This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). It provides details on the working principles, key components, process parameters, advantages and disadvantages of these processes. Specifically, it explains that ECSM is a hybrid of electrochemical machining and electric discharge machining that can machine both conductive and non-conductive materials. It also outlines the basic configuration, factors affecting parameters, and applications of EDDG for precision grinding.
The document discusses various non-traditional machining processes including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, water jet machining, abrasive jet machining, and ultrasonic machining. These processes are used for hard materials, complex shapes, or where heat and stresses from traditional machining would cause damage. Each process removes material in unique ways such as through chemical dissolution, electrochemical erosion, electrical sparks, focused light/electron beams, or abrasive particle impact.
THERMAL AND ELECTRICAL BASED PROCESSESravikumarmrk
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.
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.
The document discusses various non-traditional machining processes such as abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). It provides details on the classification of non-traditional processes, including mechanical metal removal processes, electro-chemical processes, and thermal methods. Specific information on process parameters and applications are given for AJM, WJM, and USM. The advantages and limitations of these non-traditional machining techniques are also summarized.
CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSravikumarmrk
The document discusses various chemical and electro-chemical based machining processes. It describes the principles and processes of chemical machining, electro-chemical machining (ECM), electro-chemical grinding (ECG), and electro-chemical honing (ECH). ECM involves removing metal from a workpiece through controlled chemical dissolution using an electrolyte solution, with the workpiece as the anode. ECG combines 90% chemical dissolution with 10% conventional grinding, allowing for high-precision machining of hard materials. ECH similarly combines electro-chemical attack with honing to internally grind with less pressure and tool wear.
This document provides an overview of ultrasonic machining (USM). It explains that in USM, a tool oscillated at ultrasonic frequencies (around 20 kHz) with abrasive particles in the gap between the tool and workpiece. The abrasive particles are forced to repeatedly impact the work surface due to the ultrasonic oscillations, removing material through micro-chipping. Key advantages of USM include the ability to machine hard and brittle materials precisely without producing thermal or chemical defects, while disadvantages include low material removal rates and fast tool wear. Common abrasives used include aluminum oxide and silicon carbide in a water slurry. USM is suitable for machining intricate shapes, small holes, and hard non-conductive
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.
Chemical and photo-chemical machining are non-traditional machining processes that use chemicals to remove material from a workpiece. Chemical machining involves protecting areas of the workpiece with maskants and then immersing or spraying the workpiece with chemical etchants to dissolve the exposed material. Photochemical machining uses photographic techniques to apply a light-sensitive mask before etching. Electrochemical machining applies a voltage between the workpiece and tool to create a controlled chemical dissolution of material. These processes can precisely machine complex shapes without mechanical forces.
The document discusses various non-traditional machining processes including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, water jet machining, abrasive jet machining, and ultrasonic machining. These processes are used for hard materials, complex shapes, or where heat and stresses from traditional machining would cause damage. Each process removes material in unique ways such as through chemical dissolution, electrochemical erosion, electrical sparks, focused light/electron beams, or abrasive particle impact.
THERMAL AND ELECTRICAL BASED PROCESSESravikumarmrk
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.
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.
The document discusses various non-traditional machining processes such as abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). It provides details on the classification of non-traditional processes, including mechanical metal removal processes, electro-chemical processes, and thermal methods. Specific information on process parameters and applications are given for AJM, WJM, and USM. The advantages and limitations of these non-traditional machining techniques are also summarized.
CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSravikumarmrk
The document discusses various chemical and electro-chemical based machining processes. It describes the principles and processes of chemical machining, electro-chemical machining (ECM), electro-chemical grinding (ECG), and electro-chemical honing (ECH). ECM involves removing metal from a workpiece through controlled chemical dissolution using an electrolyte solution, with the workpiece as the anode. ECG combines 90% chemical dissolution with 10% conventional grinding, allowing for high-precision machining of hard materials. ECH similarly combines electro-chemical attack with honing to internally grind with less pressure and tool wear.
