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Non Conventional Machining

This document discusses nonconventional machining processes. It introduces nonconventional machining and some of the requirements that led to their development, such as machining very hard materials or complex shapes. Some advantages are high accuracy, less tool wear, and higher tool life. Disadvantages include higher costs, more complex setups, and needing skilled operators. Specific nonconventional processes covered are ultrasonic machining, water jet machining, electrochemical machining, electrochemical grinding, electrical discharge machining (EDM), and the differences between die sinker and wire EDM. Nonconventional machining is used when attributes required cannot be achieved through traditional processes.

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HassanZameer
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30 views15 pages

Non Conventional Machining

This document discusses nonconventional machining processes. It introduces nonconventional machining and some of the requirements that led to their development, such as machining very hard materials or complex shapes. Some advantages are high accuracy, less tool wear, and higher tool life. Disadvantages include higher costs, more complex setups, and needing skilled operators. Specific nonconventional processes covered are ultrasonic machining, water jet machining, electrochemical machining, electrochemical grinding, electrical discharge machining (EDM), and the differences between die sinker and wire EDM. Nonconventional machining is used when attributes required cannot be achieved through traditional processes.

Uploaded by

HassanZameer
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Nonconventional machining process

Introduction

We all know that the term machinability refers to the case with
which a metal can be machined to an acceptable surface finish.

 Nontraditional machining processes are widely used to


manufacture geometrically complex and precision parts for
aerospace, electronics and automotive industries .
The requirements that lead to the development of
nontraditional machining.

 Very high hardness and strength of the material.


 The work piece: too flexible or slender to support the cutting or
grinding forces.
 The shape of the part is complex, such as internal and external
profiles, or small diameter holes.
 Surface finish or tolerance better than those obtainable
conventional process.
 Temperature rise or residual stress in the work piece are
undesirable.
Advantages of Non-conventional machining:

 High accuracy and surface finish

 Less/no wear

 Tool life is more

 Quieter operation
Disadvantages of non-conventional machining:

 High cost

 Complex set-up

 Skilled operator required


Ultrasonic Machining

 In UM the tip of the tool vibrates at low amplitude and at high


frequency. This vibration transmits a high velocity to fine
abrasive grains between tool and the surface of the work piece.
 Material removed by erosion with abrasive particles.
 The abrasive grains are usually boron carbides.
 This technique is used to cut hard and brittle materials like
ceramics, carbides, glass, precious stones and hardened steel.
Ultrasonic Machining
Water Jet Machining

 High pressure water (20,000-60,000 psi)


 Induct abrasive into stream
 Tight tolerances achievable
 Can cut extremely thick parts (5-10 inches
possible)
Water Jet Machining Products
Electro-Chemical Machining (ECM)

 Works on the principle of


electrolysis
 Die is progressively lowered into
workpiece as workpiece is
dissociated into ions by
electrolysis
 Low DC voltage, very High
current (700 amps)
 Used to machine Dies, easily
deformable and bittle materials.
Electrochemical grinding
 Combines electrochemical machining with conventional grinding
• Grinding wheel is the cathode
• Metal bonded wheel with diamond or Al2O3 abrasive
• Majority of material removal from electrolytic action (95%) therefore
very low wheel wear
• Much faster than conventional grinding
• Used to grind brittle and thin jobs.
Electrical Discharge Machining (EDM)

 The tool acts as a cathode (typically copper


and graphite) is immersed in a Dielectric
fluid with conductive workpiece
 DC voltage 40-400V is applied.
 Sparking at around 12,000 deg F.
 Cycle repeated at 200,000-500,000 Hz
 Dielectric:
 Acts as an insulator
 Cools tool and workpiece
 Flushes out debris from work area
Die Sinker vs. Wire EDM

 Die sinker EDM


 The die sinks into the part as it
sparks away the workpiece
 Most common Injection molding
die process
 Wire EDM
 The electrode is a wire that
traverses through the part
 Common for Extrusion Dies
EDM Products
Conclusion

Non Conventional machining processes are used when


required attributes are impossible to achieve with
traditional machining processes.

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