Advanced Machining Processes Tutorials

Sheet No (1) problems:

25) Design and construct an exponential acoustic horn made of Monel alloy (modulus
of elasticity = 179 Gpa), acoustic speed in horn material c = 4.22 × 10 5 cm/s. Its
natural frequency fr = 20 kHz, and its terminal diameters are D0 = 40 mm and
Dℓ = 5 mm. Draw the stress, force and amplitude distribution along the horn length
knowing that obtained magnetostrictor amplitude is 0.48 µm.

a) The design of horn:

1st method: Using equations of exponential horn design:
- Magnification factor:
𝐴0 𝐷0 40
𝑅𝑚 = √ = = =8
𝐴𝑙 𝐷𝑙 5

- The ascent factor h:

𝑅𝑚 = 𝑒 ℎ𝑙 → ℎ𝑙 = ln(𝑅𝑚 ) = ln(8) = 2.079
𝜔 2𝜋 × 20 × 103
ℎ= = = 16.433 (1/𝑚)
𝜋 2 𝜋
𝑐 √1 + ( ) 4.22 × 103 × √1 + (2.079)2
ℎ𝑙

- The horn length:

2.079
𝑙= = 0.1265 𝑚 = 12.65 𝑐𝑚
16.433
- The nodal point position:
𝑙 𝜋 12.65 𝜋
𝑥𝑛 = 𝑡𝑎𝑛−1 ( ) = × 𝑡𝑎𝑛−1 ( ) = 3.97 𝑐𝑚
𝜋 ℎ𝑙 𝜋 2.079

2nd method: Using Nomogram for cylindrical exponential horn:

- The horn length:

From Nomogram 𝑙 ≈ 12.6 𝑐𝑚

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- The nodal point position:

From Nomogram 𝑥𝑏 ≈ 4 𝑐𝑚

- The ascent factor h:

2.079
ℎ𝑙 = ln(𝑅𝑚 ) = ln(8) = 2.079 → ℎ= = 16.51 (1/𝑚)
0.126

The construction of the horn contour:

𝐷(𝑥) = 𝐷0 𝑒 −ℎ𝑥 → 𝐷(𝑥) = 40𝑒 −16.51𝑥

x (cm) 0 2 3.97 6 8 10 12.65

Diameter (mm) 40 28.75 20.76 14.85 10.67 7.67 5

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b) Drawing the stress, Force and amplitude distributions:

Drawing the stress distribution:
- Distribution of stress σx along the axis of exponential horn:

ℎ𝑙 2 𝜋 2 𝜋
𝜎𝑥 = 𝐸 ℎ 𝜉0 √[1 + ( ) ] [1 + ( ) ] . 𝑒 ℎ𝑥 . sin ( 𝑥)
𝜋 ℎ𝑙 𝑙

2.079 2 𝜋 2 −2 𝜋
𝜎(2) = 179 × 109 × 16.51 × 0.48 × 10−6 √[1 + ( ) ] [1 + ( ) ] . 𝑒 16.51×2×10 . sin ( × 2)
𝜋 2.079 12.65

𝜎(2) = 2043444.132 𝑁/𝑚2

x (cm) 0 2 3.97 6 8 8.68 10 12.65

Stress (Mpa) 0.00 2.04 4.94 8.26 10.55 10.76 9.81 0.00

Stress (Mpa) Stress distribution

12

10

0
0 2 4 6 8 10 12 14
-2

Maximum induced stress per cycle = 10.76 Mpa

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Drawing the Force distribution:

- Distribution of Force Fx along the axis of exponential horn:

ℎ𝑙 2 𝜋 2 𝜋
𝐹𝑥 = 𝐸 ℎ 𝜉0 𝐴0 √[1 + ( ) ] [1 + ( ) ] . 𝑒 −ℎ𝑥 . sin ( 𝑥)
𝜋 ℎ𝑙 𝑙

𝜋
𝐹(2) = 179 × 109 × 16.51 × 0.48 × 10−6 × × (40)2
4

2.079 2 𝜋 2 −2 𝜋
× 10−6 √[1 + ( ) ] [1 + ( ) ] . 𝑒 −16.51×2×10 . sin ( × 2)
𝜋 2.079 12.65

