This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). ECSM uses sparks generated between a cathode tool and workpiece in an electrolyte solution to remove material. Key parameters for ECSM include supply voltage, tool diameter, electrolyte composition, and gap distance. EDDG uses sparks to soften and abrade workpiece surfaces with diamond abrasives. Factors like wheel speed, current, and pulse time affect the EDDG process. Thermal processes like electric discharge micromachining (EDMM) and electron beam micromachining precisely shape conductive materials by localized melting/vaporization using electric
This document discusses several advanced nano finishing processes including abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. It provides details on the working principles, process parameters, advantages, limitations and applications of abrasive flow machining and chemo mechanical polishing. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching with mechanical polishing to smooth and planarize surfaces.
RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSESravikumarmrk
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.
Abrasive flow machining is a finishing process that uses a semi-solid abrasive putty to remove small amounts of material from workpieces. The putty is forced through or across the workpiece using hydraulic pressure to deburr, radius, polish and perform other surface finishing operations. It is well suited for finishing metals, ceramics and plastics in a uniform and economical manner, though it is not used for heavy material removal due to its low material removal rate. The process involves selecting abrasive media based on the material and desired finish, and using tooling and pressure to direct the flow of media through restrictions in the workpiece.
1. Chips are formed during machining when excess metal is sheared off the workpiece. There are three main types of chips: discontinuous, continuous, and continuous with built-up edge.
2. Discontinuous chips form with brittle materials while continuous chips form with ductile materials at high speeds. Continuous chips with built-up edge form with friction at low-medium speeds.
3. Chip breakers are used to break long continuous chips for safety and chip disposal. Built-up edges form from friction but can be prevented by reducing friction, pressure, temperature through rake angle, lubrication and speed/feed adjustments.
Abrasive flow machining is a deburring and surface finishing process that uses abrasive particles mixed in a viscoelastic medium. It can polish internal surfaces, holes, and intersecting holes. The document discusses the need for AFM, abrasive materials used, the one-way, two-way, and orbital classification methods, process parameters like pressure and abrasive size, capabilities like surface finish ranges and tolerances, and applications in aerospace, automotive, die and mold making, and medical industries to improve surfaces, reduce wear, increase performance, and extend component life.
The document discusses electrochemical machining (ECM). ECM is an unconventional machining process where material is removed from a workpiece made of an electrically conductive material via an electrochemical reaction. In ECM, the workpiece acts as an anode in an electrolyte solution, and a tool acts as a cathode. A direct current is passed between them, causing metal ions from the workpiece to dissolve into the electrolyte solution. ECM can machine complex shapes with high accuracy and no tool wear. It has the highest material removal rate of any unconventional machining process but requires expensive equipment and a conductive workpiece material.
This document discusses magnetorheological abrasive flow finishing (MRAFF), a process that uses a magnetorheological polishing fluid to precisely control finishing forces and achieve a final surface finish. An experimental setup was designed to study the process, consisting of MR polishing fluid cylinders, hydraulic actuators, an electromagnet, and workpiece fixture. Experiments showed no surface roughness change at zero magnetic field but improved surface finish at higher fields, as the MR fluid's viscosity changes with applied field strength. The MRAFF process involves extruding the MR fluid through the workpiece under a magnetic field, where abrasives held by iron chains rub peaks and shear material in a controllable way set by the field strength.
Abrasive water jet machining (AWJM) is a non-traditional machining process that uses a high-pressure stream of water mixed with abrasive particles to erode materials. It works by converting the kinetic energy of the water-abrasive jet into high pressure upon impacting the workpiece surface, removing material when the pressure exceeds the part's strength. The document discusses the AWJM process, including its mechanism of localized erosion, key parameters like water pressure and abrasive flow rate, applications in cutting a wide range of materials, advantages like flexibility and lack of heat, and limitations for hard or thick materials.
This document discusses several advanced nano finishing processes including abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. It provides details on the working principles, process parameters, advantages, limitations and applications of abrasive flow machining and chemo mechanical polishing. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching with mechanical polishing to smooth and planarize surfaces.
RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSESravikumarmrk
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.
Abrasive flow machining is a finishing process that uses a semi-solid abrasive putty to remove small amounts of material from workpieces. The putty is forced through or across the workpiece using hydraulic pressure to deburr, radius, polish and perform other surface finishing operations. It is well suited for finishing metals, ceramics and plastics in a uniform and economical manner, though it is not used for heavy material removal due to its low material removal rate. The process involves selecting abrasive media based on the material and desired finish, and using tooling and pressure to direct the flow of media through restrictions in the workpiece.
1. Chips are formed during machining when excess metal is sheared off the workpiece. There are three main types of chips: discontinuous, continuous, and continuous with built-up edge.
2. Discontinuous chips form with brittle materials while continuous chips form with ductile materials at high speeds. Continuous chips with built-up edge form with friction at low-medium speeds.
3. Chip breakers are used to break long continuous chips for safety and chip disposal. Built-up edges form from friction but can be prevented by reducing friction, pressure, temperature through rake angle, lubrication and speed/feed adjustments.
Abrasive flow machining is a deburring and surface finishing process that uses abrasive particles mixed in a viscoelastic medium. It can polish internal surfaces, holes, and intersecting holes. The document discusses the need for AFM, abrasive materials used, the one-way, two-way, and orbital classification methods, process parameters like pressure and abrasive size, capabilities like surface finish ranges and tolerances, and applications in aerospace, automotive, die and mold making, and medical industries to improve surfaces, reduce wear, increase performance, and extend component life.
