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.
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.
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.
This document discusses various hybrid and non-traditional machining processes. It describes electrochemical spark machining (ECSM) which combines electrochemical machining and electric discharge machining to machine both conductive and non-conductive materials. Electrical discharge diamond grinding (EDDG) uses sparks to grind materials with diamond abrasives. Electron beam micromachining uses a focused stream of electrons to melt and vaporize material for microfabrication.
UCM - Unit 5 recent trends in non-traditional machining processeskarthi keyan
This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). ECSM uses sparks generated between a cathode tool and workpiece in an electrolyte solution to remove material. Key parameters for ECSM include supply voltage, tool diameter, electrolyte composition, and gap distance. EDDG uses sparks to soften and abrade workpiece surfaces with diamond abrasives. Factors like wheel speed, current, and pulse time affect the EDDG process. Thermal processes like electric discharge micromachining (EDMM) and electron beam micromachining precisely shape conductive materials by localized melting/vaporization using electric
This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). It provides details on:
1) The principles and components of ECSM, which uses sparks to machine conductive and non-conductive materials.
2) The principles, configuration, parameters and advantages/disadvantages of EDDG, which uses sparks and diamond abrasives to precision grind materials.
3) Various advanced micro-machining processes like abrasive jet, waterjet, and ultrasonic machining and how they operate at the micro scale.
UNIT 5 -Recent Trends in Non-Traditional Machining Processes.pptxRaja P
This document discusses various hybrid and non-traditional machining processes such as electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). It provides details on the working principles, advantages and limitations of these processes. Specifically, it describes how ECSM works by combining electrochemical machining and electric discharge machining to machine both conductive and non-conductive materials. It also explains that EDDG uses sparks to grind materials with diamond abrasives, achieving higher accuracy than EDM. The document outlines the key parameters and applications of these hybrid 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.
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.
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.
This document discusses various hybrid and non-traditional machining processes. It describes electrochemical spark machining (ECSM) which combines electrochemical machining and electric discharge machining to machine both conductive and non-conductive materials. Electrical discharge diamond grinding (EDDG) uses sparks to grind materials with diamond abrasives. Electron beam micromachining uses a focused stream of electrons to melt and vaporize material for microfabrication.
UCM - Unit 5 recent trends in non-traditional machining processeskarthi keyan
This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). ECSM uses sparks generated between a cathode tool and workpiece in an electrolyte solution to remove material. Key parameters for ECSM include supply voltage, tool diameter, electrolyte composition, and gap distance. EDDG uses sparks to soften and abrade workpiece surfaces with diamond abrasives. Factors like wheel speed, current, and pulse time affect the EDDG process. Thermal processes like electric discharge micromachining (EDMM) and electron beam micromachining precisely shape conductive materials by localized melting/vaporization using electric
This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). It provides details on:
1) The principles and components of ECSM, which uses sparks to machine conductive and non-conductive materials.
2) The principles, configuration, parameters and advantages/disadvantages of EDDG, which uses sparks and diamond abrasives to precision grind materials.
3) Various advanced micro-machining processes like abrasive jet, waterjet, and ultrasonic machining and how they operate at the micro scale.
UNIT 5 -Recent Trends in Non-Traditional Machining Processes.pptxRaja P
This document discusses various hybrid and non-traditional machining processes such as electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). It provides details on the working principles, advantages and limitations of these processes. Specifically, it describes how ECSM works by combining electrochemical machining and electric discharge machining to machine both conductive and non-conductive materials. It also explains that EDDG uses sparks to grind materials with diamond abrasives, achieving higher accuracy than EDM. The document outlines the key parameters and applications of these hybrid machining techniques.
UNIT 5 RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES.pptxDineshKumar4165
Recent developments in non-traditional machining processes, their working principles, equipments, effect of process parameters, applications, advantages and limitations. Comparison of non-traditional machining processes.
This document provides an 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.
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 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.
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 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 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 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 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.
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, 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.
The document discusses non-conventional machining processes. It begins by distinguishing between conventional machining processes, which use hard cutting tools to remove material, and non-conventional processes, which use other energies like mechanical, thermal, electrical, or chemical. Non-conventional processes are then classified based on the type of energy used, including mechanical, electrochemical, electro-thermal, and chemical processes. Examples of specific non-conventional machining techniques are provided within each classification.
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.
