Unit 1 introduction
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This document provides an overview of unconventional machining processes (UCM). It discusses the need for UCM due to limitations of conventional machining. UCM is classified based on the energy used and mechanism. Examples of processes include mechanical (AWJM, USM), electrical (EDM, WEDM), chemical/electrochemical (ECM, ECG), and thermal (LBM, PAM, EBM). Selection of a UCM process depends on the workpiece parameters, shape, capability, and economic considerations. The document provides details on the working principles, equipment, parameters, finishes, and applications of different UCM processes.
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This document provides an overview of unconventional machining processes. It begins by outlining the presentation topics which include abrasive jet machining (AJM), laser beam machining (LBM), electro discharge machining (EDM), ultrasonic machining (USM), and electron beam machining (EBM). It then discusses the classification of machining processes and needs for non-traditional machining when machining very hard materials, complex shapes, or small intricate features. The document provides details on the working principles, applications, advantages and disadvantages of AJM, LBM, and EDM.
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This document discusses unconventional machining processes. It is divided into 5 units that cover different types of unconventional processes based on the energy source used, such as mechanical, thermal, electrical, chemical, and electrochemical energy. The document provides classifications of unconventional processes and discusses various processes like electrical discharge machining, laser beam machining, abrasive jet machining, ultrasonic machining, and others. It also covers characteristics, advantages, disadvantages, applications, and factors to consider when selecting an appropriate unconventional machining process.
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Unconventional Machining Processes introduces several machining techniques including ECM, EDM, EBM, LBM, PAM, USM, and AJM. It provides details on the physical parameters, shapes that can be machined, process capabilities, and process economies for each. ECM is best for deep holes, contour machining, and honing. EDM and USM are well suited for shallow holes. USM and EDM can machine precision through cavities. AJM and EDM are used for grinding. PAM is well suited for clean, rapid cuts and profiles. EBM can produce small holes and LBM is best for micro holes. The document compares the techniques and provides technical specifications
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This document provides an overview of machining and non-traditional machining processes. It discusses various traditional machining techniques like turning, milling, and grinding. It then introduces non-traditional machining processes like electrical discharge machining (EDM), laser beam machining, ultrasonic machining, and abrasive jet machining. These alternative processes allow machining of advanced materials, complex shapes, and micro-scale components. The document categorizes non-traditional machining into mechanical, electrical, chemical, electrochemical, and thermal processes and provides examples and applications of each.
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The document introduces unconventional machining processes (UCM). It begins by classifying UCM into machining and forming processes based on whether they remove or form metal. UCM is needed for hard/fragile materials, complex shapes, and higher accuracy than conventional machining. The document then classifies UCM based on the energy used - mechanical, electrical, chemical, electrochemical, and thermal.
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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.
Unit 2 mechanical energy based process
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.
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This document provides an overview of machining and non-traditional machining processes. It discusses various traditional machining techniques like turning, milling, and grinding. It then introduces non-traditional machining processes like electrical discharge machining (EDM), laser beam machining, ultrasonic machining, and abrasive jet machining. These alternative processes allow machining of advanced materials, complex shapes, and micro-scale components. The document categorizes non-traditional machining into mechanical, electrical, chemical, electrochemical, and thermal processes and provides examples and applications of each.
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The document introduces unconventional machining processes (UCM). It begins by classifying UCM into machining and forming processes based on whether they remove or form metal. UCM is needed for hard/fragile materials, complex shapes, and higher accuracy than conventional machining. The document then classifies UCM based on the energy used - mechanical, electrical, chemical, electrochemical, and thermal.
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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.
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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.
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This document discusses unconventional machining processes. It begins with a brief history of machining from ancient hand tools to modern CNC machines. It then covers the limitations of conventional machining when dealing with advanced materials. The rest of the document defines and categorizes various unconventional machining processes including mechanical, electrical, chemical, electrochemical, and thermal-based methods. Specific processes like EDM, laser beam machining, and abrasive water jet machining are described along with considerations for selecting the appropriate unconventional process.
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This document discusses unconventional machining processes as an alternative to conventional machining. Unconventional machining is needed to machine harder materials and allows for closer tolerances and less residual stress than conventional methods. Unconventional machining processes are classified based on the type of energy used, such as thermal, electrical, electrochemical, chemical, or mechanical energy, and the mechanism of material removal, such as erosion, ionic dissolution, or vaporization. Selection of the appropriate unconventional machining process depends on factors like the physical properties of the material, the desired shape, the process capabilities, and economic considerations.