The document discusses electrochemical machining (ECM). ECM is an unconventional machining process where material is removed from a workpiece made of an electrically conductive material via an electrochemical reaction. In ECM, the workpiece acts as an anode in an electrolyte solution, and a tool acts as a cathode. A direct current is passed between them, causing metal ions from the workpiece to dissolve into the electrolyte solution. ECM can machine complex shapes with high accuracy and no tool wear. It has the highest material removal rate of any unconventional machining process but requires expensive equipment and a conductive workpiece material.
This document discusses magnetorheological abrasive flow finishing (MRAFF), a process that uses a magnetorheological polishing fluid to precisely control finishing forces and achieve a final surface finish. An experimental setup was designed to study the process, consisting of MR polishing fluid cylinders, hydraulic actuators, an electromagnet, and workpiece fixture. Experiments showed no surface roughness change at zero magnetic field but improved surface finish at higher fields, as the MR fluid's viscosity changes with applied field strength. The MRAFF process involves extruding the MR fluid through the workpiece under a magnetic field, where abrasives held by iron chains rub peaks and shear material in a controllable way set by the field strength.
Abrasive water jet machining (AWJM) is a non-traditional machining process that uses a high-pressure stream of water mixed with abrasive particles to erode materials. It works by converting the kinetic energy of the water-abrasive jet into high pressure upon impacting the workpiece surface, removing material when the pressure exceeds the part's strength. The document discusses the AWJM process, including its mechanism of localized erosion, key parameters like water pressure and abrasive flow rate, applications in cutting a wide range of materials, advantages like flexibility and lack of heat, and limitations for hard or thick materials.
This document discusses process planning and cost estimation. It covers topics such as process planning activities like drawing interpretation, material evaluation, process selection, production equipment selection, tooling selection and quality assurance methods. It also discusses cost estimation activities including estimating procedures, types of estimates, elements of cost estimation, methods of estimating, importance of costing and elements of costing like labor, material and overhead costs. Key aspects of process planning and cost estimation are covered through examples and case studies.
The document discusses abrasive water jet machining (AWJM), which is a non-traditional machining process that uses the mechanical energy of high-pressure water and abrasive particles to remove material. It defines AWJM and describes the entrained and suspended types of AWJM systems, explaining how high-pressure water and abrasives are used to erode materials. Applications of AWJM include cutting of soft materials, textiles, leather, frozen foods, and uses in surgery and mass immunization.
This presentation contain discription about Fine finishing process of complex shape material which cannot be finished by normal processess. three type of finishing process has been described they are Abrasive flow machining, MAgnetic Abrasive Finishing, Magneto Rheological abrasive finishing.
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.
UCM - Unit 4 advanced nano finishing processeskarthi keyan
This document provides an overview of advanced nano finishing processes. It describes abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. For each process, it outlines the basic principles, construction and working, process parameters, advantages, limitations, and applications. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching and abrasive polishing, while magnetic processes use magnetic fields to control abrasives.
Thermal energy based machining processes like electron beam machining (EBM), laser beam machining (LBM), and plasma arc machining (PAM) work by concentrating heat energy on a small area of the workpiece to melt and vaporize material. EBM uses a beam of high velocity electrons, LBM uses a focused laser beam, and PAM uses a high temperature plasma jet, all to remove tiny bits of workpiece material through localized heating and repetition of the process. While each has advantages like precision and lack of mechanical contact, they also have disadvantages like high equipment costs and low material removal rates.
Advanced machining processes
Utilize chemical, electrical, and high-energy beams
Situations where traditional machining processes are
unsatisfactory or uneconomical:
– Workpiece material is too hard, strong, or tough.
– Workpiece is too flexible to resist cutting forces or too difficult
to clamp.
– Part shape is very complex with internal or external profiles
or small holes.
– Requirements for surface finish and tolerances are very high.
– Temperature rise or residual stresses are undesirable or
unacceptable.
So to eliminate this disadvantages non conventional machines can be used
This presentation describes the cylindrical grinding process and types of operations and machines in this process, which is why useful topic B.Tech mechanical of fourth sem students. This explains about the overview on the external cylindrical grinding 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.
Non-traditional machining techniques remove material using various energy sources besides traditional cutting tools. They are divided into mechanical, electrical, thermal, and chemical techniques. Non-traditional techniques are needed for hard or complex materials, and can machine intricate shapes and deep holes. Selection depends on the part geometry, material properties, machining capabilities, and cost effectiveness. While more expensive initially than traditional techniques, non-traditional machining offers higher precision, surface finish, and ability to machine difficult materials.
Abrasive Jet Machining Process and Water Machining ProcessPraveenManickam2
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 a vibrating tool and workpiece in an abrasive
Unconventional machining processes remove metal without direct contact between the tool and workpiece. They were developed to address the limitations of conventional machining, such as waste disposal, heat generation, and difficulty machining hard or complex materials. Some unconventional processes include metal forming techniques that shape metals using high energy inputs in short time intervals. Selection of unconventional machining involves considering physical parameters, part shapes, process capabilities, and cost. While unconventional machining enables new applications, it also has limitations such as higher costs and slower speeds than conventional techniques.
Electric discharge machining (EDM) is a machining process that uses electrical sparks to erode metals. It works by maintaining a precise gap between an electrode tool and a metal workpiece submerged in a dielectric fluid. Repeated electrical sparks are generated to melt and vaporize small amounts of metal from both the tool and workpiece, allowing complex and hard-to-machine shapes to be produced. EDM can machine metals regardless of hardness and without mechanical force, giving it advantages over traditional machining methods for difficult-to-cut materials.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
This document discusses shaped tube electrolytic machining (STEM), which is a variation of electrochemical machining (ECM) that can produce small holes with high depth-to-diameter ratios in electrically conductive materials. STEM uses a cathodic tool in the shape of a conducting cylinder with an insulating coating to drill holes in an anodic workpiece when an electric potential is applied through an electrolyte, typically an acid. The document outlines the STEM process, parameters including electrolytes, voltage, time and feed rate, capabilities including hole size and tolerances, advantages, limitations, and applications for drilling cooling holes in parts like turbine blades.
