpiece acts as an anode and is dissolved by the electrolyte, while a tool with the desired shape acts as a cathode. Key factors in ECM include the electrolyte, which carries current and removes dissolved material, the tool and workpiece materials, and a DC power supply. ECM can machine hard metals and complex shapes with high accuracy and no tool wear. Common applications of ECM include machining turbine blades, aerospace components, and other difficult-to-machine metals.
Ultrasonic Machining
1. Ultrasonic machining is a non-traditional machining process that uses a vibrating tool to remove material from a workpiece submerged in an abrasive slurry.
2. The tool vibrates at high frequency (typically 20-40 kHz) and is gradually fed into the workpiece. The abrasive grains in the slurry are driven across a small gap by the vibrating tool and impact the workpiece, removing small particles.
3. Ultrasonic machining can machine both conductive and non-conductive materials like ceramics and is well-suited for hard, brittle materials. Key factors that influence the material removal rate include vibration frequency and amplitude,
RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES
This document discusses various hybrid and non-traditional machining processes. It describes electrochemical spark machining (ECSM) which is a hybrid process that combines ECM and EDM, allowing it to machine both conductive and non-conductive materials. The document outlines the principle, material removal mechanisms, and process parameters of ECSM. It also summarizes electric discharge diamond grinding (EDDG) and discusses its basic configuration, parameters, advantages, and applications. Finally, the document provides an overview of recent trends in micro-machining including various advanced mechanical and thermal micro-machining processes.
Ultrasonic machining
This power point presentation gives brief idea about ultrasonic machining. it gives information about its applications, working and advantages
Ultrasonic machining process (USM)
Ultrasonic machining (USM) is a mechanical process that uses high frequency vibrations and an abrasive slurry to erode fine holes and cavities in hard or brittle materials. It is well-suited for machining brittle materials like glass, ceramics, and semiconductors. The material removal occurs through abrasion by the particles in the slurry, with no thermal or chemical changes to the workpiece. USM produces intricate shapes and profiles with good surface finish and integrity.
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Laser beam machining pdf
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Electron Beam Machining
Electron beam machining (EBM) involves directing a high-velocity beam of electrons in a vacuum chamber to melt or vaporize material from a workpiece. The electron beam is generated in a gun and focused onto a small spot on the workpiece using magnetic coils. This localized heating allows for precise material removal with minimal heat effects. EBM can machine nearly any material and produces close tolerances, but requires expensive equipment and vacuum systems. Common applications include machining wire drawing dies and manufacturing semiconductor and optical components.
THERMAL ENERGY BASED PROCESSES
This document discusses electron beam machining (EBM), a thermal energy-based machining process. EBM works by accelerating electrons in a vacuum and focusing them into a beam that strikes and vaporizes small amounts of workpiece material. Key components of an EBM system include an electron gun, focusing lens, and deflector coil. Process parameters like beam current and spot size are controlled. EBM allows for precise micro-machining of hard, brittle, and electrically conductive materials but has high equipment costs and a slow material removal rate. Applications include drilling small holes in parts for industries like aerospace, electronics, and diesel engines.
Electrochemical Machining
Electro-chemical machining (ECM) is a non-traditional machining process that removes metal by dissolving it in an electrolyte with the use of electric current. In ECM, the workpiece acts as an anode and is dissolved by the electrolyte, while a tool with the desired shape acts as a cathode. Key factors in ECM include the electrolyte, which carries current and removes dissolved material, the tool and workpiece materials, and a DC power supply. ECM can machine hard metals and complex shapes with high accuracy and no tool wear. Common applications of ECM include machining turbine blades, aerospace components, and other difficult-to-machine metals.
Ultrasonic Machining
1. Ultrasonic machining is a non-traditional machining process that uses a vibrating tool to remove material from a workpiece submerged in an abrasive slurry.
2. The tool vibrates at high frequency (typically 20-40 kHz) and is gradually fed into the workpiece. The abrasive grains in the slurry are driven across a small gap by the vibrating tool and impact the workpiece, removing small particles.