This document provides an overview of ultrasonic machining (USM). It explains that in USM, a tool oscillated at ultrasonic frequencies (around 20 kHz) with abrasive particles in the gap between the tool and workpiece. The abrasive particles are forced to repeatedly impact the work surface due to the ultrasonic oscillations, removing material through micro-chipping. Key advantages of USM include the ability to machine hard and brittle materials precisely without producing thermal or chemical defects, while disadvantages include low material removal rates and fast tool wear. Common abrasives used include aluminum oxide and silicon carbide in a water slurry. USM is suitable for machining intricate shapes, small holes, and hard non-conductive
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.
Chemical and photo-chemical machining are non-traditional machining processes that use chemicals to remove material from a workpiece. Chemical machining involves protecting areas of the workpiece with maskants and then immersing or spraying the workpiece with chemical etchants to dissolve the exposed material. Photochemical machining uses photographic techniques to apply a light-sensitive mask before etching. Electrochemical machining applies a voltage between the workpiece and tool to create a controlled chemical dissolution of material. These processes can precisely machine complex shapes without mechanical forces.
Abrasive jet machining is a non-traditional machining process that removes material by directing a high-velocity stream of abrasive particles carried by a gas through a nozzle onto a workpiece. The abrasive particles impact the workpiece surface at speeds up to 300 m/s, removing material through micro-cutting and brittle fracture. Key aspects of the process include the abrasive particles (usually aluminum oxide or silicon carbide around 50 microns in size), gas propulsion system, abrasive feeder, mixing chamber and nozzle (made of tungsten carbide). Abrasive jet machining can efficiently machine intricate shapes in hard, brittle materials like ceramics and glass with low heat impact.
The document discusses abrasive jet machining (AJM). It describes the principle, construction, working, advantages, disadvantages, applications, characteristics and factors affecting the material removal rate in AJM. The key points are:
1. AJM uses a high-speed stream of abrasive particles mixed with compressed air or gas to machine hard, brittle materials.
2. It consists of a mixing chamber, nozzle, pressure gauge and other components to mix and direct the abrasive particles.
3. AJM can machine intricate shapes without heat or contact, but has a low material removal rate and requires dust collection.
Water jet machining uses a high-pressure stream of water to cut materials. It is a cold cutting process that produces no heat-affected zones. The water jet travels at supersonic speeds and erodes material when the local pressure exceeds the material's strength. Key components include a hydraulic pump to pressurize water, an intensifier to further pressurize it, and a nozzle to direct the jet. It can cut a variety of materials and offers advantages over other cutting methods like reduced burrs, flexibility of cutting complex shapes, and not producing heat or fumes. However, it is not suitable for high-volume production.
Water jet machining uses high-pressure water to cut soft, non-metallic materials. It works by converting the kinetic energy of the water jet into pressure energy when it strikes the material, inducing stresses that exceed the material's shear strength and loosening small chips. The water jet machining system consists of a pump to pressurize water, which is then accelerated through a nozzle to cut the material. It allows clean, precise cutting without thermal damage and is suitable for cutting intricate contours in materials like paper, plastics, wood and rubber.
Abrasive water jet machining (AWJM) is a relatively new machining technique. Abrasive Water Jet Machining is extensively used in many industrial applic ations. AWJM is a non- conventional machining process where material is removed by impa ct erosion of high pressure high velocity of water and entrained high velocity of grit abrasi ves on a work piece. There are so many process parameter affect quality of machined surface cut by AW JM. Important process parameters which mainly affect the quality of cutting are traverse spe ed,hydraulic pressure,stand of distance,abrasive flow rate and types of abrasive. Important quality para meters in AWJM are Material Removal Rate (MRR),Surface Roughness (SR),Kerf width,tape ring of Kerf. This seminar report reviews the research work carried out so far in the area AWJM.