The document discusses milling fixtures and their components. Milling fixtures securely hold workpieces for milling operations. They have locating elements to precisely position workpieces and clamping elements to securely hold them against cutting forces. Key components of milling fixtures include a base, tenons to locate the fixture on the machine table, setting blocks to position cutters, and clamps or vices to hold workpieces in place. Different types of milling fixtures are used for operations like face milling or gang milling and can have mechanical, hydraulic or pneumatic clamping systems.
This document provides an introduction to non-conventional machining processes. It discusses how these processes use indirect energy like sparks, lasers, heat, or chemicals rather than direct contact between a tool and workpiece. Some key non-conventional machining processes described include electrical discharge machining, wire EDM, laser beam machining, electron beam machining, water jet machining, abrasive jet machining, ultrasonic machining, electrochemical machining, and electrochemical grinding. Advantages of these processes include high accuracy, less wear, longer tool life, and reduced environmental hazards compared to conventional machining.
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.
The document discusses three mechanical energy-based machining processes: abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). In AJM, a high-speed stream of abrasive particles erodes material from the workpiece. WJM uses a high-velocity water jet to convert kinetic energy into pressure that removes small chips. USM forces an abrasive slurry against the workpiece using a vibrating tool to remove extremely small chips. Key parameters for each process include abrasive properties, pressure, velocity, vibration frequency, and more. Each method can machine hard materials and provides advantages like avoiding heat, being noiseless, or enabling intricate shapes.
This document discusses recent trends in non-traditional machining processes. It describes hybrid processes that combine advantages of two non-traditional processes to improve performance. Electrochemical spark machining (ECSM) is discussed as a hybrid of electrochemical and electric discharge machining that can machine both conductive and non-conductive materials. Electrical discharge diamond grinding (EDDG) and ultrasonic micromachining are also summarized, outlining their working principles, key parameters, advantages, and applications in precision machining. The document provides an overview of recent developments in hybrid and other non-traditional machining techniques.
UNIT 5 RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES.pptxDineshKumar4165
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.
This document discusses process planning and cost estimation. It covers topics such as process planning activities like drawing interpretation, material evaluation, process selection, production equipment selection, tooling selection and quality assurance methods. It also discusses cost estimation activities including estimating procedures, types of estimates, elements of cost estimation, methods of estimating, importance of costing and elements of costing like labor, material and overhead costs. Key aspects of process planning and cost estimation are covered through examples and case studies.
The document discusses abrasive water jet machining (AWJM), which is a non-traditional machining process that uses the mechanical energy of high-pressure water and abrasive particles to remove material. It defines AWJM and describes the entrained and suspended types of AWJM systems, explaining how high-pressure water and abrasives are used to erode materials. Applications of AWJM include cutting of soft materials, textiles, leather, frozen foods, and uses in surgery and mass immunization.
This presentation contain discription about Fine finishing process of complex shape material which cannot be finished by normal processess. three type of finishing process has been described they are Abrasive flow machining, MAgnetic Abrasive Finishing, Magneto Rheological abrasive finishing.
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.
UCM - Unit 4 advanced nano finishing processeskarthi keyan
This document provides an overview of advanced nano finishing processes. It describes abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. For each process, it outlines the basic principles, construction and working, process parameters, advantages, limitations, and applications. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching and abrasive polishing, while magnetic processes use magnetic fields to control abrasives.
Thermal energy based machining processes like electron beam machining (EBM), laser beam machining (LBM), and plasma arc machining (PAM) work by concentrating heat energy on a small area of the workpiece to melt and vaporize material. EBM uses a beam of high velocity electrons, LBM uses a focused laser beam, and PAM uses a high temperature plasma jet, all to remove tiny bits of workpiece material through localized heating and repetition of the process. While each has advantages like precision and lack of mechanical contact, they also have disadvantages like high equipment costs and low material removal rates.
Advanced machining processes
Utilize chemical, electrical, and high-energy beams
Situations where traditional machining processes are
unsatisfactory or uneconomical:
– Workpiece material is too hard, strong, or tough.
– Workpiece is too flexible to resist cutting forces or too difficult
to clamp.
– Part shape is very complex with internal or external profiles
or small holes.
– Requirements for surface finish and tolerances are very high.
– Temperature rise or residual stresses are undesirable or
unacceptable.
So to eliminate this disadvantages non conventional machines can be used
This presentation describes the cylindrical grinding process and types of operations and machines in this process, which is why useful topic B.Tech mechanical of fourth sem students. This explains about the overview on the external cylindrical grinding 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.
Non-traditional machining techniques remove material using various energy sources besides traditional cutting tools. They are divided into mechanical, electrical, thermal, and chemical techniques. Non-traditional techniques are needed for hard or complex materials, and can machine intricate shapes and deep holes. Selection depends on the part geometry, material properties, machining capabilities, and cost effectiveness. While more expensive initially than traditional techniques, non-traditional machining offers higher precision, surface finish, and ability to machine difficult materials.
Abrasive Jet Machining Process and Water Machining ProcessPraveenManickam2
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 a vibrating tool and workpiece in an abrasive
Unconventional machining processes remove metal without direct contact between the tool and workpiece. They were developed to address the limitations of conventional machining, such as waste disposal, heat generation, and difficulty machining hard or complex materials. Some unconventional processes include metal forming techniques that shape metals using high energy inputs in short time intervals. Selection of unconventional machining involves considering physical parameters, part shapes, process capabilities, and cost. While unconventional machining enables new applications, it also has limitations such as higher costs and slower speeds than conventional techniques.