3. Ultrasonic machining can machine both conductive and non-conductive materials like ceramics and is well-suited for hard, brittle materials. Key factors that influence the material removal rate include vibration frequency and amplitude,
RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES
This document discusses various hybrid and non-traditional machining processes. It describes electrochemical spark machining (ECSM) which is a hybrid process that combines ECM and EDM, allowing it to machine both conductive and non-conductive materials. The document outlines the principle, material removal mechanisms, and process parameters of ECSM. It also summarizes electric discharge diamond grinding (EDDG) and discusses its basic configuration, parameters, advantages, and applications. Finally, the document provides an overview of recent trends in micro-machining including various advanced mechanical and thermal micro-machining processes.
Ultrasonic machining
This power point presentation gives brief idea about ultrasonic machining. it gives information about its applications, working and advantages
Ultrasonic machining process (USM)
Ultrasonic machining (USM) is a mechanical process that uses high frequency vibrations and an abrasive slurry to erode fine holes and cavities in hard or brittle materials. It is well-suited for machining brittle materials like glass, ceramics, and semiconductors. The material removal occurs through abrasion by the particles in the slurry, with no thermal or chemical changes to the workpiece. USM produces intricate shapes and profiles with good surface finish and integrity.
Electro chemical machining
Electrochemical machining (ECM) is a non-traditional machining process where material is removed from a conductive workpiece through controlled anodic dissolution. During ECM, electrolytic reactions occur between the tool (cathode) and workpiece (anode) in an electrolyte like NaCl solution. Positively charged metal ions from the workpiece dissolve into the electrolyte, while hydrogen gas forms on the tool. The dissolved metal precipitates as sludge. ECM provides excellent surface finish and stress-free surfaces due to atomic-level material removal. The material removal rate depends on process parameters like current, electrolyte composition, and material properties based on Faraday's laws of electrolysis.
Electron beam machining
The document summarizes electron beam machining (EBM). EBM works by converting the kinetic energy of high-speed electrons into heat energy when they impinge on a workpiece. This heat energy vaporizes material. The process requires vacuum. An electron gun generates electrons that pass through magnetic lenses to focus the beam on the workpiece. Material removal occurs through melting and vaporization. EBM can machine small, complex holes and is used in aerospace and nuclear industries. It offers good finishes but has low material removal rates and high costs.
Electro chemical grinding
Electro-chemical grinding (ECG) is a process that uses both mechanical grinding and electrochemical removal to shape electrically conductive materials. In ECG, a negatively charged grinding wheel with abrasive particles contacts the positively charged workpiece in the presence of an electrolyte fluid. This sets up an electrochemical reaction that dissolves metal from the workpiece, with around 90% of material removed electrochemically and 10% by abrasion. ECG produces very smooth, burr-free surfaces with little heat, making it suitable for grinding fragile or heat-sensitive parts. Applications include shaping tungsten carbide cutting tools, sharpening needles, grinding turbine blades, and removing cracks from steel structures.
Electrochemical grinding (ecg)
Electrochemical grinding (ECG) is a process where a rotating grinding wheel acts as a cathode and the workpiece is the anode. An electrolyte like NaNO3 is used and a voltage is applied, causing material to be removed from the workpiece electrochemically with some additional removal by abrasion from diamond or aluminum oxide particles on the wheel. ECG can machine difficult materials, achieve close tolerances on thin parts without distortion, and offers advantages over conventional grinding like higher removal rates and elimination of burrs. However, it also has higher costs and is limited to electrically conductive materials.
Electrical energy based processes
This document discusses electrical discharge machining (EDM). EDM uses a thin wire electrode to produce sparks between the wire and workpiece, reaching temperatures of 10,000 degrees Celsius. This melts and vaporizes the workpiece material, which is then flushed away by a dielectric fluid. The document discusses EDM principles, specifications, dielectric fluids, power generating circuits, process parameters like surface finish and current density, advantages and disadvantages of EDM, and applications like wire-cut EDM.
Electrochemical honing
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.
Unit 5 -RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES
Recent developments in non-traditional machining processes, their working principles, equipments,
effect of process parameters, applications, advantages and limitations. Comparison of non-traditional
machining processes.
