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Unit 2 --- ucm
- 1. UNIT- 2 MECHANICAL ENERGY BASED PROCESSES
- 2. Abrasive Jet Machining (AJM)
- 4. Arrangement of Abrasive Jet Machining (AJM) .
- 5. Construction details . Gas Used Nitrogen , Carbon di-oxide , compressed air Abrasive Particles Used Aluminium oxide , Silicon Carbide, Glass Powder , Dolomite and Specially Prepared sodium bicarbonate Nozzle Tungsten Carbide , Synthetic Sapphire (Ceramic)
- 6. . .
- 7. Construction details • Aluminium oxide (Al2O3 ) - 10 to 50 microns • Silicon Carbide (SiC) - 25 and 50 Microns • Glass Powder - 0.3 to 0.6 mm Abrasive Particle Sizes
- 9. . • . The Shape and Size of Cut is controlled by a movement adjusting mechanism given to work piece or Tool Cam Mechanism Pantograph Mechanism
- 10. . . Air Pressure 2 Kg/cm2 to 8 Kg/cm2
- 11. MRR - PARAMETERS
- 12. MASS FLOW RATE
- 14. Gas Pressure
- 15. Velocity of Abrasive particles
- 16. Mixing Ratio
- 18. .
- 19. Advantages 1. We can cut all kind of materials 2. No heat produced in process , so no thermal damage 3. Very thin and brittle material can be machined 4. Low initial investment 5. Good Surface Finish 6. Intricate holes can be cut in hard and brittle material
- 20. Dis-Advantages 1. Low MRR 2. Soft Material cannot be machined 3. Machining accuracy is poor 4. Nozzle Wear Rate is High 5. Abrasive Powder cannot be reused 6. Embedding of Abrasive particle in work piece is the high damage thing in this process 7. It requires Dust Collection System
- 21. Application
- 24. Introduction
- 25. Principle
- 27. . . Pump or Intensifier Used to Increase the water Pressure Up to 1500 – 4000 N / mm2
- 28. . . Accumulator Used to Store the water Used to avoid water Pulsation
- 29. . . Nozzle Used to Increase the velocity of water jet Made up of Sintered Diamond, Tungsten Carbide and Synthetic Sapphire Nozzle Exit Diameter 0.05 – 0.35mm Velocity of Water Jet From Nozzle 920 m/s
- 30. . . Regulating Chamber Used to Control the flow of water jet to Nozzle
- 31. WJM
- 33. MRR
- 34. MRR
- 35. MRR
- 36. .
- 37. .
- 38. ADVANTAGES
- 39. DIS-ADVANTAGES
- 40. APPLICATION
- 41. . .
- 42. .
- 49. SUITABLE
- 50. PRINCIPLE
- 52. . Ultrasonic Generator Used to convert the current from low frequency to high frequency
- 53. Abrasive Slurry
- 54. . Transducer Used to convert Electrical energy into Mechanical Vibrations
- 55. . Tool Holder Made up of Titanium alloy , Monel , Aluminium, Stainless steel
- 56. . Tool Material Low Carbon Material and Stainless steel The tool is brazed, soldered or Fastened mechanically to the transducer through a tool holder
- 57. Working of USM
- 58. Transducer convert the high frequency electrical energy into Mechanical Vibrations Oscillator convert the Low frequency electrical energy into high frequency electrical energy 20 – 30 HZ Vibrations are transferred to tool material Abrasive Slurry Passed Between the vibrating tool and work piece The refrigeration system used to cool the abrasive slurry to 5 – 6 Degree celcius
- 59. COMPARISON
- 60. TRANSDUCER
- 62. MAGNETOSTRICTIVE TRANSDUCER . Change in length is independent of the direction of the magnetic field But depend only on the magnitude of the field and Nature of the material
- 64. MAGNETOSTRICTIVE TRANSDUCER LT battery used to heat the filament So electrons are produced Those electrons are accelerated by HT Battery So AC current Produced in the circuit
- 65. So Rod start to vibrate due to magnetostric tive effect This vibrations rod create Ultrasonic Waves , which sent out MAGNETOSTRICTIVE TRANSDUCER
- 66. MAGNETOSTRICTIVE TRANSDUCER The Longitudinal Extension and contraction of the Rod AB produce an EMF in the coil L2
- 67. Resonance Frequency of the oscillatory circuit Frequency of Vibrating Rod = Resonance will occur when At resonance , the rod vibrates vigorously and ultrasonic waves are produced at high frequencies
- 70. PIEZOELECTRIC TRANSDUCER Its more efficient than magnetostrictive transducer The modern USM are of this type.
- 72. Circuit
- 73. Arrangement of the circuit
- 74. Working LT battery used to heat the filament So electrons are produced Those electrons are accelerated by HT Battery So AC current Produced in the circuit This AC current Passes through L1 and L2 and its transferred to Secondary circuit This AC current passed to the plates A and B and it make the Crystal to vibrate due to the principle of inverse piezoelectric effect. The vibrations of crystal creates Ultrasonic waves
- 75. Resonance
- 76. Advantages – Piezoelectric transducer Disadvantages – Piezoelectric transducer 1. Piezoelectric quartz is high cost 2. Cutting and shaping of crystal is very complex.
- 78. STRAIGHT AND TAPER ROD AS HORN
- 79. HORN
- 81. FEED MECHANISM
- 82. . 1. Its high sensitive 2. Compact in size
- 83. . 1. Feed rate is high
- 84. MRR MRR Per unit time
- 85. Wear Ratio
- 86. Factors considered for MRR in USM
- 87. Grain size of Abrasives
- 88. Abrasive material It Depend on 1.The type of material to be machined 2. Requirement of Surface finish For Machining - Tungsten Carbide - Die Steel Boron Carbide Silicon Carbide Abrasives For Machining - Glass - Ceramics Aluminium oxide
- 89. Concentration of Slurry Abrasive Slurry = Abrasive Particles + Water
- 90. Amplitude of Vibration MRR increase with the increase of Amplitude of Vibration
- 91. Frequency MRR increases with the increase of Ultrasonic wave Frequency
- 93. Tool Material Lengthy tool causes overstresses So tool should be short and rigid Process Parameters
- 94. Process Parameters Wear Ratio 1.5 : 1 For Tungsten Carbide Work Pieces 100 : 1 For Glass Work Pieces 50 : 1 For Quartz Work Pieces 75 : 1 For Ceramics 1 : 1 For Hardened tool steel Work Pieces
- 95. Abrasive Material and Cutting Power Process Parameters
- 98. Applications
- 101. .
- 102. Specifications Voltage = 250 V GAP = 0.005 – 0.05 mm Temperature = 10000 degree celcius Spark occur = 10 – 30 micro seconds Current density = 15 – 500 A