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This document provides an overview of unconventional machining processes. It begins by defining conventional machining and its limitations in machining complex geometries and hard materials. Unconventional machining uses indirect energy sources like sparks, heat, or chemicals instead of direct tool contact. The document then discusses various unconventional processes like EDM, laser beam machining, water jet machining, and their characteristics. It classifies unconventional processes and provides details on electrochemical machining, electrochemical grinding, and ultrasonic machining. In closing, it acknowledges the development of these nontraditional techniques for precision manufacturing applications.
2 marks
Ultrasonic machining (USM) and abrasive jet machining (AJM) are unconventional machining processes. USM uses ultrasonic vibrations to cause abrasive particles in a liquid slurry to impact and remove material from a workpiece. It can machine very hard materials with high accuracy and no heat generation. AJM uses a high-velocity stream of abrasive particles in gas to erode material. It is useful for cutting brittle materials and can access difficult areas. Laser beam machining uses an intense laser beam to melt and vaporize material with precision and no physical contact.
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1. Unconventional machining processes have been developed to machine difficult materials into complex shapes accurately and easily. They include mechanical processes like abrasive jet machining, water jet machining, and ultrasonic machining as well as thermoelectric processes like laser beam machining and electrochemical processes.
2. Abrasive jet machining works by removing material through high velocity abrasive particles. Water jet machining uses a high pressure water jet. Ultrasonic machining uses abrasive particles carried in a liquid under ultrasonic vibration to machine materials.
3. Electric discharge machining machines conductive materials using electric sparks between an electrode tool and workpiece separated by dielectric fluid. It is used for complex shapes
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The document discusses unconventional machining processes. It provides details about E. Deepak, a 3rd year student, and their class and roll number. It then lists and describes various unconventional machining methods categorized into mechanical, thermal, and chemical methods. Specifically, it focuses on water jet machining as a mechanical method, explaining that it involves using a high velocity water jet to cut soft, non-metallic materials by converting the jet's kinetic energy into pressure energy to remove particles from the workpiece.
Unconventional machining process unit-1
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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.Ucm comparison
This document compares various unconventional machining processes including EDM, ECM, EBM, LBM, PAM, USM, AJM, and WJM. It provides details on the metal removal technique, suitable work materials, tool materials, metal removal rate, surface finish, power requirements, capital costs, efficiency, applications, and limitations for each process. The processes can machine a variety of conductive and non-conductive materials and are used for complex shapes that would be difficult with traditional machining. However, some have limitations such as lower metal removal rates, accuracy, or an inability to machine large or non-conductive workpieces.
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This document provides an overview of advanced machining processes including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, water jet machining, and abrasive jet machining. It describes the basic mechanisms and capabilities of each process. Examples are given of complex parts that can be manufactured using these processes like biomedical implants, turbine blades, and microscopic gears. Nanofabrication techniques are also discussed for producing extremely small features at the micro and nanoscale.
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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.
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Advanced machining processes
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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
Unconventional machining process
Unconventional machining uses indirect energy sources like abrasives, laser beams, or electrical discharges to machine materials instead of direct contact between a tool and workpiece. It can machine hard materials and complex shapes without tool wear issues. Some common unconventional machining methods are abrasive jet machining, ultrasonic machining, electrochemical machining, electrical discharge machining, and laser beam machining. Each method uses a different indirect energy source to remove material from the workpiece.
Non traditional
Nontraditional machining processes like waterjet machining (WJM) and abrasive waterjet machining (AWJM) use mechanical energy from water and abrasives for material removal. WJM is used for softer materials while AWJM can machine harder materials. AWJM has advantages over traditional machining like fast setup, low heat generation, and ability to machine complex shapes. Parameters like orifice size, water pressure, abrasive type and flow rate, and traverse speed need to be optimized for effective AWJM.
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EDM is an electrical discharge machining process that uses electrical sparks to erode materials to shape and cut electrically conductive materials, even very hard metals. It has various applications in industries like molds, dies, aerospace where complex shapes are required. While EDM allows machining hard metals and complex shapes, it has slow material removal rates and high power consumption compared to traditional machining.
