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UNCONVENTIONAL MACHINING
Basics
• Machining is a broad term to describe removal of material
from a work piece.
Machining categories:
• Very high hardness and strength of the material. (above 400 HB.)
• The shape of the part is complex, such as internal and external profiles,
or small diameter holes.
• Conventional machining has many disadvantages like tool wear which are
not present in Non-conventional machining.
1) high cost
2) complex set-up
3) most of the machines are numerical operated
Classifications
1. Type of energy required, namely, mechanical, electrical,
chemical etc.
• Pure water is very well suited for cutting of soft, and sensitive
materials in a very precise manner.
• Hydraulic unit
• Intensifier
• Accumulator
• Filters
• Water transmission lines
• On/off valve
• Water jet nozzles
• Abrasive water jet nozzle
• Water jet catchers
• Fluid additives
• Hydraulic unit
• Consists of an electrically drive, variable-
displacement.
• Pressure –compensated hydraulic pump.
• Typical hydraulic pressure are adjustable about
20 MPa.
• Intensifier
To increase the water pressure up to 380MPa
• Accumulator or shock attenuator
1. WJM – Pure
At high pressure if the water contains any solid particulates damages the nozzle
And slight change chemistry affect the erosion resistance.
SOLUTIONS:
1. WATER SOFTENING TREATMENT
2. USING RO
3. USING DEIONIZING CIRCUIT
Processes Characteristics
• The flow rate and the pressure of the water jet have
different effect on cutting.
• This is apparent coz high flow rate at low pressure will not
cut.
• Pressure of the water jet determines the avg. kinetic
energy of a particle in the water jet.
or
Where,
The velocity of the water jet formed can be estimated, assuming no losses as
using Bernoulli’s equation
3
1
3
Advantages
• No work hardening or thermal effects or NO HAZ
• Very thick parts can not be cut with waterjet cutting and still
hold dimensional accuracy.
• If the part is too thick, the jet may dissipate some, and cause
it to cut on a diagonal, or to have a wider cut at the bottom of
the part than the top. It can also cause a rough wave pattern
on the cut surface.
Waterjet lag
REMEDY OR ADVANCES IN THE PROCESS
THICKNESS ABOVE 5mm Upto 160 mm dry Thin and M.S. – 25mm
OF JOB and upto and 120 mm medium plates High alloy
medium under water steel – 15mm
thicknesses
Al – 10mm
SPEED Low Very high even High for thin Very low
for high strength plates
materials
HEAT Very high HAZ Lower than oxy Very small HAZ No HAZ no
IMPACT ON and high fuel for high warpage
MATERIAL warpage strength material
KERF - Wider than laser Small cutting Narrow kerf
and water jet kerf (0.2-0.3
mm)
COMPARISION
PROPERTY OXY FUEL PLASMA LASER WATER JET/
CUTTING CUTTING CUTTING AWJM
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Machining System
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Machining System – Contd.
A gas (Nitrogen, CO2 or air) is supplied at 2 – 8 kg/cm2
Oxygen should never be used. (because, it causes violent
chemical action with the workpiece chips or abrasive particles).
Gas passes through a mixing chamber after filtration and
regulation.
In the mixing chamber, abrasive particles (10 – 40 m) are present
and vibrated at 50 Hz.
Amplitude of vibration – to control the feed rate of abrasives.
(Gas + abrasives) - passed through a 0.45 mm diameter tungsten
carbide nozzle at a speed of 150 – 300 m/s.
The nozzle is directed over the area to be machined.
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Machining System – Contd.
Aluminium oxide (Al2O3) and silicon carbide (SiC) powders are
used for heavy cleaning, cutting and deburring.
Magnesium carbonate is recommended for use in light cleaning
and etching.
Sodium bicorbonate – fine cleaning and cutting of soft materials.
Commercial grade powders are not suitable – b’cos their sizes are
not well classified. Also, they may contain silica which can cause a
health hazard.
Abrasive powders are not reused. B’cos, contaminations and worn
grits will reduce the machining rate (MRR).
The nozzle stand off distance is 0.81 mm.
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Machining System – Contd.
Relative motion between nozzle and workpiece – can be manual
Or automatically controlled using cam drives, tracer mechanisms
or using computer controlled according to the cut geometry
required.
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Material Removal
The abrasive particles from the nozzle follow parallel paths for a short distance
Then the abrasive jet flares outward like a narrow cone.