Hybrid manufacturing combines two or more non-traditional manufacturing processes. Electrochemical grinding combines electrochemical machining and grinding. It uses a grinding wheel and electrolytic fluid to remove material from a conductive workpiece. The process produces close tolerances and smooth surfaces. Key advantages are minimal wheel wear and ability to machine hard materials. Applications include machining difficult materials like carbides and composites. Future developments could improve efficiency and surface quality when machining advanced materials.
Unconventional manufacturing processes remove material using mechanical, thermal, electrical or chemical energy rather than sharp cutting tools. They are used for very hard, brittle materials that cannot be easily machined through traditional processes. There are several types of unconventional processes including abrasive jet machining (AJM), electrochemical machining (ECM), and laser beam machining (LBM). AJM works by using a high velocity stream of abrasive particles to remove material through micro-cutting or brittle fracture. Water jet machining (WJM) uses high pressure water to cut softer materials while abrasive water jet machining (AWJM) adds abrasive particles to the water jet to cut harder materials. Both WJM
This document provides an overview of mechanical energy-based machining processes including abrasive jet machining, water jet machining, abrasive water jet machining, and ultrasonic machining. It describes the basic working principles of each process including the equipment used and key process parameters. Abrasive jet machining involves a high velocity stream of abrasive particles carried by compressed gas that machines materials by mechanical abrasion. Water jet machining uses ultrahigh pressure water to cut materials, while abrasive water jet machining adds abrasive particles to the water jet to increase cutting ability and speed. Ultrasonic machining involves vibrating a tool at high frequency against a workpiece with an abrasive slurry to erode material
Abrassive Water-Jet Machining by Himanshu VaidHimanshu Vaid
Waterjet cutting is a versatile machining process that uses a high-pressure stream of water, or water with an abrasive added, to cut materials. It can cut both soft materials like cardboard as well as hard materials like steel. Waterjet cutting produces no heat affected zone and leaves a smooth, burr-free edge. It is suitable for cutting a wide range of materials and shapes quickly and with high precision. The main limitations are slower cutting of very hard materials and potential loss of accuracy for thick parts.
Abrasive jet machining uses abrasive particles mixed with air or water that are forced through a nozzle at high velocity to erode material from the workpiece surface. Finer abrasive particles produce better surface finishes down to 0.5 micrometers, but removal rates are very slow at around 0.5 cubic centimeters per hour. The process is suitable for machining hard and brittle materials and can be used for drilling small holes, cutting ceramics and glass, and finishing complex shapes. Key factors that influence the machining include the abrasive particle size, carrier gas velocity and mixing ratio, work material properties, and standoff distance between the nozzle and workpiece.
Ultrasonic machining uses high-frequency vibrations to remove material by abrasion. It can machine hard and brittle materials to complex shapes with good accuracy. The process involves an abrasive slurry and a tool that oscillates at ultrasonic frequencies (over 18 kHz) to remove material. It is a non-traditional machining method that is not limited by the electrical or chemical properties of the work material. Recent developments include combining ultrasonic abrasion with electrochemical reactions to increase material removal rates.
In abrasive jet machining (AJM), compressed air carries abrasive particles like aluminum oxide or silicon carbide through a nozzle to machine hard, brittle materials. The high-velocity abrasive particles remove material by micro-cutting and brittle fracture. AJM can drill intricate shapes, machine fragile materials, and is used for drilling, cutting, deburring, cleaning, and etching. Material removal rate is low, abrasives may embed, and environmental impact is high. AJM is suitable for hard, brittle materials like glass, ceramics, and mica.
Micro machining and classification, and Electro chemical micro machining Elec...Mustafa Memon
A detail description of Micro machining, its classification
Electro chemical micro machining
Electric Discharge Micro machining
micro turning
their resource and application
By Muhammad Mustafa memon
BE Qucest larkana
ME MUET jamshoro
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.