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- Traditional machining processes have limitations like generating unwanted chips and heat that cause issues. Non-traditional machining (NTM) methods were developed to address these limitations.
- NTM methods use different energy sources like mechanical, electrical, chemical, or thermal energy for material removal rather than traditional cutting. They can machine complex geometries, delicate parts, and hard/brittle materials.
- NTM processes are classified based on the energy source and material removal mechanism used. Some common types are abrasive jet machining (AJM), electrochemical machining (ECM), and electric discharge machining (EDM).
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This document discusses advanced machining processes, which utilize chemical, electrical, or high-energy beams to machine materials that cannot be processed through traditional machining methods. It describes 10 common types of advanced machining, including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, plasma arc cutting, ultrasonic machining, water jet machining, abrasive jet machining, and nanofabrication methods. The document explains the need for these advanced processes and provides examples of typical parts machined through these methods.
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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.
Unit 1
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.
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This document discusses unconventional machining processes as an alternative to conventional machining. Unconventional machining is needed to machine harder materials and allows for closer tolerances and less residual stress than conventional methods. Unconventional machining processes are classified based on the type of energy used, such as thermal, electrical, electrochemical, chemical, or mechanical energy, and the mechanism of material removal, such as erosion, ionic dissolution, or vaporization. Selection of the appropriate unconventional machining process depends on factors like the physical properties of the material, the desired shape, the process capabilities, and economic considerations.
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This document provides an overview of unconventional machining processes. It begins by defining conventional machining and its limitations in machining complex geometries and hard materials. Unconventional machining uses indirect energy sources like sparks, heat, or chemicals instead of direct tool contact. The document then discusses various unconventional processes like EDM, laser beam machining, water jet machining, and their characteristics. It classifies unconventional processes and provides details on electrochemical machining, electrochemical grinding, and ultrasonic machining. In closing, it acknowledges the development of these nontraditional techniques for precision manufacturing applications.
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Ultrasonic machining (USM) and abrasive jet machining (AJM) are unconventional machining processes. USM uses ultrasonic vibrations to cause abrasive particles in a liquid slurry to impact and remove material from a workpiece. It can machine very hard materials with high accuracy and no heat generation. AJM uses a high-velocity stream of abrasive particles in gas to erode material. It is useful for cutting brittle materials and can access difficult areas. Laser beam machining uses an intense laser beam to melt and vaporize material with precision and no physical contact.
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1. Unconventional machining processes have been developed to machine difficult materials into complex shapes accurately and easily. They include mechanical processes like abrasive jet machining, water jet machining, and ultrasonic machining as well as thermoelectric processes like laser beam machining and electrochemical processes.
2. Abrasive jet machining works by removing material through high velocity abrasive particles. Water jet machining uses a high pressure water jet. Ultrasonic machining uses abrasive particles carried in a liquid under ultrasonic vibration to machine materials.
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This document outlines a course on unconventional machining processes. It covers five units: (1) Introduction, (2) Mechanical energy-based processes, (3) Electrical energy-based processes, (4) Chemical and electro-chemical energy-based processes, and (5) Thermal energy-based processes. Unit 1 introduces unconventional machining and provides an overview of different processes. Units 2 through 5 go into more depth on specific unconventional machining methods, including abrasive jet machining, electrical discharge machining, electrochemical machining, and laser beam machining. The course objectives are for students to learn about various unconventional machining processes, process parameters, and their applications.
Deepak 16ss1a2916
The document discusses unconventional machining processes. It provides details about E. Deepak, a 3rd year student, and their class and roll number. It then lists and describes various unconventional machining methods categorized into mechanical, thermal, and chemical methods. Specifically, it focuses on water jet machining as a mechanical method, explaining that it involves using a high velocity water jet to cut soft, non-metallic materials by converting the jet's kinetic energy into pressure energy to remove particles from the workpiece.
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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.Ucm comparison
This document compares various unconventional machining processes including EDM, ECM, EBM, LBM, PAM, USM, AJM, and WJM. It provides details on the metal removal technique, suitable work materials, tool materials, metal removal rate, surface finish, power requirements, capital costs, efficiency, applications, and limitations for each process. The processes can machine a variety of conductive and non-conductive materials and are used for complex shapes that would be difficult with traditional machining. However, some have limitations such as lower metal removal rates, accuracy, or an inability to machine large or non-conductive workpieces.