EDM & WCEDM
Electrical Discharge Machining (EDM) is a manufacturing process that uses electrical sparks to remove material from a conductive workpiece. In the EDM process, a tool electrode is moved close to the workpiece and an electric spark is generated via a dielectric fluid between them, vaporizing a small amount of material. This process is repeated many times to gradually shape the workpiece. EDM can machine very hard materials and complex shapes without causing mechanical stress to the workpiece. Common applications include drilling micro holes, cutting intricate profiles, and machining hardened steel dies and molds.
Unit 4 chemical and electrochemical energy based processes
This document discusses various chemical and electrochemical machining processes. It describes chemical machining (CHM) which uses chemical etching to remove material from a workpiece. It involves using etchants and maskants to selectively remove material. Electrochemical machining (ECM) uses electrolysis principles to remove material from a workpiece submerged in an electrolyte solution. Variations include electrochemical grinding (ECG) which combines ECM with conventional grinding, and electrochemical honing (ECH) which uses non-conductive honing stones instead of a grinding wheel. These processes allow burr-free machining of complex shapes in hard and brittle materials with good surface finish and accuracy.
ECM : Electrochemical machining - Principle,process,subsystems & applications
ECM : Electrochemical machining - Principle,process,subsystems & applications. Specialized processes under ECM.
Advance manufacturing process
Non-traditional machining processes like EDM, USM, and WEDM are useful for machining hard materials and complex shapes with precision. EDM works by using electrical sparks to erode material from a part placed close to an electrode tool, allowing intricate shapes to be produced. USM uses an abrasive slurry and vibrating tool to cut materials. WEDM is similar to EDM but uses a continuously moving wire as the electrode. These non-traditional processes are more precise than traditional machines and can machine tough materials that would be difficult to cut otherwise.
Abrassive Flow Machining
The document describes abrasive flow machining (AFM) and summarizes two research papers on the topic. It defines AFM and discusses different types of AFM machines. The first research paper studies the effect of process variables in AFM and develops models to optimize the process. The second paper examines using AFM to finish difficult-to-machine titanium alloy and finds that boron carbide and silicon carbide abrasives most effectively remove surface imperfections within few cycles. Scanning electron microscopy images show the removal of heat-affected layers on the titanium.
Edm
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.
Abrasive jet machining.51 ppt
Abrasive jet machining is an unconventional machining process that uses a high-velocity stream of abrasive particles suspended in a gas to remove material through erosion. It can machine hard and brittle materials that cannot be cut through conventional processes. The process involves mixing abrasive particles with a pressurized gas and passing them through a nozzle to erode away the workpiece material. It provides advantages like ability to machine heat-sensitive materials without damaging them and capability to cut intricate holes, but has low material removal rates and accuracy issues due to stray cutting.
Unit 3 electrical energy based process
Electrical discharge machining (EDM) is a machining process that uses electrical sparks to remove material from a conductive workpiece. EDM works by producing sparks between an electrode tool and the workpiece submerged in a dielectric fluid, which erodes away tiny amounts of material. This allows EDM to machine very hard or brittle materials and create complex shapes regardless of material hardness. EDM provides a high-precision, burr-free finish and can machine thin walls and small features. Wire cut EDM is a similar process that uses a continuously moving thin wire as the electrode to cut intricate shapes.
RUM ( Rotatory Ultrasonic Maching)
This document provides an overview of rotary ultrasonic machining (RUM), also known as micro-ultrasonic machining (MUSM). It defines micromachining and RUM/MUSM, explaining that RUM allows machining features down to 100 micrometers. The document outlines the RUM process, including using a rotating tool with diamond abrasives that machines materials via ultrasonic impacts and grinding. It discusses RUM equipment, process parameters like tool type and vibration conditions, and applications for machining hard materials like titanium alloys, silicon carbide, and dental ceramics.
Electro chemical machining - Thanuj Kumar M
This document provides an introduction to electro-chemical machining (ECM) processes. It discusses the basic principles of ECM including the electrolysis process that occurs. Key elements of ECM are described such as the electrolyte, tool, workpiece, and power supply. Process parameters that influence material removal rate and surface finish are outlined. Applications of ECM include machining complex shapes that would be difficult with traditional methods. Advantages include no cutting forces, high accuracy, and little tool wear.