This document presents information on abrasive jet machining (AJM). It discusses the working principle of AJM, which involves a focused stream of abrasive particles carried by compressed air or gas impacting the work surface through a nozzle to remove material by erosion. The key components of an AJM system are identified as the pump, control system, mixing chamber, and nozzle. Applications of AJM include micro-machining of brittle objects, deburring, cutting of optical fibers, and machining of lenses. Advantages include the ability to machine intricate shapes in hard materials without contact or heat, while disadvantages include lower accuracy and material removal rates compared to other machining methods.
Unit 4 discusses several non-traditional machining processes including abrasive jet machining. Abrasive jet machining involves using a high-velocity jet of abrasive particles carried by a carrier gas to remove material from a workpiece. Key aspects of the process are that abrasive particles around 50 micrometers are accelerated to 200 meters per second by compressed air or gas and directed at the workpiece by a nozzle. Process parameters that can be controlled include the abrasive type and size, carrier gas properties, abrasive jet velocity and flow rate, standoff distance, and impingement angle. Abrasive jet machining is suitable for drilling intricate shapes in hard and brittle materials.
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.
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.
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
Abrasive jet machining is a non-traditional machining process that removes material by directing a high-velocity stream of abrasive particles carried by a gas through a nozzle onto a workpiece. The abrasive particles impact the workpiece surface at speeds up to 300 m/s, removing material through micro-cutting and brittle fracture. Key aspects of the process include the abrasive particles (usually aluminum oxide or silicon carbide around 50 microns in size), gas propulsion system, abrasive feeder, mixing chamber and nozzle (made of tungsten carbide). Abrasive jet machining can efficiently machine intricate shapes in hard, brittle materials like ceramics and glass with low heat impact.
The document discusses abrasive jet machining (AJM). It describes the principle, construction, working, advantages, disadvantages, applications, characteristics and factors affecting the material removal rate in AJM. The key points are:
1. AJM uses a high-speed stream of abrasive particles mixed with compressed air or gas to machine hard, brittle materials.
2. It consists of a mixing chamber, nozzle, pressure gauge and other components to mix and direct the abrasive particles.
3. AJM can machine intricate shapes without heat or contact, but has a low material removal rate and requires dust collection.
Water jet machining uses a high-pressure stream of water to cut materials. It is a cold cutting process that produces no heat-affected zones. The water jet travels at supersonic speeds and erodes material when the local pressure exceeds the material's strength. Key components include a hydraulic pump to pressurize water, an intensifier to further pressurize it, and a nozzle to direct the jet. It can cut a variety of materials and offers advantages over other cutting methods like reduced burrs, flexibility of cutting complex shapes, and not producing heat or fumes. However, it is not suitable for high-volume production.
Water jet machining uses high-pressure water to cut soft, non-metallic materials. It works by converting the kinetic energy of the water jet into pressure energy when it strikes the material, inducing stresses that exceed the material's shear strength and loosening small chips. The water jet machining system consists of a pump to pressurize water, which is then accelerated through a nozzle to cut the material. It allows clean, precise cutting without thermal damage and is suitable for cutting intricate contours in materials like paper, plastics, wood and rubber.
Abrasive water jet machining (AWJM) is a relatively new machining technique. Abrasive Water Jet Machining is extensively used in many industrial applic ations. AWJM is a non- conventional machining process where material is removed by impa ct erosion of high pressure high velocity of water and entrained high velocity of grit abrasi ves on a work piece. There are so many process parameter affect quality of machined surface cut by AW JM. Important process parameters which mainly affect the quality of cutting are traverse spe ed,hydraulic pressure,stand of distance,abrasive flow rate and types of abrasive. Important quality para meters in AWJM are Material Removal Rate (MRR),Surface Roughness (SR),Kerf width,tape ring of Kerf. This seminar report reviews the research work carried out so far in the area AWJM.