Electric discharge machining (EDM) is a machining process that uses electrical sparks to erode metals. It works by maintaining a precise gap between an electrode tool and a metal workpiece submerged in a dielectric fluid. Repeated electrical sparks are generated to melt and vaporize small amounts of metal from both the tool and workpiece, allowing complex and hard-to-machine shapes to be produced. EDM can machine metals regardless of hardness and without mechanical force, giving it advantages over traditional machining methods for difficult-to-cut materials.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
This document discusses shaped tube electrolytic machining (STEM), which is a variation of electrochemical machining (ECM) that can produce small holes with high depth-to-diameter ratios in electrically conductive materials. STEM uses a cathodic tool in the shape of a conducting cylinder with an insulating coating to drill holes in an anodic workpiece when an electric potential is applied through an electrolyte, typically an acid. The document outlines the STEM process, parameters including electrolytes, voltage, time and feed rate, capabilities including hole size and tolerances, advantages, limitations, and applications for drilling cooling holes in parts like turbine blades.
The document discusses milling fixtures and their components. Milling fixtures securely hold workpieces for milling operations. They have locating elements to precisely position workpieces and clamping elements to securely hold them against cutting forces. Key components of milling fixtures include a base, tenons to locate the fixture on the machine table, setting blocks to position cutters, and clamps or vices to hold workpieces in place. Different types of milling fixtures are used for operations like face milling or gang milling and can have mechanical, hydraulic or pneumatic clamping systems.
This document provides an introduction to non-conventional machining processes. It discusses how these processes use indirect energy like sparks, lasers, heat, or chemicals rather than direct contact between a tool and workpiece. Some key non-conventional machining processes described include electrical discharge machining, wire EDM, laser beam machining, electron beam machining, water jet machining, abrasive jet machining, ultrasonic machining, electrochemical machining, and electrochemical grinding. Advantages of these processes include high accuracy, less wear, longer tool life, and reduced environmental hazards compared to conventional machining.
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.
The document discusses three mechanical energy-based machining processes: abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). In AJM, a high-speed stream of abrasive particles erodes material from the workpiece. WJM uses a high-velocity water jet to convert kinetic energy into pressure that removes small chips. USM forces an abrasive slurry against the workpiece using a vibrating tool to remove extremely small chips. Key parameters for each process include abrasive properties, pressure, velocity, vibration frequency, and more. Each method can machine hard materials and provides advantages like avoiding heat, being noiseless, or enabling intricate shapes.
This document discusses recent trends in non-traditional machining processes. It describes hybrid processes that combine advantages of two non-traditional processes to improve performance. Electrochemical spark machining (ECSM) is discussed as a hybrid of electrochemical and electric discharge machining that can machine both conductive and non-conductive materials. Electrical discharge diamond grinding (EDDG) and ultrasonic micromachining are also summarized, outlining their working principles, key parameters, advantages, and applications in precision machining. The document provides an overview of recent developments in hybrid and other non-traditional machining techniques.
UNIT 5 RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES.pptxDineshKumar4165
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.
This document provides an overview of advanced nano finishing processes. It describes abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. For each process, it outlines the basic principles, construction and working, process parameters, advantages, limitations, and applications. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching and abrasive polishing, while magnetic abrasive finishing uses magnetic particles to form an abrasive brush for finishing. Magneto rheological finishing takes advantage of smart fluids that change viscosity in magnetic fields for precision mach
This document provides an overview of advanced nano finishing processes. It describes abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. For each process, it outlines the basic principles, construction and working, process parameters, advantages, limitations, and applications. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching and abrasive polishing, while magnetic processes utilize magnetic fields to control abrasives.
UNIT 4 -Advanced Nano finishing Processes.pptxRaja P
This document provides an overview of advanced nano finishing processes. It describes abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. For each process, it outlines the basic principles, construction and working, process parameters, advantages, limitations, and applications. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching and abrasive polishing, while magnetic processes use magnetic fields to control abrasives.
This document provides information on various advanced nano finishing processes including abrasive flow machining (AFM), chemo-mechanical polishing (CMP), magnetic abrasive finishing (MAF), magneto-rheological finishing (MRF), and magneto-rheological abrasive flow finishing (MRAFF). It describes the principles, process parameters, advantages, limitations, and applications of each process. AFM uses a semisolid abrasive media to remove small amounts of material from surfaces. CMP combines chemical etching and mechanical polishing, while MAF uses magnetic particles to form an abrasive brush. MRF utilizes a magneto-rheological fluid that becomes a solid under magnetic fields for finishing.
This document provides an introduction to electrical discharge machining (EDM). EDM is an unconventional machining process where material is removed by electric sparks between an electrode tool and conductive workpiece, with no direct contact between them. Key aspects of EDM covered include the construction of EDM machines, the role of dielectric fluids, factors that affect the material removal rate such as capacitance and spark parameters, and electrode tool materials and wear characteristics. Graphite, copper, and copper-tungsten are commonly used as tool materials in EDM due to properties like machinability and erosion resistance.
This document provides an overview of mechanical energy based unconventional machining processes. It discusses abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). For each process, it describes the basic working principles, key components, process parameters that influence material removal rate, advantages, disadvantages, and applications. It also compares different types of transducers used in USM and discusses factors affecting the machining performance of USM.
