Non Traditional Machining Processes

1. Non Traditional Machining Processes Presented By : YashpalMaru (111133) Sitesh (111209) Karan Sharma (111616) Abhilash(111671) Ankitlal (111672) Anshu(111753) SonuMeena(111865)

2. The Need for Advanced Machining Processes • Traditional machining processes • Material removal by mechanical means, such as chip forming, abrasion, or micro-chipping • Advanced machining processes • Utilize chemical, electrical, and high-energy beams • The following cannot be done by traditional processes: • Work piece strength and hardness very high, >400HB • Work piece material too brittle, glass, ceramics, heat-treated alloys • Work piece too slender and flexible, hard to clamp • Part shape complex, long and small hole • Special surface and dimensional tolerance requirements www.mindsover.com

3. Development • Development of harder and difficult to machine materials such as hast alloy, nitra alloy, waspalloy, nimonics, carbides, stainless steel, heat resisting steels and many other HSTR alloys • Used in aerospace industry, nuclear engineering and other industries owing to their high strength to weight ratio, hardness and heat resisting quality.

4. CHIPS FORMATION IN CONVENTIONAL MACHINING PROCESS CHIP TOOL WORKPIECE Thus the major characteristics of conventional machining are: • Generally macroscopic chip formation by shear deformation • Material removal takes place due to application of cutting forces – energy domain can be classified as mechanical • Cutting tool is harder than work piece at room temperature as well as under machining conditions TOOL WORKPIECE CHIP

5. Schematic representation of various metal cutting operations.

6. The broad classification is given as follows: • Thus classification of NTM processes is carried out depending on the nature of energy used for material removal. • Mechanical Processes • ⎯ Abrasive Jet Machining (AJM) • ⎯ Ultrasonic Machining (USM) • ⎯ Abrasive Water Jet Machining (AWJM) • Electrochemical Processes • ⎯ Electrochemical Machining (ECM) • ⎯ Electro Chemical Grinding (ECG) • ⎯ Electro Jet Drilling (EJD)

7. • Electro-Thermal Processes • ⎯ Electro-discharge machining (EDM) • ⎯ Laser Beam Machining (LBM) • ⎯ Electron Beam Machining (EBM) • • Chemical Processes • ⎯ Chemical Milling (CHM) • ⎯ Photochemical Milling (PCM) etc.

8. Abrasive Jet Machining (AJM) Abrasive feeder filter Pressure control valve exhaust Mixing chamber Drier Nozzle ¼ turn valve Air compressor Electro-magnetic shaker work piece

9. LASER Beam Machining (LBM)

10. Electron Beam Machining (EBM)

11. Chemical Machining (CHM)

12. PAM

13. ELECTROCHEMICAL MACHINING (ECM)

14. Combines chemical attack and electrical attack • High material removal rate • Masking is used to control attack • Conforming electrodes are to control shape • Commonly used for aircraft parts such as airfoil shapes • Normally followed by abrasive finishing or laser peening to remove partially adhering particles • Works with a wide variety of metals

15. Electrolyte • An electrolyte is any substance containing freeions that make the substance electrically conductive. The most typical electrolyte is an ionic solution, but molten electrolytes and solid electrolytes are also possible. • Function of electrolyte- • Carrying current between tool and work peice • Remove products of machining and other insoluble products from cutting region • Dissipate heat produced in the operation. • Maintain a constant temperature in the machining region • Electrolyte used- Sodium chloride, Sodium Nitrate, Sodium Hydroxide

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