𝐹(2) = 1324.438 𝑁 𝑶𝑹

𝜋
𝐹(2) = 𝜎(2) 𝐴(2) = 2.04 × 106 × × 402 × 10−6 × 𝑒 −2×16.51×(2/100)
4

= 1324.438 𝑁

x (cm) 0 2 3.97 6 8 8.68 10 12.65

Force (N) 0 1324.43 1674.6 1431.8 944.46 769.47 453.92 0

Force (N) Force distribution

1800
1600
1400
1200
1000
800
600
400
200
0
-200 0 2 4 6 8 10 12 14

Maximum Force per cycle = 1674.6 N

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27) An exponential horn is made of Monel of acoustic speed c = 4.2 × 10 5 cm/s; the
horn has the following features: maximum diameter D0 = 36 mm, resonant length
ℓ = 12 cm, operating frequency = 20 kHz. The horn should be provided with a
central hole for slurry suction of 2.5 mm diameter from nodal point to x = 12 cm.
Calculate magnification factor, location of the node, horn diameter at nodal point,
horn outside diameter at x = 2, 7, 12 cm.

Design of the exponential horn:

- The ascent factor h:
𝜋 𝜋
𝑙= → 0.12 = → 𝒉 = 14.48 (1/𝑚)
2
√(𝜔) − ℎ2 103
2
𝑐 √(2𝜋 × 20 × 3 ) − ℎ2
4.2 × 10

- Magnification factor Rm:

𝑹𝒎 = 𝑒 ℎ𝑙 = 𝑒 (14.48×0.12) = 5.687
- The terminal diameter Dl:
𝐴0 362
𝑅𝑚 = 5.687 = √ = √ 2 → 𝑫𝒍 = 6.8 𝑚𝑚
𝐴𝑙 𝐷𝑙 − 2.52
- The nodal point position:
𝑙 𝜋 12 𝜋
𝒙𝒏 = 𝑡𝑎𝑛−1 ( ) = × 𝑡𝑎𝑛−1 ( ) ≈ 4.1 𝑐𝑚
𝜋 ℎ𝑙 𝜋 1.737

Construction of the exponential horn:

𝐴(𝑥) = 𝐴0 𝑒 −2ℎ𝑥
- Zone (1) 0 – 4.1 cm
𝐷(𝑥) = 𝐷0 𝑒 −ℎ𝑥

𝐷(1) = 36 𝑒 −(14.48×0.01) = 31.15 𝑚𝑚

x (cm) 0 1 2 3 4.1
Diameter (mm) 36 31.15 26.95 23.32 19.88

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- Zone (2) 4.1 – 12 cm

𝐷(𝑥) 2 − 𝑑𝑙 2 = (𝐷0 2 ) 𝑒 −2ℎ𝑥 → 𝐷(𝑥) = √𝑑𝑙 2 + (𝐷0 2 ) 𝑒 −2ℎ𝑥

𝐷(7) = √2.52 + (362 ) 𝑒 −2(14.48×0.07) = 13.3 𝑚𝑚

x (cm) 4.1 7 9 12

Diameter (mm) 20.0 13.3 10.1 6.8

20

15

10

0
0 2 4 6 8 10 12
-5

-10

-15

-20

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28) For a given piece of USM equipment, operating at a resonant frequency fr = 20

kHz, it is required to design an exponential acoustic horn of ball bearing steel 100
Cr 6 (c = 5.05 × 105 cm/s), provided with a 3-mm diameter hole for the suction of
the abrasive slurry from the nodal point and another one for the fixation in the
primary horn. Assume D0 = 39 mm, Dl = 8 mm, and fixation hole diameter dc = 16
mm and depth 18 mm.

Design of the exponential horn:

- Magnification factor:

𝐴0 392 − 162
𝑅𝑚 = √ = √ 2 = 4.79
𝐴𝑙 8 − 32

- The ascent factor h:

𝑅𝑚 = 𝑒 ℎ𝑙 → ℎ𝑙 = ln(𝑅𝑚 ) = ln(4.79) = 1.566
𝜔 2𝜋 × 20 × 103
ℎ= = = 11.1 (1/𝑚)
𝜋 2 𝜋 2
𝑐 √1 + ( ) 5.05 × 103 × √1 + ( )
ℎ𝑙 1.566

- The horn length:

1.566
𝑙= = 0.1411 𝑚 = 14.11 𝑐𝑚
11.1
- The nodal point position:
𝑙 𝜋 14.11 𝜋
𝑥𝑛 = 𝑡𝑎𝑛−1 ( ) = × 𝑡𝑎𝑛−1 ( ) = 4.978 𝑐𝑚
𝜋 ℎ𝑙 𝜋 1.566