The document discusses various unconventional machining processes. It covers mechanical energy based processes like abrasive jet machining, water jet machining and ultrasonic machining in Unit 1. Unit 2 discusses thermal and electrical energy based processes. Key processes covered are electrical discharge machining and electrochemical machining. Unit 3 focuses on chemical and electrochemical energy based processes like electrochemical machining. The document provides details on the working, parameters, advantages and applications of these various unconventional machining processes.
The document discusses various unconventional machining processes. It covers mechanical energy based processes like abrasive jet machining, water jet machining and ultrasonic machining in Unit 1. Unit 2 discusses thermal and electrical energy based processes. Key processes covered are electrical discharge machining and electrochemical machining. Unit 3 focuses on chemical and electrochemical energy based processes like electrochemical machining. The document provides details on the working, parameters, advantages and applications of these various unconventional machining processes.
This document discusses various advanced nano finishing processes. It describes abrasive flow machining, where a semisolid abrasive media acts as a deformable grading wheel to remove small amounts of material. It also covers chemo-mechanical polishing, which uses chemical reactions to soften materials for mechanical polishing. Magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing are also introduced, along with their working principles and applications in finishing complex parts.
UNIT 4 ADVANCED NANO FINISHING PROCESSES.pptxDineshKumar4165
Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, magneto rheological abrasive flow finishing their working principles, equipments, effect of process parameters, applications, advantages and limitations
The document discusses various thermal energy based machining processes including EDM, laser beam machining, and plasma arc machining. It provides details on the principles, types, and process parameters for each. EDM works by producing sparks between an electrode and workpiece using a dielectric fluid, vaporizing small amounts of material. Laser beam machining uses a focused laser beam to melt and vaporize workpiece material. Plasma arc machining involves using a high-temperature ionized gas to cut and melt materials.
The document discusses various thermal energy based machining processes including EDM, laser beam machining, and plasma arc machining. It provides details on the principles, types, process parameters and applications of each process. EDM works by producing sparks between an electrode and workpiece using a dielectric fluid, vaporizing small amounts of material. Laser beam machining uses a focused laser beam to melt and vaporize material. Plasma arc machining involves heating a gas to an ionized plasma state and directing the plasma through a torch onto the workpiece.
The document discusses various thermal energy based machining processes including EDM, laser beam machining, and plasma arc machining. It provides details on the principles, types, process parameters and applications of each process. EDM works by producing sparks between an electrode and workpiece using a dielectric fluid, vaporizing small amounts of material. Laser beam machining uses a focused laser beam to melt and vaporize material. Plasma arc machining involves heating a gas to an ionized plasma state and directing the plasma through a torch onto the workpiece.
This document provides an overview of unconventional machining processes. It begins with an introduction to conventional machining processes and then discusses the need for unconventional processes to machine advanced materials. The document categorizes unconventional processes as mechanical, electrical, chemical/electrochemical, or thermal based. Specific unconventional processes like ultrasonic machining and abrasive water jet cutting are then described in more detail.
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2. INTRODUCTION
• Recent developments in non traditional
machining process is the hybrid process. This
process was developed by combining the
advantages of two non traditional machining
processes and eliminating the limitations of
those processes.
3. VARIOUS TYPES OF HYBRID PROCESS
1. Electric discharge diamond grinding (EDDG)
2. Electro chemical spark machining (ECSM)
3. Magneto rheological abrasive flow finishing
(MRAFF)
4. • It enhances volumetric material removal rate.
• Computer controls of the processes have
good results and better performance.
• Awareness of capabilities will resolve many
problems in machining.
• Application of adaptive control machining
becomes easier.
MAIN PURPOSES OF
IMPLEMENTING HYBRID PROCESS
5. Electro chemical spark machining
(ECSM)
• Electro chemical spark machining is a hybrid
process of electro chemical machining and
electric discharge machining. This process is
Unique because it is suitable for both
conducting and non conducting material.
• It is used for selective deposition,
microwelding and machining of special non
conductive material
6. • The anode and the cathode are immersed
inside the electrolyte. Due to potential
difference developed, hydrogen bubbles are
generated and thus spark is created between
the cathode and workpiece.
• This produces high energy that helps in
material removal or vapourization of material
take place as shown in figure
PRINCIPLE OF (ECSM)
10. MATERIAL REMOVAL IN ECSM
• Melting and vapourisation
• Chemical reaction when proper electrolyte is
not selected.
• Cracks propagate through random thermal
stresses.
• Due to mechanical shock and cavitations
effect.
11. PROCESS PARAMETERS IN ECSM
• A supply voltage ranges between 35 – 50 V.
• Cutting tool has a wire diameter of 200 m.
• The workpiece used here is soda lime glass.
• The gap to be maintained between the cathode
and workpiece is around 50 – 500 m depending
on the type of application.
• The electrolyte solution is 14 – 20% of water and
sodium chloride.
• The table speed is 4 rpm.
12. • Electric discharge diamond grinding process is
a spark erosion process used for precision
grinding. Spark is produced between metal
bonded grinding wheel and workpiece.
• Heat generated during sparking softens the
workpieces surface and grinding process is
easily abraded using diamond abrasive
particles.
ELECTRICAL DISCHARGE DIAMOND
GRINDING (EDDG)
15. • When the workpieces is the electrically
conductive material
• When the workpiece is electrically
nonconductive material.
BASIC CONFIGURATION OF EDDG
21. • It can grind any conductive and non conductive
materials.
• Less corrosive effect is produced.
• This process involves continuous dressing and
declogging of the abrasive wheel and thus
increases the wheel life to 25%.
• Higher material removal rate than EDM
• Lower operating cost
• Produces higher accuracy
ADVANTAGES OF EDDG
22. • Recast layer is formed after grinding
• Possibilities of oil fires
• Wheels are fragile
DISADVANTAGES OF EDDG
23. APPLICATION OF EDDG
• It is used in grinding of thin sections
• Grinding of high hardness materials such as
cermates, super alloys and metal matrix
composites.