Non Traditional Machining is playing vital role in now a days in mechanical Industries so student it should be need sound knowledge in this particular subject due to impact of this subject i am prepare in this materials it is most useful for my students...
All The Best ...
By: Author-Prof.S.Sathishkumar
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.
UCM - Unit 2 -thermal and electrical energy based processeskarthi keyan
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.
The document discusses various recent trends in engines, including homogeneous charge compression ignition (HCCI) engines, lean-burn engines, stratified charge engines, surface ignition engines, electronic engine management systems, common rail direct injection diesel engines, gasoline direct injection engines, and hybrid electric vehicles. It provides details on the working principles and advantages of each type.
The document discusses various alternative fuels to gasoline and diesel, including alcohols (methanol and ethanol), vegetable oils, biodiesel, natural gas (compressed and liquefied) and liquefied petroleum gas. It describes the need for alternative fuels due to depletion of conventional fuels and to reduce pollution and global warming. The production processes of various fuels are explained along with their properties, advantages, and disadvantages when used in spark ignition or compression ignition engines. Modifications required in engines to use alternative fuels are also mentioned.
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.
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 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.
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 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 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 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 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.
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, 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.
The document discusses non-conventional machining processes. It begins by distinguishing between conventional machining processes, which use hard cutting tools to remove material, and non-conventional processes, which use other energies like mechanical, thermal, electrical, or chemical. Non-conventional processes are then classified based on the type of energy used, including mechanical, electrochemical, electro-thermal, and chemical processes. Examples of specific non-conventional machining techniques are provided within each classification.
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.
Non Traditional Machining is playing vital role in now a days in mechanical Industries so student it should be need sound knowledge in this particular subject due to impact of this subject i am prepare in this materials it is most useful for my students...
All The Best ...
By: Author-Prof.S.Sathishkumar
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.
UCM - Unit 2 -thermal and electrical energy based processeskarthi keyan
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.
The document discusses various recent trends in engines, including homogeneous charge compression ignition (HCCI) engines, lean-burn engines, stratified charge engines, surface ignition engines, electronic engine management systems, common rail direct injection diesel engines, gasoline direct injection engines, and hybrid electric vehicles. It provides details on the working principles and advantages of each type.
The document discusses various alternative fuels to gasoline and diesel, including alcohols (methanol and ethanol), vegetable oils, biodiesel, natural gas (compressed and liquefied) and liquefied petroleum gas. It describes the need for alternative fuels due to depletion of conventional fuels and to reduce pollution and global warming. The production processes of various fuels are explained along with their properties, advantages, and disadvantages when used in spark ignition or compression ignition engines. Modifications required in engines to use alternative fuels are also mentioned.
The document discusses emission formation and control. It describes the mechanisms of formation of NOx, HC, CO, and particulate emissions from engines. Methods of controlling emissions discussed include three-way catalytic converters, particulate traps, and EGR. Measurement equipment for emissions include chemiluminescence detectors for NOx and FID for HC. Smoke and particulate are measured using light extinction and filtering methods. International and national emission standards like Euro norms and Bharat Stage norms in India are also overviewed.
This document discusses combustion in compression ignition (CI) engines. It describes how in a CI engine, only air is compressed, raising its temperature and pressure. Fuel is then injected and combusts due to the high temperature and pressure. Combustion occurs in four stages: ignition delay period, rapid combustion, controlled combustion, and afterburning. Factors like injection timing and fuel quality can affect the ignition delay period. The document also discusses different types of combustion chambers and spray formation in CI engines.
This document outlines the topics covered in 5 units of a course on advanced internal combustion engines. Unit I covers spark ignition engines, including air-fuel ratio requirements, stages of combustion, factors affecting knock, and fuel injection systems. Unit II discusses compression ignition engines and combustion analysis. Unit III addresses emission formation and control. Unit IV covers alternate fuels for engines. Unit V presents recent trends, including new engine types and technologies.
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.
This document provides information on chemical and electro-chemical machining processes. It discusses chemical machining which removes metal through controlled etching using a chemical solution. Electro-chemical machining (ECM) removes metal through anodic dissolution when a workpiece is made the anode in an electrolytic cell. Electro-chemical grinding (ECG) and honing (ECH) combine electrochemical effects with conventional grinding/honing, removing mostly by chemical action and some by mechanical action. Process parameters like current density, electrolyte composition and feed rate affect the material removal rate and surface finish. ECM, ECG and ECH allow burr-free machining of difficult-to-cut materials.