Electro chemical honing process
The Electrochemical Honing process is a type of electrochemical machining that provides a smooth, accurate surface finish on cylindrical parts. It involves using an abrasive tool and electrolyte to remove material from the workpiece through both electrochemical and mechanical action. Some key aspects of the process include using an abrasive tool that moves longitudinally and rotationally within the workpiece while electrolyte is fed through holes under pressure. This assists the electrochemical removal of material while the abrasives further smooth the surface. The process can achieve a surface roughness between 0.1 and 0.5 microns and an accuracy of 0.01 mm in diameter and less than 0.05 mm in roundness. It provides advantages over conventional honing
Electro Chemical Machining Process
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.
electrochemical grinding
1. Electrochemical grinding (ECG) is a non-traditional machining process that removes electrically conductive material by grinding with a negatively charged abrasive wheel, electrolyte fluid, and a positively charged workpiece. Materials are removed through electrolysis and some abrasion, leaving a smooth burr-free surface.
2. ECG can machine very hard and brittle materials more effectively than traditional processes due to generating little heat. Key parameters that affect the material removal rate include the abrasive wheel properties, workpiece material and surface, machining conditions, electrolyte type and properties, and voltage applied.
3. ECG provides advantages like burr-free surfaces, less work hardening, higher precision
Electrochemical Machining (ECM)
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).
Electro chemical machining parameters
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.
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Electro chemical machining
Electrochemical machining (ECM) is a non-traditional machining process where material is removed from a conductive workpiece through controlled anodic dissolution. During ECM, electrolytic reactions occur between the tool (cathode) and workpiece (anode) in an electrolyte like NaCl solution. Positively charged metal ions from the workpiece dissolve into the electrolyte, while hydrogen gas forms on the tool. The dissolved metal precipitates as sludge. ECM provides excellent surface finish and stress-free surfaces due to atomic-level material removal. The material removal rate depends on process parameters like current, electrolyte composition, and material properties based on Faraday's laws of electrolysis.
Electron beam machining
The document summarizes electron beam machining (EBM). EBM works by converting the kinetic energy of high-speed electrons into heat energy when they impinge on a workpiece. This heat energy vaporizes material. The process requires vacuum. An electron gun generates electrons that pass through magnetic lenses to focus the beam on the workpiece. Material removal occurs through melting and vaporization. EBM can machine small, complex holes and is used in aerospace and nuclear industries. It offers good finishes but has low material removal rates and high costs.
Electro chemical grinding
Electro-chemical grinding (ECG) is a process that uses both mechanical grinding and electrochemical removal to shape electrically conductive materials. In ECG, a negatively charged grinding wheel with abrasive particles contacts the positively charged workpiece in the presence of an electrolyte fluid. This sets up an electrochemical reaction that dissolves metal from the workpiece, with around 90% of material removed electrochemically and 10% by abrasion. ECG produces very smooth, burr-free surfaces with little heat, making it suitable for grinding fragile or heat-sensitive parts. Applications include shaping tungsten carbide cutting tools, sharpening needles, grinding turbine blades, and removing cracks from steel structures.
Electrochemical grinding (ecg)
Electrochemical grinding (ECG) is a process where a rotating grinding wheel acts as a cathode and the workpiece is the anode. An electrolyte like NaNO3 is used and a voltage is applied, causing material to be removed from the workpiece electrochemically with some additional removal by abrasion from diamond or aluminum oxide particles on the wheel. ECG can machine difficult materials, achieve close tolerances on thin parts without distortion, and offers advantages over conventional grinding like higher removal rates and elimination of burrs. However, it also has higher costs and is limited to electrically conductive materials.
Electrical energy based processes
This document discusses electrical discharge machining (EDM). EDM uses a thin wire electrode to produce sparks between the wire and workpiece, reaching temperatures of 10,000 degrees Celsius. This melts and vaporizes the workpiece material, which is then flushed away by a dielectric fluid. The document discusses EDM principles, specifications, dielectric fluids, power generating circuits, process parameters like surface finish and current density, advantages and disadvantages of EDM, and applications like wire-cut EDM.
Electrochemical honing
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.
Unit 5 -RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES
Recent developments in non-traditional machining processes, their working principles, equipments,
effect of process parameters, applications, advantages and limitations. Comparison of non-traditional
machining processes.
