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UCM - Unit 2 -thermal and electrical energy based processes
- 1. THERMAL AND ELECTRICAL ENERGYBASED PROCESSES UNIT -2
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- 3. EDM-Principle • A thinwire of round shape used as an electrode, which is supplied to the work area through a pair of wheels. With the aid of current a high power spark is produced between wire- electrode and work piece. Due to this high amount of heat is produced nearly to 10000 degree Celsius. This heat energy used to melt and vaporize the work material. Then with the supply of dielectric fluid the molten stage materials are flushed away, likewise the machining is carried out in the work piece.
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- 5. Specifications Voltage = 250V GAP = 0.005 – 0.05 mm Temperature = 10000 degree celcius Spark occur = 10 – 30 micro seconds Current density = 15 – 500 A
- 6. Di electric Fluid– Flushing Method 1. Pressure Flushing 2. Suction Flushing 3. Side Flushing
- 7. Pressure Flushing Di electricFluid – Flushing Method
- 8. Suction Flushing Di electricFluid – Flushing Method
- 9. Side Flushing Di electricFluid – Flushing Method
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- 11. Electrode (Tool) • Graphite( Non Metallic) • Copper (Metallic) • Coppre - Tungsten
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- 13. 1. Relaxation Circuit •Commonly used • Simplicity • Less cost
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- 16. 2. R-C-L Circuit •MRR increases with the decrease of R Capacitor charging time is the problem in R-C circuit. So to overcome this , inductance (L) is introduced in the circuit
- 17. Rotary Pulse Generator •R-C and R-C-L yield low MRR • Rotary Pulse Generator over come Drawback of above to circuits • It give high MRR • It give good Surface finish • It give low tool wear • It provide better control in all Parameters
- 18. Rotary Pulse Generator •Here Capacitor is discharged through the diode during first half cycle. • In the next half cycle sum of voltages is given with charged capacitor to the circuit. • So high spark produced • It results high MRR Draw Back •Poor Surface Finish
- 19. Controlled Pulse GeneratorCircuit
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- 21. 1. Operating Parameters 2.Taper 3. Surface finish 4. Current Density PROCESS PARAMETERS
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- 25. Wire – CutEDM (WEDM) Travelling Wire Cut EDM (TWEDM)
- 26. Disadvantages of WEDM •High Capital cost • Cutting Rate is slow • Not suitable for large work pieces
- 27. Applications of WEDM •In the manufacturing of Gears Tools Rotors Turbine Blades Cams
- 28. Wire Cut EDMVs EDM
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- 31. THERMAL ENERGY BASEDPROCESSES
- 32. PRINCIPLE Here the machiningis done by usage of heat energy. The heat energy is focused on a particular portion for melt & Vaporize the work material Example : 1. Electron Beam Machining (EBM) 2. Laser Beam Machining (LBM) 3. Plasma Arc Machining (PAM)
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- 43. Process parameters 2.Control ofSpot Diameter
- 47. Process parameters 3.Control ofFocal Distance of magnetic lens
- 48. LASER BEAM MACHINING PhotonEmission
- 49. PRINCIPLE OF LASERBEAM PRODUCTION
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- 52. TYPES OF LASER 1.Gas lasers 2. Solid lasers 3. Liquid lasers 4. Semi Conductor lasers
- 53. SOLID LASER RUBY LASER SyntheticRuby rod made up of crystal of aluminium oxide
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- 57. MACHINING APPLICATIONS OFLASER 1. Laser in Metal Cutting 2. Laser in Drilling 3. Laser in Welding 4. Laser in Surface Treatment 5. Trimming 6. Blanking 7. Micromachining applications
- 58. Laser in SurfaceTreatment A thin layer of cobalt alloy coating is applied on Turbine blade for heat and Wear Resistance. A thin Ceramic coating is applied on metal Surface for heat and Wear Resistance. Its also used to seal the micro cracks which are usually present in hard – Chromium electroplates
- 59. Advantages of LBM 1.All Kind of metals are machined 2. Micro holes are possible 3. Soft materials like rubber can be machined 4. No tool wear and contact with w/p 5. Automated process 6. Controlling of beam is easy
- 60. 1. High initialCost 2. Operating cost is high 3. Required skilled labours 4. Rate of production is low 5. Need safety equipments 6. Life of flash lamp is low 7. The machined holes are not straight and round Disadvantages of LBM
- 61. PLASMA ARC MACHINING OR PLASMAJET MACHINING
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- 66. Direct Arc Plasma Torch TYPESOF PLASMA ARC TORCHES
- 67. In-Direct Arc PlasmaTorch .
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