24. MICROMACHINING
• Micromachining is machining of miniature
components. It is also defined as removal of
material in the form of chips or debris having
the size in the range of micron with
dimensions greater than or equal to one micro
and smaller than or equal to 999 micron.
26. • Minimising energy and material use
• Faster devices
• Increased selectively and sensitivity
• It has improved accuracy and reliability
• It is basically concern with machining of micro
/ nano components or material or material
removal at micro / nano level.
FEATURES OF MICROMACHINING
28. • The working principle of advanced mechanical
type micro machining processes are fine
abrasive particles with high kinetic energy bits
the workpiece at an angle.
ADVANCED MECHANICAL MICRO
MACHINING PROCESSES
30. • Abrasive jet micromachining works in the
same principle of abrasive jet machining (AJM)
• A high speed stream of mixture of fluid (air or
gas) with abrasive particle is injected through
the nozzle on the workpiece to be machined.
ABRASIVE JET MICROMACHINING
31. • Particle size
• Size distribution
• Moisture content and
• Surface texture
Powder flowability and
compactability depends on
36. EFFECT OF PROCESS PARAMETER IN
AJMM
• Powder compaction
• Powder stratification
• Powder humidity
37. ADVANTAGES AND DISADVANTAGES
OF AJMM
ADVANTAGES
• Shallow holes can be accurately machined.
• Machining of grooves with the use of mask
pattern or target material can be done.
DISADVANTAGES OF AJMM
• Low erosion rate
• Minimum thickness of the substrate should be
0.3 mm or otherwise buckling of the plate occurs.
• Constant powder feeding is affected due to
compaction, stratification and humidity.
38. APPLICATIONS OF AJMM
• Micro accelerometer beam
• Matrix of micro E-cores
• Capillary electro phores is chips
• 3D suspended microstructures
• 3D passive glass micro mixer.
39. ABRASIVE WATERJET
MICROMACHINING
• Abrasive waterjet micromachining works in
the same principle of abrasive waterjet
machining.
• Abrasive waterjet cut by erosion. A million of
such particles impact on a workpiece per
second travelling with 2 times the speed of
sound for machining the work surface.
40. • Abrasive water jet generation
• Abrasive waterjet subsystem
• Abrasive waterjet machining centers.
COMPONENTS OF AWJMM
44. ABRASIVE WATER JET SUBSYSTEM
• Ultra high pressure water feed system
• The cutting head
• Abrasive feed system
45. Abrasive Water Jet Micro Machining
Centre
• Motion system - ball screw and linear motors.
• Machine structure
• Workpiece holding
• Human machine interface and control system
46. ADVANTAGES OF AWJMM
• Alloy steel and all grades of stainless steel can be machined.
• Machining of layered materials such as rubber or polymer
bonded to metal can be cut.
• It can cur thicker material than a laser.
DISADVANTAGES OF AWJMM
• Difficult to machine metals like armour plating, titanium and
copper base alloys.
• High residual stresses are produced in thin and toughened
glass during machining.
ADVANTAGES AND DISADVANTAGES
OF AWJMM
47. • Used in jewellery and craft markets
• Used in precision cleaning, peening to remove
and dismantle nuclear plants
• Used in cutting precision pocket milling,
turning and drilling.
APPLICATIONS OF AWJMM
48. • Ultrasonic micromachining process works in
the same principle of ultrasonic machining
process.
• Ultrasonic micromachining produces
ultrasonic vibration, when combined with a
abrasive slurry to create a accurate cavity of
any shape through the impact of fine grains.
Ultrasonic micromachining is a mechanical
process that it produces high quality surface.
ULTRASONIC MICROMACHINING
PROCESS
51. • High frequency oscillating current generator
• The acoustic head
• Tool spindle mechanism
• Controlled axes
• The micro tool
• Abrasive slurry
• Workpiece
ULTRASONIC MICROMACHINING HAS
7 BASIC COMPONENTS
52. • The range of output produced is 5 to 15 kW
and controlled range of 19-22 kHz. The main
function of this generator is to convert low
frequency 50 Hz electrical power to high
frequency 220 Hz.
• It has 2 parts (i) Transducer (ii) horn.
53. • High wear resistance
• Good elasticity and fatigue strength
• Optimum toughness and hardness
• Cemented carbide tools are used for its
hardness toughness and thermal conductivity
that is used to cut glass.
Microtool
54. • The slurry consists of small abrasives particles
mixed with water or oil and abrasive
concentration 30 to 60% by weight
• Alumina is best for cutting glass, germanium and
ceramics
• Diamond powder for cutting diamond rubies
• The size of the abrasives range between 300 to
2000 grit
• Coarse grades are used for roughing operation
Abrasive Tools
56. 1.Amplitude of vibration = 5 μm
2. Workpiece material = silicon
3. Tool material = Tungsten
4. Tool size = 50, 100,150 μm
5. Abrasive grain type = polycrystalline diamond
powder
6. size = 1 – 3 μm
7. Total tool feed = 515 μm
PROCESS VARIABLES OF USMM
57. • Effect of process parameters on material
removal rate
• Effect of process parameter on tool wear
• Effect of process parameter on surface finish
• Effect of process parameter on accuracy
EFFECT OF PROCESS PARAMETERS ON
QUALITY CHARACTERISTICS OF USMM
58. Material removal rate (MRR) depends upon
• Machining parameters
• Abrasive slurry
• Work material properties
• Tool material properties and tool geometry
The machining parameters that affect the material
removal rate are
• amplitude of vibration
• frequency of vibration
• static load
EFFECT OF PROCESS PARAMETERS ON
MATERIAL REMOVAL RATE
59. The factors that influences tool wear are
• Static load
• Work material
• Tool size
• Tool material
• Type of abrasives and its grain size
• Machining time
• Depth of machining
EFFECT OF PROCESS PARAMETERS ON
TOOL WEAR
60. Effect of Machining Parameter on
Surface Finish
• By using fine grains
• Driven by smaller vibrations and amplitude.
