ME-6004- UNCONVENTIONAL MACHINING PROCESS

UNIT-1

CONVENTIONAL MACHINING PROCESS:

METAL IS REMOVED BY USING SOME SHARP TOOLS WHICH IS HARDER THAN THE WORKPIECE AND
IS SUBJECTED TO WEAR.IN THIS PROCESS TOOL AND WORK PIECE ARE IN DIRECT CONTACT WITH EACH
OTHER.

DEMERITS OF CONVENTIONAL:

 Metal is removed by chip formation which is expensive and difficult process

 Chips produced are unwanted by-products.

 Disposal and recycling of chips is a tedious process.

 Large cutting forces are involved, so proper work holding devices are required.

 Large amt of heat are generated between tool & work piece

UNCONVENTIONAL MACHINING PROCESS:

This process do not employ conventional tool for metal removal instead, they directly utilize
some form of energy for metal machining. In this process there is no physical contact between tool
and workpiece.

NEED FOR UCM:

 very high hardness and strength of the material ( above 400 HB) can be processed.

 The degree of accuracy and surface finish are poor in conventional type.

 Played a considerable role in aerospace , automobile, tool and die making industries.

 So the unconventional methods are developed to overcome these difficulties

 Ceramics and composites can be machined using UCM

 ME-6004- UNCONVENTIONAL MACHINING PROCESS
CLASSIFICATION OF UCM

 I) BASED ON TYPE OF ENERGY

a) Thermal energy

b) Electrical Energy

c) Electro- chemical energy

d) chemical energy

e)mechanical energy

 II)Based on mechanism involved:

 A) erosion

 B) ionic dissolution

 C) vaporisation

 Based on source of energy required

 HYDROSTATIC PRESSURE

 HIGH CURRENT DENSITY

 IONISED MATERIAL

 ) Based on medium of transfer of energy:

 High voltage particles

 Electrolyte

 Electron

 Hot gases

MECHANICAL ENERGY: Material is removed by mechanical erosion of the work piece

 Ultrasonic Machining (USM)

 Abrasive Jet Machining (AJM)

 Water Jet Machining (WJM)

ELECTRICAL ENERGY: Electrical energy is used to cut the material

 Electro Discharge Machining (EDM)

 Wire Cut Electrical Discharge Machining (WCEDM)

 ME-6004- UNCONVENTIONAL MACHINING PROCESS

ELECTRO-CHEMICAL ENERGY METHODS: Metal is removed by ion displacement of

workpiece in contact with chemical solution

 Electro Chemical Machining (ECM)

 Electro Chemical Grinding (ECG)

 Electro Chemical Honing (ECH)

 Electro Chemical Deburring (ECD)

THERMAL ENERGY: Heat energy is concentrated on a small area of the work piece to melt and
vaporize the tiny bits of work material.

 Laser beam Machining (LBM)

 Plasma Arc Machining (PAM)

 Electronic Beam Machining (EBM)

 Ion Beam Machining (IBM)

SELECTION OF PROCESS:

SL.NO MATERIAL METHOD

1 Non metals like ceramic, plastics, glass USM, AJM,EBM,LBM

2 Regractories USM, AJM,EDM,EBM

3 Titanium EDM

4 Super Alloy AJM, ECM, EDM, PAM

5 Steel ECM, CHM, EDM,PAM

 ME-6004- UNCONVENTIONAL MACHINING PROCESS

FACTORS CONSIDERED FOR THE PROCESS SELECTION:

 PHYSICAL PARAMETERS:

Parameter ECM EDM EBM LBM PAM USM AJM

VOLT 5-30 50-500 2X10^5 4.5X10^3 250 220 220

CURRENT(A) 40000 15-500 0.001 2 600 12 1

Kw 100 2.7 0.15 20 220 2.4 .22

Gap (mm) 0.5 0.05 100 150 7.5 .25 .75

Work material difficult Tungsten All All All Tungsten Hard &

hard mtrl Carbide brittle

Shapes to be machined:

 Micro holes- LBM

 Small holes- EBM

 Honing- ECM

 Grinding-AJM, EDM

 Threading-EDM

PROCESS CAPABILITY

 Can be analysed w.r.t

 Metal removal rate

 Tolerance maintained

 Surface finish

 Depth of surface

 Power required
 ME-6004- UNCONVENTIONAL MACHINING PROCESS
Process Economy:

 Capital cost
 Tooling cost
 Power requirement
 Metal removal rate efficiency
 Tool consumption

LIMITATION:

 More expensive process

 Mtrl removal rate is slow
 AJM,CHM,PAM & EBM are not commercially economical

ADVANTAGES:

 increase productivity

 reduction of rejected components

 close tolerance is possible

 tool mtrl not be harder than work piece

 harder mtrl can be machined by this method

 do not have any scrab mtrl

ME-6004- UNCONVENTIONAL MACHINING PROCESS