When the sharp-edged abrasive particles of Al2O3 or SiC hit a brittle and
fragile material at high speed, tiny brittle fractures are created from which
small particles dislodge.
The dislodged particles are carried away by the air or gas.
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Material Removal Rate
Material or Volumetric Removal Rate (MRR or VRR) is given by the
formula
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Process Parameters
MRR, machining accuracy, surface roughness and nozzle wear are influenced
by
Size and distance of the nozzle.
Composition, strength, size, and shape of abrasives
Flow rate
Composition, pressure, and velocity of the carrier gas.
MRR is mainly dependent on the flow rate and size of abrasives.
Larger grain sizes produce greater removal rates.
At a particular pressure, the VRR increases with the abrasive flow rate up to an
optimum value and then decreases with any further increase in flow rate.
The mass flow rate of the gas decreases with an increase in the abrasive flow
rate
Hence the mixing ratio increases and causes a decrease in the removal rate
because of the decreasing energy available for material removal.
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Process Parameters – Contd.
Typical MRR is 16.4 mm3/min when cutting glass.
Cutting rates for metals vary from 1.6 to 4.1 mm3/min.
For harder ceramics, cutting rates are about 50 percent higher than those for
glass – 24.6 mm3/min.
The minimum width of cut can be 0.13 mm.
Tolerances are typically within 0.05 mm by using good fixation and motion
control.
Attainable surface roughness - 0.2 to 1.5 µm using 10 and 50 µm particles,
respectively.
Taper is present in deep cuts.
High nozzle pressures result in a greater removal rate, but the nozzle life is
decreased.
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Process Characteristics
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Applications
Drilling holes, cutting slots, cleaning hard surfaces, deburring, polishing,
and radiusing.
Deburring of cross holes, slots, and threads in small precision parts that require
a burr-free finish, such as hydraulic valves, aircraft fuel systems, and medical
appliances.
No initial hole is required for starting the operation as required by wire EDM.
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Limitations
The removal rate is slow.
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Ultrasonic Machining (USM)
Ultrasonic waves: Magnetostrictive transducers
Magnetostrictive transducers use the inverse magnetostrictive effect to convert
magnetic energy into ultrasonic energy.
Ceramics have the advantage over crystals in that they are easier to shape
by casting, pressing and extruding.
Principle of Ultrasonic Machining
In the process of Ultrasonic Machining,
material is removed by micro-chipping or
erosion with abrasive particles.
Then the tool slows down its speed and eventually reaches zero again at
the lowest position.
When the grit size is close to the mean position, the tool hits the grit with
its full speed.
The smaller the grit size, the lesser the momentum it receives from the
tool.
As the tool continues to move downwards, the force acting on these grits
increases rapidly, therefore some of the grits may be fractured.
As the tool moves further down, more grits with smaller sizes come in
contact with the tool, the force acting on each grit becomes less.
Eventually, the tool comes to the end of its strike, the number of grits
under impact force from both the tool and the workpiece becomes
maximum.
Grits with size larger than the minimum gap will penetrate into the tool
and work surface to different extents according to their diameters and the
hardness of both surfaces.
Abrasive Slurry
The abrasive slurry contains fine abrasive grains. The grains are usually
boron carbide, aluminum oxide, or silicon carbide ranging in grain size
from 100 for roughing to 1000 for finishing. (150 microns to 5 microns)
It is used to microchip or erode the work piece surface and it is also used
to carry debris away from the cutting area.
Tool holder
• The shape of the tool holder is cylindrical or conical, or a modified cone
which helps in magnifying the tool tip vibrations.
Tool
Tool material should be tough and ductile. Low carbon steels and stainless
steels give good performance.
Tools are usually 25 mm long ; its size is equal to the hole size minus
twice the size of abrasives.
Mass of tool should be minimum possible so that it does not absorb the
ultrasonic energy.
Materials that can be machined on USM
Hard materials like stainless steel, glass, ceramics, carbide, quatz and semi-
conductors are machined by this process.
Brittle materials
Applications
It is mainly used for
(1) drilling
(2) grinding,
(3) Profiling
(4) coining
(5) piercing of dies
Advantages of USM Disadvantages of USM
Machining any materials regardless of
their conductivity
USM has low material removal
rate.
USM apply to machining semi-
conductor such as silicon, germanium
etc. Tool wears fast in USM.