• Smaller static force at smaller depth of cut and
larger lateral feed.
• Larger grain size of 2 to 120 m is used for
roughing operation.
• Smaller grain size of 0.2 to 10 m is used for
finishing operations
61. The factors affecting accuracy in USMM are
• accuracy of feed motion
• accuracy of fixtures used
• quality of assembly element
• abrasive grit size
• tool wear
• transverse vibration effect
• depth of cut
Effect of Process Parameter on
Accuracy
62. • Machining of any materials regardless of their conductivity
• Machining of semiconductor as silicon germanium
• Suitable for machining precise brittle materials
• Can drill circular or non circular holes in hard materials
• Less stress is produced because of its non thermal
characteristics
DISADVANTAGES
• Low material removal rate
• Tool wear is faster in USMM
• Machining area and depth is restrained in USMM.
ADVANTAGES AND DISADVANTAGES
OF USMM
63. APPLICATIONS OF USMM
• Used for making press tool dies
• Drilling small holes in helicopter power transmission
shaft
• Drilling of diamond dies, machining of aluminium
oxides Al2O3
• Producing hollow cubes
• Used in surgical tools manufacturer for better
evaculation of chips
• Plague from the teeth are removed without any
damage
64. THERMAL ADVANCED
MICROMACHINING PROCESSESS
• In thermal advanced micromachining intense heat is
produced and localized which increases the workpiece
temperature in a zone or beam diameter equal to its
melting and vapourization temperature.
• The material removal is at micro-nano level in form of
debris.
Types of thermal advanced micromachining
(i) Electric discharge micromachining
(ii) Electron beam micromachining
(iii) Laser beam micromachining
65. Electric Discharge Micro Machining
• Electric discharge micromachining (EDMM)
works in the same principle of electric
discharge machining (EDM).
• EDM removes material by thermal erosive
action of electrical discharge (spark) produced
by a pulse DC power supply between anode
and cathode. The tool acts as the cathode and
the workpiece acts as the cathode and the
workpiece acts as the anode.
71. • Prebreakdown phase – The initial stage of the
ignition stage is prebreakdown phase.
• During this phase two phenomena occurs that
breakdown of dielectric between electrodes take
place.
(i) Bubble formation
(ii) Electronic impact mechanism
• The temperature of the embroyonic plasma
increases and the energy balance equation is
given by
IGNITION STAGE
72. • The power utilization is given by
• Work done during expansion of plasma channel
• Power flux utilized for vaporization and
dissociation of dielectric media.
• Power flux dissipating towards anode and
cathode.
• The power fraction utilized by the plasma
Pcircuit = V(t) X I(t)
HEATING STAGE
73. • In the removal stage, the heat generated during
plasma formation and expansion is transferred to
anode and cathode by two ways.
I)By radiation heat transfer
II) Ion or electron bombardment
• The power transfer due to particle bombardment
and radiation flux is given by
△Pcathode = △Pions + △Pelectron + △Pradiation
Removal Stage
74. • Mechanism of material removal by melting
and evaporisation.
• Material removal rate is between 0.6 to 6
mm3 /hr
• Dimensional accuracy is 2 m (sinking EDM)
and 1 m (wire EDM).
• Surface finish is 0.4 to 0.5 m
PROCESS PARAMETERS OF EDMM
75. • Dielectric - Water is used as dielectric which
provides good discharge repetition rate.
• Tool - Electrode wear can be reduced by using
diamond electrode.
• Workpiece
EFFECT OF PROCESS PARAMETERS ON
EDMM
76. ADVANTAGE
• It is used for cutting complex or odd shape
materials that are electrically conductive.
• It is used in machining hardened materials
• It has high machining rate
• It has good dimensional accuracy and surface
integrity.
DISADVANTAGE
• It is not suitable for high aspect ratio holes and
features.
ADVANTAGES AND DISADVANTAGES
OF EDMM
77. • Used in drilling 6.5 holes in 50 m plate
• Used in making 1.2 slots in 2.5 m wall.
• Used in shaping microfluids mixer and channel
• Used in machining microgears or internal
gears.
APPLICATIONS OF EDMM
79. • EBMM works on the same principle of EBM.
Electron beam micromachining uses a high
velocity stream, of electron focused on the
workpiece surface to remove material by
melting and vapourization.
ELECTRON BEAM MICROMACHINING
PROCESS
80. • The main components of EBMM are the electron
gun, the anode, cathode, magnetic lens and
deflection coils with a vacuum chamber.
• The anode applies a potential field that
accelerates the electron with voltage of approx
50000 to 200000volts to create velocity over
200000 km/s.
• The power is defined by the accelerating voltage
and the beam current which ranges from 100 μA
to 1 Amps.
CONSTRUCTION AND WORKING
81. • An electromagnetic lens reduce the area of
the beam to a diameter of 25 μm.
• This beam of fast moving electron gets
focused to 10 to 200 μm area at density of
6500 GW/mm2
• The pulse duration ranges from 50 μs to 10 ms
• This process is limited to thin parts in the
range of 0.2 to 6 mm thick.
CONSTRUCTION AND WORKING
83. • The pulse time and beam current level of the pulse
ensure high reproductability.