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This document discusses various nontraditional machining and thermal cutting processes. It begins by defining these processes as those that remove material using mechanical, thermal, electrical, or chemical energy without a conventional cutting tool. These alternative processes are important for machining new metals and non-metals, producing complex geometries, and avoiding surface damage from traditional methods. The document then groups and describes various nontraditional processes including mechanical (ultrasonic machining, water jet cutting), electrochemical (electrochemical machining), thermal (electric discharge machining, laser beam machining), and chemical (chemical milling) processes.
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This document provides an overview of advanced machining processes including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, water jet machining, and abrasive jet machining. It describes the basic mechanisms and capabilities of each process. Examples are given of complex parts that can be manufactured using these processes like biomedical implants, turbine blades, and microscopic gears. Nanofabrication techniques are also discussed for producing extremely small features at the micro and nanoscale.
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
NON-CONVENTIONAL MACHINING PROCESSES
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
Unconventional machining process
Unconventional machining uses indirect energy sources like abrasives, laser beams, or electrical discharges to machine materials instead of direct contact between a tool and workpiece. It can machine hard materials and complex shapes without tool wear issues. Some common unconventional machining methods are abrasive jet machining, ultrasonic machining, electrochemical machining, electrical discharge machining, and laser beam machining. Each method uses a different indirect energy source to remove material from the workpiece.
Non traditional
Nontraditional machining processes like waterjet machining (WJM) and abrasive waterjet machining (AWJM) use mechanical energy from water and abrasives for material removal. WJM is used for softer materials while AWJM can machine harder materials. AWJM has advantages over traditional machining like fast setup, low heat generation, and ability to machine complex shapes. Parameters like orifice size, water pressure, abrasive type and flow rate, and traverse speed need to be optimized for effective AWJM.
ELECTRIC DISCHARGE MACHINING
EDM is an electrical discharge machining process that uses electrical sparks to erode materials to shape and cut electrically conductive materials, even very hard metals. It has various applications in industries like molds, dies, aerospace where complex shapes are required. While EDM allows machining hard metals and complex shapes, it has slow material removal rates and high power consumption compared to traditional machining.
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This document discusses several thermal and electrical energy-based machining processes including electric discharge machining (EDM), wire cut EDM, laser beam machining, plasma arc machining, and electron beam machining. It covers topics such as working principles, equipment, process parameters, surface finish, metal removal rate, electrode wear, and applications of these processes.
UNCONVENTIONAL MACHINE PROCESS INTRODUCTION
- Traditional machining processes have limitations like generating unwanted chips and heat that cause issues. Non-traditional machining (NTM) methods were developed to address these limitations.
- NTM methods use different energy sources like mechanical, electrical, chemical, or thermal energy for material removal rather than traditional cutting. They can machine complex geometries, delicate parts, and hard/brittle materials.
- NTM processes are classified based on the energy source and material removal mechanism used. Some common types are abrasive jet machining (AJM), electrochemical machining (ECM), and electric discharge machining (EDM).
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This document discusses advanced machining processes, which utilize chemical, electrical, or high-energy beams to machine materials that cannot be processed through traditional machining methods. It describes 10 common types of advanced machining, including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, plasma arc cutting, ultrasonic machining, water jet machining, abrasive jet machining, and nanofabrication methods. The document explains the need for these advanced processes and provides examples of typical parts machined through these methods.
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This document provides an overview of unconventional machining processes. It is divided into 5 units that cover various process types. Unit I introduces unconventional machining and discusses why these processes are needed. The main process classifications are mechanical, electrical, chemical/electrochemical, and thermal. Unit II covers mechanical processes like abrasive jet machining, water jet machining, and ultrasonic machining. Key parameters and modeling approaches are described. Similarly, subsequent units provide details on electrical, chemical, and thermal based unconventional processes. Process principles, equipment, parameters, and applications are discussed for each.
3units.pdf
This document provides an introduction to unconventional machining processes. It discusses mechanical energy based processes like abrasive jet machining, water jet machining, and ultrasonic machining. It also covers electrical energy based processes like electrical discharge machining. The key points are: mechanical processes use abrasives or water to erode material, while EDM uses electric sparks; various process parameters and characteristics are described for each method; advantages include ability to machine hard materials with less force and residual stress, while limitations include lower material removal rates.