Hybrid manufacturing combines two or more non-traditional manufacturing processes. Electrochemical grinding combines electrochemical machining and grinding. It uses a grinding wheel and electrolytic fluid to remove material from a conductive workpiece. The process produces close tolerances and smooth surfaces. Key advantages are minimal wheel wear and ability to machine hard materials. Applications include machining difficult materials like carbides and composites. Future developments could improve efficiency and surface quality when machining advanced materials.
Unconventional manufacturing processes remove material using mechanical, thermal, electrical or chemical energy rather than sharp cutting tools. They are used for very hard, brittle materials that cannot be easily machined through traditional processes. There are several types of unconventional processes including abrasive jet machining (AJM), electrochemical machining (ECM), and laser beam machining (LBM). AJM works by using a high velocity stream of abrasive particles to remove material through micro-cutting or brittle fracture. Water jet machining (WJM) uses high pressure water to cut softer materials while abrasive water jet machining (AWJM) adds abrasive particles to the water jet to cut harder materials. Both WJM
This document provides an overview of mechanical energy-based machining processes including abrasive jet machining, water jet machining, abrasive water jet machining, and ultrasonic machining. It describes the basic working principles of each process including the equipment used and key process parameters. Abrasive jet machining involves a high velocity stream of abrasive particles carried by compressed gas that machines materials by mechanical abrasion. Water jet machining uses ultrahigh pressure water to cut materials, while abrasive water jet machining adds abrasive particles to the water jet to increase cutting ability and speed. Ultrasonic machining involves vibrating a tool at high frequency against a workpiece with an abrasive slurry to erode material
Abrassive Water-Jet Machining by Himanshu VaidHimanshu Vaid
Waterjet cutting is a versatile machining process that uses a high-pressure stream of water, or water with an abrasive added, to cut materials. It can cut both soft materials like cardboard as well as hard materials like steel. Waterjet cutting produces no heat affected zone and leaves a smooth, burr-free edge. It is suitable for cutting a wide range of materials and shapes quickly and with high precision. The main limitations are slower cutting of very hard materials and potential loss of accuracy for thick parts.
Abrasive jet machining uses abrasive particles mixed with air or water that are forced through a nozzle at high velocity to erode material from the workpiece surface. Finer abrasive particles produce better surface finishes down to 0.5 micrometers, but removal rates are very slow at around 0.5 cubic centimeters per hour. The process is suitable for machining hard and brittle materials and can be used for drilling small holes, cutting ceramics and glass, and finishing complex shapes. Key factors that influence the machining include the abrasive particle size, carrier gas velocity and mixing ratio, work material properties, and standoff distance between the nozzle and workpiece.
Ultrasonic machining uses high-frequency vibrations to remove material by abrasion. It can machine hard and brittle materials to complex shapes with good accuracy. The process involves an abrasive slurry and a tool that oscillates at ultrasonic frequencies (over 18 kHz) to remove material. It is a non-traditional machining method that is not limited by the electrical or chemical properties of the work material. Recent developments include combining ultrasonic abrasion with electrochemical reactions to increase material removal rates.
In abrasive jet machining (AJM), compressed air carries abrasive particles like aluminum oxide or silicon carbide through a nozzle to machine hard, brittle materials. The high-velocity abrasive particles remove material by micro-cutting and brittle fracture. AJM can drill intricate shapes, machine fragile materials, and is used for drilling, cutting, deburring, cleaning, and etching. Material removal rate is low, abrasives may embed, and environmental impact is high. AJM is suitable for hard, brittle materials like glass, ceramics, and mica.
Micro machining and classification, and Electro chemical micro machining Elec...Mustafa Memon
A detail description of Micro machining, its classification
Electro chemical micro machining
Electric Discharge Micro machining
micro turning
their resource and application
By Muhammad Mustafa memon
BE Qucest larkana
ME MUET jamshoro
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.