This document discusses various thermal and electrical energy-based machining processes. It provides details on electric discharge machining (EDM) and wire cut EDM, including their working principles, process parameters, applications and advantages/disadvantages. It also describes laser beam machining and plasma arc machining, their working principles, types of lasers/plasmas used, and applications in metal cutting, drilling and surface treatment.
This document provides information on unconventional machining processes including mechanical energy based processes. It discusses abrasive jet machining where compressed air carries abrasive particles to impact and machine hard materials. Water jet machining uses high pressure water to cut. Abrasive water jet machining adds abrasives to the water jet. Ultrasonic machining uses high frequency vibrations and an abrasive slurry to machine hard brittle materials. Key parameters that affect the material removal rate in these processes are discussed such as abrasive grain size, gas/water pressure, and velocity. Advantages include ability to machine hard materials without heat, while disadvantages include low material removal rates and accuracy issues.
The document discusses advances in metrology, including laser interferometry and coordinate measuring machines (CMMs). It describes the principles and components of laser interferometry, including laser sources, optical elements, and measurement receivers. Coordinate measuring machines are discussed, including their construction, types of probes, accuracy considerations, and applications for precision inspection. Computer-aided inspection using machine vision systems is also summarized, outlining the key stages of image generation, processing, and analysis.
This document discusses measurement of mechanical parameters including torque, temperature, and force. It describes various methods for measuring torque using a Prony brake arrangement and dynamometers. Temperature measurement techniques covered include bimetallic strips, thermocouples, thermometers, pyrometers, and resistance temperature detectors. Methods for measuring force include load cells, strain gauges, and capacitive load cells.
1. The document discusses various methods for measuring different elements of screw threads and gears, including major diameter, minor diameter, effective diameter, pitch, flank angle, and roundness.
2. Thread measurement methods include using micrometers, V-blocks, taper parallels, and rollers. Pitch can be measured using a pitch gauge, toolmaker's microscope, or pitch measuring machine.
3. Effective diameter is typically measured using one, two, or three wire methods. Flank angle and thread form are evaluated using optical projection or thread plug/ring/caliper gauges.
1. The document discusses the syllabus for the course 20ME601 - Metrology and Measurements.
2. The syllabus is divided into 5 units which cover topics like basics of metrology, linear and angular measurements, form measurement, measurement of mechanical parameters, and advances in metrology.
3. Key concepts discussed include types of metrology, components of a generalized measurement system, standards, units, types of measurements/methods of measurements, types of measuring instruments, factors affecting accuracy and precision, and types of errors in measurements.
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
Traditionally, dealing with real-time data pipelines has involved significant overhead, even for straightforward tasks like data transformation or masking. However, in this talk, we’ll venture into the dynamic realm of WebAssembly (WASM) and discover how it can revolutionize the creation of stateless streaming pipelines within a Kafka (Redpanda) broker. These pipelines are adept at managing low-latency, high-data-volume scenarios.
CHINA’S GEO-ECONOMIC OUTREACH IN CENTRAL ASIAN COUNTRIES AND FUTURE PROSPECTjpsjournal1
The rivalry between prominent international actors for dominance over Central Asia's hydrocarbon
reserves and the ancient silk trade route, along with China's diplomatic endeavours in the area, has been
referred to as the "New Great Game." This research centres on the power struggle, considering
geopolitical, geostrategic, and geoeconomic variables. Topics including trade, political hegemony, oil
politics, and conventional and nontraditional security are all explored and explained by the researcher.
Using Mackinder's Heartland, Spykman Rimland, and Hegemonic Stability theories, examines China's role
in Central Asia. This study adheres to the empirical epistemological method and has taken care of
objectivity. This study analyze primary and secondary research documents critically to elaborate role of
china’s geo economic outreach in central Asian countries and its future prospect. China is thriving in trade,
pipeline politics, and winning states, according to this study, thanks to important instruments like the
Shanghai Cooperation Organisation and the Belt and Road Economic Initiative. According to this study,
China is seeing significant success in commerce, pipeline politics, and gaining influence on other
governments. This success may be attributed to the effective utilisation of key tools such as the Shanghai
Cooperation Organisation and the Belt and Road Economic Initiative.