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.
CHAPTER 1.pdf
The document discusses conventional and unconventional machining processes. Conventional machining involves direct contact between the tool and workpiece and removal of metal through chip formation, which produces chips as waste. Unconventional processes do not require direct contact and instead use various forms of energy like thermal, electrical or electrochemical to remove metal. Common unconventional processes described include EDM, ECM, laser beam machining and water jet machining. The document also covers CNC machines and how part programs control automated machining through coded G and M commands.
UNIT- 1 --- UCM.pptx
The document discusses various unconventional machining processes. It begins by introducing mechanical energy based processes like abrasive jet machining, water jet machining, and ultrasonic machining. It then describes the working of each process in 1-2 sentences. For example, it notes that abrasive jet machining involves removing material by directing a high-velocity stream of abrasive particles using compressed gas, and that ultrasonic machining uses high-frequency vibrations and an abrasive slurry to erode material. The document also provides brief summaries of key parameters that affect the material removal rate in each process.
UNIT I.pptx
The document discusses various unconventional machining processes including abrasive jet machining (AJM), water jet machining (WJM), abrasive water jet machining (AWJM), and ultrasonic machining (USM). It provides an overview of the working principles, equipment used, process parameters, material removal rate, and applications of each process. Specifically, it explains that AJM uses a high-speed stream of abrasive particles to remove material, WJM uses a high-velocity water jet, AWJM adds abrasive particles to the water jet, and USM removes material using abrasive particles oscillated at ultrasonic frequencies. The document also discusses factors for selecting among these unconventional machining processes.
UCMP_PPT.pdf
This document provides information on various unconventional machining processes. It begins by classifying these processes into categories based on the type of energy used, including mechanical, electrical, thermal, and chemical. Specific processes discussed include ultrasonic machining, water jet cutting, abrasive jet machining, electrochemical machining, electric discharge machining, and chemical machining. Key aspects like principles of operation, equipment, process variables, applications, and limitations are summarized for each process.
Unit 2
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.
Unit 2
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.
THERMAL AND ELECTRICAL BASED PROCESSES
The document discusses various thermal energy based machining processes including EDM, EBM, LBM, and PAM. It provides details on the principles, specifications, and process parameters for EDM such as the use of a wire electrode, dielectric fluids, and circuit types. It also describes the principles of EBM using an electron beam, LBM using lasers, and PAM using ionized plasma gas. Key advantages and applications are highlighted for each process.
UNIT 2.pptx
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.
UCM - Unit 2 -thermal and electrical energy based processes
This document discusses various thermal and electrical energy based machining processes. It provides details on electrical discharge machining (EDM) including its principle of using a wire electrode to generate sparks and melt workpiece material. It describes EDM process parameters, circuits, flushing methods, and applications. The document also covers laser beam machining and plasma arc machining, explaining their working principles and key factors like accuracy and gases used. Application areas for different thermal processes are highlighted.
UNIT-2 -THERMAL AND ELECTRICAL ENERGY BASED PROCESSES.pptx
This document discusses various thermal and electrical energy based machining processes. It provides details on electrical discharge machining (EDM) including its principle of using a wire electrode to generate sparks and melt workpiece material. EDM process parameters like voltage, gap, and current density are specified. Different flushing methods and functions of dielectric fluids are explained. Various EDM power generating circuits and their characteristics are also outlined. The document then discusses wire EDM and its applications. Finally, it covers thermal energy based processes like electron beam machining, laser beam machining, and plasma arc machining, providing details on their working principles, process parameters, advantages, and applications.
Similar to Unit 1 introduction (20)
Modern/Unconventional Machining Methods/ Non-traditional methods
Modern/Unconventional Machining Methods/ Non-traditional methods
Unit 4 chemical and electrochemical energy based processes
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UCM - Unit 2 -thermal and electrical energy based processes
UCM - Unit 2 -thermal and electrical energy based processes
UNIT-2 -THERMAL AND ELECTRICAL ENERGY BASED PROCESSES.pptx
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Unit 1 introduction
- 2. Syllabus • Unconventional machining Process • Need • Classification • Brief overview
- 3. WHAT IS UCM?
- 4. Conventional Machining Process • Metal Removal ? • Nature of Contact ? • Scrap ?