EDM & WCEDM
Electrical Discharge Machining (EDM) is a manufacturing process that uses electrical sparks to remove material from a conductive workpiece. In the EDM process, a tool electrode is moved close to the workpiece and an electric spark is generated via a dielectric fluid between them, vaporizing a small amount of material. This process is repeated many times to gradually shape the workpiece. EDM can machine very hard materials and complex shapes without causing mechanical stress to the workpiece. Common applications include drilling micro holes, cutting intricate profiles, and machining hardened steel dies and molds.
Unit 4 chemical and electrochemical energy based processes
This document discusses various chemical and electrochemical machining processes. It describes chemical machining (CHM) which uses chemical etching to remove material from a workpiece. It involves using etchants and maskants to selectively remove material. Electrochemical machining (ECM) uses electrolysis principles to remove material from a workpiece submerged in an electrolyte solution. Variations include electrochemical grinding (ECG) which combines ECM with conventional grinding, and electrochemical honing (ECH) which uses non-conductive honing stones instead of a grinding wheel. These processes allow burr-free machining of complex shapes in hard and brittle materials with good surface finish and accuracy.
ECM : Electrochemical machining - Principle,process,subsystems & applications
ECM : Electrochemical machining - Principle,process,subsystems & applications. Specialized processes under ECM.
Advance manufacturing process
Non-traditional machining processes like EDM, USM, and WEDM are useful for machining hard materials and complex shapes with precision. EDM works by using electrical sparks to erode material from a part placed close to an electrode tool, allowing intricate shapes to be produced. USM uses an abrasive slurry and vibrating tool to cut materials. WEDM is similar to EDM but uses a continuously moving wire as the electrode. These non-traditional processes are more precise than traditional machines and can machine tough materials that would be difficult to cut otherwise.
Abrassive Flow Machining
The document describes abrasive flow machining (AFM) and summarizes two research papers on the topic. It defines AFM and discusses different types of AFM machines. The first research paper studies the effect of process variables in AFM and develops models to optimize the process. The second paper examines using AFM to finish difficult-to-machine titanium alloy and finds that boron carbide and silicon carbide abrasives most effectively remove surface imperfections within few cycles. Scanning electron microscopy images show the removal of heat-affected layers on the titanium.
Edm
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.
Abrasive jet machining.51 ppt
Abrasive jet machining is an unconventional machining process that uses a high-velocity stream of abrasive particles suspended in a gas to remove material through erosion. It can machine hard and brittle materials that cannot be cut through conventional processes. The process involves mixing abrasive particles with a pressurized gas and passing them through a nozzle to erode away the workpiece material. It provides advantages like ability to machine heat-sensitive materials without damaging them and capability to cut intricate holes, but has low material removal rates and accuracy issues due to stray cutting.
Unit 3 electrical energy based process
Electrical discharge machining (EDM) is a machining process that uses electrical sparks to remove material from a conductive workpiece. EDM works by producing sparks between an electrode tool and the workpiece submerged in a dielectric fluid, which erodes away tiny amounts of material. This allows EDM to machine very hard or brittle materials and create complex shapes regardless of material hardness. EDM provides a high-precision, burr-free finish and can machine thin walls and small features. Wire cut EDM is a similar process that uses a continuously moving thin wire as the electrode to cut intricate shapes.
RUM ( Rotatory Ultrasonic Maching)
This document provides an overview of rotary ultrasonic machining (RUM), also known as micro-ultrasonic machining (MUSM). It defines micromachining and RUM/MUSM, explaining that RUM allows machining features down to 100 micrometers. The document outlines the RUM process, including using a rotating tool with diamond abrasives that machines materials via ultrasonic impacts and grinding. It discusses RUM equipment, process parameters like tool type and vibration conditions, and applications for machining hard materials like titanium alloys, silicon carbide, and dental ceramics.
Electro chemical machining - Thanuj Kumar M
This document provides an introduction to electro-chemical machining (ECM) processes. It discusses the basic principles of ECM including the electrolysis process that occurs. Key elements of ECM are described such as the electrolyte, tool, workpiece, and power supply. Process parameters that influence material removal rate and surface finish are outlined. Applications of ECM include machining complex shapes that would be difficult with traditional methods. Advantages include no cutting forces, high accuracy, and little tool wear.