This document presents information on abrasive jet machining (AJM). It discusses the working principle of AJM, which involves a focused stream of abrasive particles carried by compressed air or gas impacting the work surface through a nozzle to remove material by erosion. The key components of an AJM system are identified as the pump, control system, mixing chamber, and nozzle. Applications of AJM include micro-machining of brittle objects, deburring, cutting of optical fibers, and machining of lenses. Advantages include the ability to machine intricate shapes in hard materials without contact or heat, while disadvantages include lower accuracy and material removal rates compared to other machining methods.
Unit 4 discusses several non-traditional machining processes including abrasive jet machining. Abrasive jet machining involves using a high-velocity jet of abrasive particles carried by a carrier gas to remove material from a workpiece. Key aspects of the process are that abrasive particles around 50 micrometers are accelerated to 200 meters per second by compressed air or gas and directed at the workpiece by a nozzle. Process parameters that can be controlled include the abrasive type and size, carrier gas properties, abrasive jet velocity and flow rate, standoff distance, and impingement angle. Abrasive jet machining is suitable for drilling intricate shapes in hard and brittle materials.
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.
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.
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.
The abrasive jet machine is classified as a non-conventional machine and in this slide introduction about it the structure and, advantage, and disadvantage
This document discusses nontraditional manufacturing processes. It provides an overview of ultrasonic machining (USM), describing the process, material removal mechanism, advantages, disadvantages, and applications. It also summarizes waterjet machining (WJM) and abrasive waterjet machining (AWJM), explaining the principles, advantages, disadvantages, and applications of these processes. Finally, it briefly introduces abrasive jet machining (AJM), describing the basic process and its uses.
This document discusses various methods for measuring power, flow, temperature, and torque. It describes common flow measurement devices like venturi meters, orifice meters, and rotameters. It also outlines different temperature measurement techniques using bimetallic strips, thermocouples, resistance temperature detectors, and pyrometers. Finally, it mentions torque measurement using devices like Prony brake arrangements and dynamometers, as well as reliability, calibration, and readability considerations.
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2. Thread measurement involves measuring various thread elements like major diameter, minor diameter, pitch, and form using methods such as thread plug gauges, thread wires, and thread micrometers.
3. Gear measurement includes measuring parameters like pitch, lead, backlash, tooth thickness, and errors using equipment such as involute measuring machines, gear tooth vernier calipers, and gear testers.
4. Surface finish is measured using techniques like stylus probes, profilometers, and comparisons to standard samples which analyze roughness parameters like Ra
The document discusses various chemical and electro-chemical based machining processes. It describes the principles and processes of electro-chemical machining (ECM), electro-chemical grinding (ECG), and electro-chemical honing (ECH). ECM involves removing metal from a workpiece through controlled chemical etching using an electrolyte solution. In ECG and ECH, metal is removed by both chemical dissolution and conventional grinding/honing actions using an electrolyte solution to improve material removal rate and tool life. Key parameters like voltage, current density, electrolyte composition and feed rate are discussed.
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This document provides an overview of metrology and measurements. It discusses the general applications of metrology in various industries. It also outlines the key units of the course, which cover the basics of metrology, linear and angular measurements, advanced metrology techniques, form measurements, and measurement of power, flow and temperature. The first unit introduces concepts like the need for metrology, measurement methods, elements of measuring systems, standards and types of errors. Accuracy, precision, sensitivity, stability, and repeatability are some key metrological parameters discussed.
The document discusses various chemical and electro-chemical based machining processes. It describes the principles and processes of chemical machining, electro-chemical machining (ECM), electro-chemical grinding (ECG), and electro-chemical honing (ECH). ECM involves removing metal from a workpiece through controlled chemical dissolution using an electrolyte solution, with the workpiece as the anode. ECG combines 90% chemical dissolution with 10% conventional grinding, allowing for high-precision machining of hard materials. ECH similarly combines electro-chemical attack with honing to internally grind with less pressure and tool wear.