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELgerogepatton
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%.
Understanding Inductive Bias in Machine LearningSUTEJAS
This presentation explores the concept of inductive bias in machine learning. It explains how algorithms come with built-in assumptions and preferences that guide the learning process. You'll learn about the different types of inductive bias and how they can impact the performance and generalizability of machine learning models.
The presentation also covers the positive and negative aspects of inductive bias, along with strategies for mitigating potential drawbacks. We'll explore examples of how bias manifests in algorithms like neural networks and decision trees.
By understanding inductive bias, you can gain valuable insights into how machine learning models work and make informed decisions when building and deploying them.
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
1. **Synchronous TDM**: In synchronous TDM, time slots are pre-assigned to each signal, regardless of whether the signal has data to transmit or not. This can lead to inefficiencies if some time slots remain empty due to the absence of data.
2. **Asynchronous TDM (or Statistical TDM)**: Asynchronous TDM addresses the inefficiencies of synchronous TDM by allocating time slots dynamically based on the presence of data. Time slots are assigned only when there is data to transmit, which optimizes the use of the communication channel.
### Applications of TDM
- **Telecommunications**: TDM is extensively used in telecommunication systems, such as in T1 and E1 lines, where multiple telephone calls are transmitted over a single line by assigning each call to a specific time slot.
- **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
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.
2. TOPICS
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.
3. 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.
4. VARIOUS TYPES OF HYBRID PROCESS
1. Electric discharge diamond grinding (EDDG)
2. Electro chemical spark machining (ECSM)
3. Magneto rheological abrasive flow finishing
(MRAFF)
5. • 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
6. 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
7. • 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)
11. 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.
12. 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.
13. • 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)
16. • When the workpieces is the electrically
conductive material
• When the workpiece is electrically
nonconductive material.
BASIC CONFIGURATION OF EDDG
22. • 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
23. • Recast layer is formed after grinding
• Possibilities of oil fires
• Wheels are fragile
DISADVANTAGES OF EDDG
24. 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.
25. 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.
27. • 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
29. • 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
31. • 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
32. • Particle size
• Size distribution
• Moisture content and
• Surface texture
Powder flowability and
compactability depends on
37. EFFECT OF PROCESS PARAMETER IN
AJMM
• Powder compaction
• Powder stratification
• Powder humidity
38. 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.
39. APPLICATIONS OF AJMM
• Micro accelerometer beam
• Matrix of micro E-cores
• Capillary electro phores is chips
• 3D suspended microstructures
• 3D passive glass micro mixer.
40. 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.
41. • Abrasive water jet generation
• Abrasive waterjet subsystem
• Abrasive waterjet machining centers.
COMPONENTS OF AWJMM
45. ABRASIVE WATER JET SUBSYSTEM
• Ultra high pressure water feed system
• The cutting head
• Abrasive feed system
46. Abrasive Water Jet Micro Machining
Centre
• Motion system - ball screw and linear motors.
• Machine structure
• Workpiece holding
• Human machine interface and control system
47. 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
48. • 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
49. • 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
52. • 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
53. • 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.
54. • 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
55. • 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
57. 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
58. • 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
59. 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
60. 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
61. 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
62. 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
63. • 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
64. 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
65. 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
66. 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.
72. • 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
73. • 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
74. • 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
75. • Mechanism of material removal by melting
and evaporisation.
• Material removal rate is between 0.6 to 6
mm3 /hr
• Dimensional accuracy is 2 m (sinking EDM)
and 1 m (wire EDM).
• Surface finish is 0.4 to 0.5 m
PROCESS PARAMETERS OF EDMM
76. • 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
77. 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
78. • Used in drilling 6.5 holes in 50 m plate
• Used in making 1.2 slots in 2.5 m wall.
• Used in shaping microfluids mixer and channel
• Used in machining microgears or internal
gears.
APPLICATIONS OF EDMM
80. • 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
81. • 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
82. • 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
84. • 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
85. • 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
86. 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
87. • 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
88. • 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
89. 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
93. • 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
94. 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
95. • 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
96. • 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
98. 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)
99. 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
101. 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
102. • Nature of power supply
• Inter electrode gap
• Concentration, temperature and electrolyte
flow.
• Microtool feed rate
EFFECT OF PROCESS PARAMETERS ON
ECMM
103. 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
104. • 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