Electro chemical honing process
The Electrochemical Honing process is a type of electrochemical machining that provides a smooth, accurate surface finish on cylindrical parts. It involves using an abrasive tool and electrolyte to remove material from the workpiece through both electrochemical and mechanical action. Some key aspects of the process include using an abrasive tool that moves longitudinally and rotationally within the workpiece while electrolyte is fed through holes under pressure. This assists the electrochemical removal of material while the abrasives further smooth the surface. The process can achieve a surface roughness between 0.1 and 0.5 microns and an accuracy of 0.01 mm in diameter and less than 0.05 mm in roundness. It provides advantages over conventional honing
Electro Chemical Machining Process
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.
electrochemical grinding
1. Electrochemical grinding (ECG) is a non-traditional machining process that removes electrically conductive material by grinding with a negatively charged abrasive wheel, electrolyte fluid, and a positively charged workpiece. Materials are removed through electrolysis and some abrasion, leaving a smooth burr-free surface.
2. ECG can machine very hard and brittle materials more effectively than traditional processes due to generating little heat. Key parameters that affect the material removal rate include the abrasive wheel properties, workpiece material and surface, machining conditions, electrolyte type and properties, and voltage applied.
3. ECG provides advantages like burr-free surfaces, less work hardening, higher precision
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Unit 5 -RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES
Unit 5 -RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES
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Unit 4 chemical and electrochemical energy based processes
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ECM : Electrochemical machining - Principle,process,subsystems & applications
Similar to Electro chemical machining
Electrochemical Machining (ECM)
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).
Electro chemical machining parameters
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.
Electro chemical machining (1)
Electro Chemical Machining (ECM) is a machining process that uses electrochemical processes to remove material from a workpiece. In ECM, the workpiece acts as an anode and tool as a cathode, both immersed in an electrolyte like NaCl. When voltage is applied, material is removed from the workpiece through electrochemical reactions. ECM can machine complex shapes with good surface finish and no tool wear. It is used for applications like machining turbine blades, gears, and medical and aerospace components due to its precision and ability to machine hard and brittle materials.
Sourabh tailor (seminar)
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.
Spark generation in Electrochemical discharge machining(ECDM) of non-conducti...
This document discusses electrochemical discharge machining (ECDM), a hybrid machining process that combines features of electrochemical machining (ECM) and electrical discharge machining (EDM). It examines how tapered tool electrodes can improve spark generation consistency over cylindrical tools in ECDM. The document outlines the ECDM process, describing its components, operation using a tapered tool electrode on a glass workpiece, advantages like machining nonconductive materials, and limitations such as difficulty handling electrolytes. Finite element modeling is also used to simulate material removal from spark energy transfer.
ELECTROCHEMICAL MACHINING-PPT.pptx
ELECTRO CHEMICAL MACHINING is a process of removing material from another metal by using electrolyte solution.
The metal is immersed in a solution
Then the material is removed
This process is based on faradays law of electrolysis
process
Chemical reaction takes place in this process
We can achieve the required shape in these process
It requires different electrolytes
Electrochemical machining is of 3 types
Electric chemical grinding
Electro chemical deburring
Electro CHEMICAL honing
Non conventional machining process
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.
Electric Discharge Machining
Electric Dischage Machining, Working Principle, Neat diagramme, Advantages, limitations, applications, Process parameters
Novel Electric Discharge Machining method for better machining
Alternating Energy EDM is currently a developing type of machining, the results obtained are very enthusiastic.
The usage of the sintered electrode is the main reason for the astonishing results, and it's rotation make it even better.
WC i.e. Tungsten Carbide has high erosion tendency and low resistivity, whereas PCD i.e. Polycrystalline Diamond has low erosion and high resistivity, due to which plasma channel is more likely to form between WC with Workpiece instead of PCD with Workpiece as the gap between WC as well as PCD with Workpiece is same.
But after WC section gets eroded, the gap between WC section with Workpiece is not enough to create and sustain plasma channel, then plasma channel is formed between PCD section with Workpiece and due to low erosion tendency and high resistivity no significant material removal takes place only finishing operation takes place.
After eroding of PCD, Diamonds expose to workpiece and micro grind it.