- 5. Demerits • Disposal of Waste • By products of chips • Work holding Devices for larger cutting force • Heat Generation • Not possible without chips
- 6. Unconventional Manufacturing process • Unconventional Manufacturing process 1. Unconventional Machining process or Non Traditional Machining Process 2. Unconventional Forming process
- 7. Unconventional Manufacturing process Machining process • Metal Removal • No Direct Contact b/w tool and work piece Forming process • Metals are formed • Releases large amount of Energy in very short time interval
- 8. NEED FOR UCM
- 9. Need • Machining - produces finished products with high degree of accuracy • Conventional machining • Utilizes cutting tools (harder than workpiece material). • Needs a contact between the tool and workpiece. • Needs a relative motion between the tool and workpiece.
- 10. Need • The need for higher productivity, accuracy and surface quality • Improve the capability of automation system and decreasing their sophistication (decreasing the investment cost) requirements • Very hard fragile materials difficult to clamp for traditional machining • When the work piece is too flexible or slender • When the shape of the part is too complex • Internal and external profiles, or small diameter holes.
- 11. CLASSIFICATION
- 12. Unconventional Machining Processes - Based on Energy 12
- 13. Unconventional Machining Processes - Based Mechanism 13
- 14. Unconventional Machining Processes - Based on Energy used for Removal 14
- 15. Unconventional Machining Processes - Based on Transfer of Energy 15
- 16. Mechanical Based Processes 1. Working principles 2. Equipment used AJM WJM AWJM USM 3. Process parameters 4. MRR 5. Variation in techniques used 6. Applications 16
- 17. Electrical Based Processes Electrical EDM WEDM 1. Working principle 2. Equipment used 3. Process parameters 4. Surface finish & MRR 5. Electrode/Tool 6. Power & Control circuits 7. Tool wear 8. Dielectric 9. Flushing 10. Applications 17
- 18. Chemical & Electrochemical Based Processes 1. Working principles 2. Etchants & Maskants 3. Techniques of applying maskants CHM 4. Process parameters ECM 5. Surface finish & MRR ECG 6. Electrical circuits in case of ECM ECH 7. Applications 18
- 19. Thermal Based Processes 1. Working principles 2. Equipment used 3. Types LBM 4. Beam control techniques PAM 5. Applications EBM 19
- 21. Selection Process • Selection Process is based of following parameters - Physical Parameter - Shapes to be Machined - Process Capability - Economic consideration
- 22. Physical Parameter Parameter ECM EDM Potential, V 5- 30 50-500 Current, A 40,000 15-500 Power, kW 100 2.70 Gap, mm 0.5 0.05 Medium Electrolyte Die electric fluid Work Tungsten EBM LBM 200 x 103 4.5 x 103 0.001 2 0.15 20 100 150 Vacuum Air PAM USM AJM 250 220 220 600 12 1.0 220 2.4 0.22 7.5 0.25 0.75 Abrasive Argon Nitrogen grains Tungsten M/C diff All Mtl All Mtl All Mtl HSS Material carbide carbide
- 23. Shapes to be Machined Process Holes ( Micro, Small, deep,Shallow) Precision Work Horning Etching Grinding Deburring Threading Profile Cut Machines LBM, EBM,ECM, USM & EDM USM & EDM ECM ECM & EDM AJM & EDM USM & AJM EDM PAM
- 24. Process Capability or Machining Characteristics Process LBM EBM EDM ECM PAM USM AJM MRR ( mm3/s ) 0.10 0.15 - 40 15 - 80 27 2500 14 0.014 Surface Finish (μm) 0.4 - 6.0 0.4 - 6.0 0.25 0.2 -0.8 Rough 0.2 - 0.7 0.5- 1.2 Accuracy (μm) 25 25 10 50 250 7.5 50 Power (kW/ cm3/ min 2700 450 1.8 7.5 0.90 9.0 312.5
- 25. Process Economy Process EDM CHM ECM AJM USM EBM LBM PAM Convention al Capital Cost Medium Medium V. High V. Low High High Medium V. Low V. Low Tool & Fixtures High Low Medium Low High Low Low Low Low Power Requirement Low High Medium Low Low Low V. Low V. Low Low Efficiency High Medium V. Low Low Medium V. High V. High V. Low V. Low
- 26. Limitation • More Expensive • Slow Process • Commercial