Electric vehicle and photovoltaic advanced roles in enhancing the financial p...IJECEIAES
Climate change's impact on the planet forced the United Nations and governments to promote green energies and electric transportation. The deployments of photovoltaic (PV) and electric vehicle (EV) systems gained stronger momentum due to their numerous advantages over fossil fuel types. The advantages go beyond sustainability to reach financial support and stability. The work in this paper introduces the hybrid system between PV and EV to support industrial and commercial plants. This paper covers the theoretical framework of the proposed hybrid system including the required equation to complete the cost analysis when PV and EV are present. In addition, the proposed design diagram which sets the priorities and requirements of the system is presented. The proposed approach allows setup to advance their power stability, especially during power outages. The presented information supports researchers and plant owners to complete the necessary analysis while promoting the deployment of clean energy. The result of a case study that represents a dairy milk farmer supports the theoretical works and highlights its advanced benefits to existing plants. The short return on investment of the proposed approach supports the paper's novelty approach for the sustainable electrical system. In addition, the proposed system allows for an isolated power setup without the need for a transmission line which enhances the safety of the electrical network
International Conference on NLP, Artificial Intelligence, Machine Learning an...gerogepatton
International Conference on NLP, Artificial Intelligence, Machine Learning and Applications (NLAIM 2024) offers a premier global platform for exchanging insights and findings in the theory, methodology, and applications of NLP, Artificial Intelligence, Machine Learning, and their applications. The conference seeks substantial contributions across all key domains of NLP, Artificial Intelligence, Machine Learning, and their practical applications, aiming to foster both theoretical advancements and real-world implementations. With a focus on facilitating collaboration between researchers and practitioners from academia and industry, the conference serves as a nexus for sharing the latest developments in the field.
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Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
TIME DIVISION MULTIPLEXING TECHNIQUE FOR COMMUNICATION SYSTEMHODECEDSIET
Time Division Multiplexing (TDM) is a method of transmitting multiple signals over a single communication channel by dividing the signal into many segments, each having a very short duration of time. These time slots are then allocated to different data streams, allowing multiple signals to share the same transmission medium efficiently. TDM is widely used in telecommunications and data communication systems.
### How TDM Works
1. **Time Slots Allocation**: The core principle of TDM is to assign distinct time slots to each signal. During each time slot, the respective signal is transmitted, and then the process repeats cyclically. For example, if there are four signals to be transmitted, the TDM cycle will divide time into four slots, each assigned to one signal.
2. **Synchronization**: Synchronization is crucial in TDM systems to ensure that the signals are correctly aligned with their respective time slots. Both the transmitter and receiver must be synchronized to avoid any overlap or loss of data. This synchronization is typically maintained by a clock signal that ensures time slots are accurately aligned.
3. **Frame Structure**: TDM data is organized into frames, where each frame consists of a set of time slots. Each frame is repeated at regular intervals, ensuring continuous transmission of data streams. The frame structure helps in managing the data streams and maintaining the synchronization between the transmitter and receiver.
4. **Multiplexer and Demultiplexer**: At the transmitting end, a multiplexer combines multiple input signals into a single composite signal by assigning each signal to a specific time slot. At the receiving end, a demultiplexer separates the composite signal back into individual signals based on their respective time slots.
### Types of TDM
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### Applications of TDM
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- **Digital Audio and Video Broadcasting**: TDM is used in broadcasting systems to transmit multiple audio or video streams over a single channel, ensuring efficient use of bandwidth.
- **Computer Networks**: TDM is used in network protocols and systems to manage the transmission of data from multiple sources over a single network medium.
### Advantages of TDM
- **Efficient Use of Bandwidth**: TDM all
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As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
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 μm (sinking EDM)
and 1 μm (wire EDM).
• Surface finish is 0.4 to 0.5 μm
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 μ holes in 50 μm plate
• Used in making 1.2 μ slots in 2.5 μm 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