Material Removal- WC section
Finishing- PCD section
Micro grinding- Diamonds (mechanically)
Electro Chemical Machining
Electrochemical machining is a non-traditional machining process that removes metal by an electrochemical process. It works based on Faraday's laws of electrolysis by passing a current between an electrode tool and a metal workpiece separated by an electrically conductive fluid. The workpiece acts as the anode and dissolves as metal ions are carried away from the gap by the flowing electrolyte. Key process parameters include current density, tool feed rate, electrolyte flow velocity, and gap size, which control the metal removal rate. ECM can machine hard metals and complex shapes with good surface finish and no tool wear. Its applications include die sinking, drilling turbine blades, and micro machining.
ELECTROCHEMICAL MACHINING - NON TRADITIONAL MACHINING
Electrochemical machining (ECM) is a non-traditional machining process that removes metal through an electrochemical process rather than traditional cutting or grinding. In ECM, a power supply creates a voltage between the workpiece (anode) and tool (cathode) through an electrolyte, causing metal ions from the workpiece to dissolve and flow to the tool. This allows for complex internal and external geometries to be machined in hard metals. ECM is well-suited for mass production of parts with intricate shapes and difficult-to-machine materials due to its ability to machine stress-free and with high precision and surface finish.
Edm new
Electric discharge machining (EDM) involves removing material from a workpiece using electrical discharges between two electrodes separated by a dielectric liquid. It was invented in the 1940s by Russian physicists and can machine hard metals and intricate shapes that other methods cannot. The document discusses the history, working principle, material removal mechanism, advantages, and applications of EDM. It also covers technical parameters like electrode materials, dielectric fluids, and process variables that influence the material removal rate.
Electro chemical machine ( ecm )
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Module 3
Electrochemical machining (ECM) is a non-traditional machining process that removes metal by applying a high electrical current between an electrolyte-filled gap of the tool and workpiece. During ECM, the workpiece acts as the anode and the tool acts as the cathode. As current is passed, metal ions from the workpiece dissolve into the electrolyte solution. The tool is shaped to produce the desired shape in the workpiece. Key factors that affect the ECM process include the current density, gap size between tool and workpiece, electrolyte composition and flow rate, and process parameters such as tool feed rate. ECM can machine hard materials and produce complex shapes with a burr-free
Electrical Discharge Machining
This document discusses electrical discharge machining (EDM). EDM is a machining process that uses electrical sparks to remove material from a workpiece. In EDM, a tool electrode is moved close to the workpiece and an electric current is applied, creating sparks that erode away material. Key aspects covered include the basic components and setup of an EDM machine, the working principle of how material is removed through electric sparks, important process parameters, and applications where EDM is commonly used such as machining hard metals and complex shapes.
ppt of machine learning and materials slide ppt showing mechanical machine
Non-conventional machining processes remove material without chip formation through melting, evaporation, or brittle fracture. They are used for difficult profiles and hard materials. There are several types of non-traditional machining classified as mechanical, thermal, chemical/electrochemical, or other. Mechanical processes like ultrasonic and waterjet machining use abrasives suspended in fluid. Thermal processes melt or vaporize material using heat sources like plasma or electrons. Chemical/electrochemical dissolution removes material using chemical or electrochemical reactions.
ppt_ucm_removed (1)_removed.pdfgjkgfjjggf
Non-conventional machining processes such as ultrasonic machining, electrical discharge machining, and laser beam machining remove metal through non-contact methods like melting, vaporization, or chemical reactions rather than traditional chip formation. They are used for difficult materials and complex profiles. Abrasive jet machining works by mixing an abrasive powder with compressed air or gas and directing it at high speeds through a nozzle to remove material from the workpiece.
15. Non Conventional Machining Processes
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
MODULE_3.ppt
Electrochemical machining (ECM) is a non-traditional machining process that uses electrical current between an electrolyte tool and a conductive workpiece to remove metal atoms. It can machine complex cavities in hard materials with a burr-free surface finish. The process involves an electrolyte flowing between the tool and workpiece where an electrical current ionizes metal atoms from the workpiece. ECM can machine materials regardless of their strength or hardness and leaves no heat affected zone. It is commonly used for duplicating complex parts and machining difficult-to-cut materials like turbine blades.