• Beam current varies from 100 μA to 1 A and governs
the energy / pulse being supplied to workpiece.
• Pulse duration for EBMM ranges from 50 μs to 10 ms.
• The working distance and the focused beam diameter
are determined by magnitude of current.
• The permissible minimum distance between 2 drilled
holes is in order of 2 to 3 times the hole diameter.
PROCESS PARAMETERS OF EBMM
84. • Pulse beam time and operation
• Cutting speed
• Source disposal effect and power retention
factor
• Conduction losses and temperature rises
• Heat affected zone
• Cross sectional area of beam
EFFECT OF PROCESS PARAMETER ON
EBMM
85. ADVANTAGES
• It is easy to modulate the electron beam
parameters
• High precision stresses on the workpieces are
relaxed due to rise in temperature of the material
DISADVANTAGES OF EBMM
• The process is conducted in vacuum
• Requirement of high energy
• The equipment is expensive
ADVANTAGES AND DISADVANTAGES
OF EBMM
86. • Used for drilling and cutting of metals, non metals,
ceramics and composite
• Used to drill thousands of hole on the material both
electrically conductive and non conductive material
• Used in making fine gas orifices in space nuclear reactors.
• Used in drilling holes in wire drawing dies
• Used in metering holes in injector nozzle of diesel engine.
• Employed for pattern generations for integrated circuit
fabrication
• Used in drilling small diameter holes 250 μm
• Used in drill holes with very high depth to diameter ratio.
APPLICATIONS OF EBMM
87. • Laser consists of an amplifying medium where
stimulated emission and amplification of light is
created.
• Mirrors are used as optical resonators and oscillation
occurs because of amplifying medium. An optical
resonator provides a feedback and a pump source to
input energy in the amplifying medium. Laser is placed
between suitable aligned mirrors.
• The types of lasers used for machining are CO2 laser,
excimer laser yattrium, Aluminium, sapphire laser.
LASEB BEAM MICRO MACHINING
PROCESS
88. 1. Direct writing
2. Mask projection
3. Interference technique
• specific power consumption - 1000 W/mm3/min
• MRR - 5 mm3/min
MECHANISM OF MATERIAL REMOVAL
IN LBMM
92. • Mechanism of material removal by melting and
vapourization
• Medium – normal atmosphere
• Tool – High power laser beam
• Maximum MRR – 5 mm3 /min
• Specific power consumption = 100 W/mm3 min
• Material – All material except material of high reflectivity
(Aluminum and copper)
• Shape applications – drilling five holes
• Limitation – very high power consumption cannot machine
materials with high heat conductivity and reflectivity
PROCESS PARAMETERS OF LBMM
93. ADVANTAGES OF LBMM
• This process is forceless and contactless
• Minor heat affected zone
• machining is free from burr and bulging
• No additional tooling cost by wear
• Material removal rate is controllable.
DISADVANTAGES OF LBMM
• Very high power consumption
• It cannot machine materials of high
• High conductivity and reflectivity
• Not suitable for Aluminium and copper
• The equipment required for micromachining is very costly
• Need highly skilled operators to machine
ADVANTAGES AND DISADVANTAGES
OF LBMM
94. • It is used in machining threads in a single poly fibre.
• Machining of microholes and microchannels on
integrated chips.
• Micro cutting in tungsten pin using 511 nanometer
using ND laser
• Micro fluidic devices in silicon showing laser drilled
holes and connecting channels
• Micro machined letters on a single human hair
• Cutting of 1mm tube cutting, 100 μm wide V grooves
APPLICATIONS OF LBMM
95. • Electro chemical micromachining works in the
same principle of Electro chemical machining.
• Faraday’s law of electrolysis states that the
amount of substance deposited or dissolved in
proportional to the quantity of electricity that
is passed through the electrolyte.
ELECTRO CHEMICAL
MICROMACHINING PROCESS
97. Electrolyte of ECMM
• Electrolyte are basically two types.
• Passive electrolyte containing oxidizing anions
(sodium nitrate, sodium chloride)
• Non passive electrolyte containing aggressive
anions (sodium chloride)
98. IEG – Inter Electrode Gap
• In ECMM process, the IEG is kept in range of 6 -15μm.
• Methods of monitoring and measuring the IEG is during
pulse of time of 0.1 to 5ms.
• Machining accuracy is directly proportional to the inter
electrode gap size.
Micro Tool Design and Fabrication
• The computer based tool design for ECMM is feasible,
economical and time saving one.
• Micro tools are fabricated using electro chemical etching
and wire electro discharge grinding as shown in figure
Inter Electrode Gap
100. Through Mask ECMM – 3scales are considered
• Workpiece scale – geometry of the workpiece
can be controlled by the current distributions
• Pattern scale – Current distribution depends
upon the spacing of the features and their
geometry
• Feature scale – shape is evaluated through the
current distribution.
Current Distribution and Shape
Evolution
101. • Nature of power supply
• Inter electrode gap
• Concentration, temperature and electrolyte
flow.
• Microtool feed rate
EFFECT OF PROCESS PARAMETERS ON
ECMM
102. ADVANTAGES
• Precision manufacturing of miniature
components
• Production of high accuracy holes.
DISADVANTAGES
• Material removal rate is very low
• The equipment used is of high cost
ADVANTAGES AND DISADVANTAGES
OF ECMM
103. • 3D micromachining of microstructure in copper
sheet used in electronic circuit board
• Smooth surface and sharp borders are machined
in titanium surfaces by using mask ECMM
• Manufacture of nozzle plate for inkjet printer
heads.
• Use in aerospace, automobile and other heavy
industries for shaping, sizing, deburring and
finishing operation.
APPLICATIONS OF ECMM