ECM
Electrochemical machining (ECM) is a non-traditional machining process that uses electrical current between an electrolyte tool and a conductive workpiece to remove metal atoms. It can machine complex cavities in hard materials with a burr-free surface finish. The process involves an electrolyte flowing between the tool and workpiece where an electrical current ionizes and removes metal. ECM can machine materials regardless of their strength or hardness and leaves no heat affected zone. It is commonly used for duplicating complex parts and machining difficult-to-cut materials like turbine blades.
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ELECTROCHEMICAL MACHINING - NON TRADITIONAL MACHINING
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ppt of machine learning and materials slide ppt showing mechanical machine
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Electro chemical machining
- 1. Electro Chemical Machining J. Hemwani, GPC, Betul (M.P.) 460001 1
- 2. ECM -- Principle ▪ Non-conventional machining system in which metal is removed by electrochemical process as ‘Reverse Electroplating’ means it removes metal instead of adding it. ▪ Works on Faraday’s law of electrolysis— “Thus ECM can be thought of a controlled anodic dissolution at atomic level of the work piece that is electrically conductive by a shaped tool due to flow of high current at relatively low potential difference through an electrolyte which is quite often water based neutral salt solution”. ▪ Anode: Work-piece;; Cathode: Tool;; Electrolyte : An electrically conductive fluid J. Hemwani, GPC, Betul (M.P.) 460001 2
- 3. Principle of Electro Chemical Machining J. Hemwani, GPC, Betul (M.P.) 460001 3
- 4. ECM -- Process ▪ In ECM, the work-piece is connected to the positive terminal of a low voltage high current DC generator. ▪ The shaped tool is connected to the negative terminal and the shape of the tool is transferred to work piece. ▪ Machining takes place due to anodic dissolution at atomic level of the work material due to electrochemical reaction. ▪ A gap between the tool and the work-piece is required to be maintained to proceed with steady state machining. ▪ Generally a neutral salt solution of sodium chloride (NaCl) is taken as the electrolyte. J. Hemwani, GPC, Betul (M.P.) 460001 4
- 5. ECM -- Process ▪ The electrolyte and water undergoes ionic dissociation as shown below as potential difference is applied “NaCl ↔ Na+ + Cl- H2O ↔ H+ + (OH)- ▪ Thus the hydrogen ions will take away electrons from the cathode (tool) and from hydrogen gas. ▪ Work- piece (anode) ions would combine with chloride ions to form chloride. ▪ Sodium ions would combine with hydroxyl ions to form sodium hydroxide. ( Na+ + OH- = NaOH.) ▪ The work piece gets gradually machined and gets precipitated as the sludge. J. Hemwani, GPC, Betul (M.P.) 460001 5
- 6. ECM -- Process ▪ There is not coating on the tool, only hydrogen gas evolves at the tool or cathode. ▪ The good machinability Tool should have high thermal conductivity and strong enough to withstand pressures. piece. ▪ Electrolyte cools the cutting zone which becomes hot due to the flow of high current . ▪ The control parameters include voltage, inlet & outlet Pressure of electrolyte, Temperature of electrolyte, and the feed rate of the tool. J. Hemwani, GPC, Betul (M.P.) 460001 6
- 7. Electro Chemical Machining J. Hemwani, GPC, Betul (M.P.) 460001 7
- 8. ECM -- Advantages ▪ ECM is well suited for the machining of complex two- dimensional shapes. ▪ In ECM there is very little or no tool wear. ▪ With the help of ECM Delicate parts having difficult geometries can be machined. ▪ As the material removal takes place due to atomic level dissociation, the machined surface is of excellent quality. ▪ With the help of ECM materials having poor machinability can be machined. J. Hemwani, GPC, Betul (M.P.) 460001 8
- 9. ECM -- Disadvantages ▪ ECM Tool Design is complicated and time consumimg. ▪ Initial tooling cost of ECM tool is high. ▪ ECM may be environmentally harmful because of by- product gases etc. ▪ ECM consumes large amount of power hence costly. J. Hemwani, GPC, Betul (M.P.) 460001 9
- 10. Thank You J. Hemwani, GPC, Betul (M.P.) 460001 10