Construction of the exponential horn:

𝐴(𝑥) = 𝐴0 𝑒 −2ℎ𝑥
- Zone (1) 0 – 1.8 cm
𝐷(𝑥) 2 − 𝑑𝑐 2 = (𝐷0 2 − 𝑑𝑐 2 ) 𝑒 −2ℎ𝑥

𝐷(𝑥) = √𝑑𝑐 2 + [(𝐷0 2 − 𝑑𝑐 2 ) 𝑒 −2ℎ𝑥 ] = √162 + [(392 − 162 ) 𝑒 −2ℎ𝑥 ]

𝐷(1) = √162 + [(392 − 162 ) 𝑒 −2×11.1×(1/100) ] = 35.62 𝑐𝑚

x (cm) 0 1 1.8
Diameter (mm) 39 35.62 33.2

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- Zone (2) 2 – 4.978 cm

𝐷(𝑥) 2 = (𝐷0 2 − 𝑑𝑐 2 ) 𝑒 −2ℎ𝑥

𝐷(3) = √(392 − 162 ) 𝑒 −2×11.1×(3/100) = 25.49 𝑐𝑚

x (cm) 2 3 4 4.978

Diameter (mm) 28.5 25.49 22.76 20.5

- Zone (3) 4.978 – 14.11 cm

𝐷(𝑥) 2 − 𝑑𝑙 2 = (𝐷0 2 − 𝑑𝑐 2 ) 𝑒 −2ℎ𝑥

𝐷(𝑥) = √𝑑𝑙 2 + [(𝐷0 2 − 𝑑𝑐 2 ) 𝑒 −2ℎ𝑥 ]

𝐷(10) = √32 + (392 − 162 ) 𝑒 −2×11.1×(10/100) = 12.1 𝑐𝑚

x (cm) 4.978 6 8 10 12 14.11

Diameter (mm) 20.7 18.5 14.9 12.1 9.9 8

25
20
15
10
5
0
-5 0 2 4 6 8 10 12 14 16

-10
-15
-20
Horn contour
-25

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29) Calculate the USM time required for a hole of diameter 6 mm in tungsten carbide
plate (fracture hardness = 6900 N/mm2) if the thickness of the plate is 1.5-hole
diameter. The mean abrasive grain size is 15 μm diameter. The feed force is equal
to 3.5 N. The amplitude of tool oscillation is 25 μm and the frequency is equal to
25 kHz. The tool material used is copper having fracture hardness equal to 1.5×103
N/mm2. The slurry contains one-part abrasives to one-part water. Take the values
of different constants as k1 = 0.3, k2 = 1.8 mm2, k3 = 0.6, and abrasive density= 3.8
g/cm3. Calculate the ratio of removed volume by throwing to hammering.

Machining time calculation:

- The depth of penetration hp for the grain-throwing model (free-impact):
𝜌𝑎 3.8 × 103
ℎ𝑡ℎ = 𝜋𝑎𝑡 𝑓𝑟 𝑑𝑎 √ = 𝜋 × 50 × 10−6 × 25 × 103 × 15 × 10−6 √
6 𝜎𝑤 6 × 6.9 × 109

= 1.784 × 10−8 𝑚
- The depth of penetration hp for for the hammering model:

𝟒 𝑭𝒂𝒗 𝒂𝒕 𝒅𝒂 𝟒 × 𝟑. 𝟓 × 𝟓𝟎 × 𝟏𝟎−𝟔 × 𝟏𝟓 × 𝟏𝟎−𝟔

𝒉𝒘 = √ =√ = 𝟐. 𝟏𝟖𝟐 × 𝟏𝟎−𝟕 𝒎
𝝅 𝝈𝒘 𝒌𝟐 (𝒋 + 𝟏) 𝟔𝟗𝟎𝟎
𝝅 × 𝟔. 𝟗 × 𝟏𝟎𝟗 × 𝟏. 𝟖 × 𝟏𝟎−𝟔 × ( + 𝟏)
𝟏𝟓𝟎𝟎

- The total volumetric removal rate:

𝑉𝑅𝑅 = 𝑉𝑅𝑅𝑡ℎ + 𝑉𝑅𝑅ℎ

1
𝑉𝑅𝑅 = 𝑘1 𝑘2 𝑘3 √ 𝑓𝑟 (√ℎ𝑡ℎ 3 + √ℎ𝑤 3 )
𝑑𝑎

1
𝑉𝑅𝑅 = 0.3 × 1.8 × 10−6 × 0.6√ × 25000 (√(1.784 × 10−8 )3 + √(2.182 × 10−7 )3 )
15 × 10−6

𝑉𝑅𝑅 = 2.1815 × 10−10 𝑚3 /𝑠 = .21815 𝑚𝑚3 /𝑠

- The machining time required:
𝜋
𝑉 × 62 × 9
𝑡= = 4 = 1166.48 𝑠𝑒𝑐 = 19.44 𝑚𝑖𝑛
𝑉𝑅𝑅 0.21815
The ratio of the volume calculation:

𝑉𝑅𝑅𝑡ℎ ℎ𝑡ℎ 3 (1.784 × 10−8 )3

𝑅𝑎𝑡𝑖𝑜 = =√ 3 =√ = 0.0233
𝑉𝑅𝑅ℎ ℎ𝑤 (2.182 × 10−7 )3

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30) A square through hole 5 × 5 mm2 is to be ultrasonically machined in a tungsten

carbide plate of 4 mm thickness. The slurry is made of one part of 10 μm B4C
abrasives in one part of water. If the feed force is 5 N, the tool oscillates at
amplitude of 15 μm and frequency of 25 kHz. Assuming that only 75 % of pulses
are effective. The fracture hardness of tungsten carbide workpiece is 7000 N/mm2
and that of the copper tool is 1500 N/mm2. Calculate the machining time taking k1
= 0.3, k2 = 1.8 mm2, and k3 = 0.6, and abrasive density = 2.52 g/cm3.

Machining time calculation:

- The depth of penetration hp for the grain-throwing model (free-impact):

𝜌𝑎 2.52 × 103
ℎ𝑡ℎ = 𝜋𝑎𝑡 𝑓𝑟 𝑑𝑎 √ = 𝜋 × 30 × 10−6 × 25 × 103 × 10 × 10−6 √ = 5.77 × 10−9 𝑚
6 𝜎𝑤 6 × 7 × 109

- The depth of penetration hp for for the hammering model:

4 𝐹𝑎𝑣 𝑎𝑡 𝑑𝑎 4 × 5 × 30 × 10−6 × 10 × 10−6

ℎ𝑤 = √ =√ = 1.636 × 10−7 𝑚
𝜋 𝜎𝑤 𝑘2 (𝑗 + 1) 7000
𝜋 × 7 × 109 × 1.8 × 10−6 × ( + 1)
1500

- The total volumetric removal rate:

𝑉𝑅𝑅 = 𝑉𝑅𝑅𝑡ℎ + 𝑉𝑅𝑅ℎ

1
𝑉𝑅𝑅 = 𝑘1 𝑘2 𝑘3 √ 𝑓𝑟 (√ℎ𝑡ℎ 3 + √ℎ𝑤 3 )
𝑑𝑎

1
𝑉𝑅𝑅 = 0.3 × 1.8 × 10−6 × 0.6√ × 25000 (√(5.77 × 10−9 )3 + √(1.636 × 10−7 )3 )
10 × 10−6

𝑉𝑅𝑅 = 1.706 × 10−10 𝑚3 /𝑠 = 0.1706 𝑚𝑚3 /𝑠

𝑽𝑹𝑹 = 0.1706 × 0.75 = 𝟎. 𝟏𝟐𝟕𝟗𝟓 𝒎𝒎𝟑 /𝒔

- The machining time required:
𝑉 5×5×4
𝒕= = = 586.17 𝑠𝑒𝑐 = 𝟗. 𝟕𝟔𝟗 𝒎𝒊𝒏
𝑉𝑅𝑅 0.1706

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32) Estimate the machining time required to machine a hole in WC 5 mm thick. The
grits are 20 μm radius, static stress is 0.15 N/mm2, oscillation amplitude is 35 μm,
and the machine operates at frequency of 25,000 cps. The compressive fracture
strength of WC is 2270 N/mm2. What would be the volumetric removal rate if the
shape is a square 4 mm × 4 mm?

Machining time calculation:

- The linear removal rate is given by:

𝑉𝑅𝑅𝐿 = 5.9 𝑓𝑟 (𝜎𝑡 /𝐻𝑟 )(𝑑𝑎 /2)0.5 (𝑎𝑡 /2)0.5

𝑉𝑅𝑅𝐿 = 5.9 × 25000 × (0.15/2270) × 200.5 × 350.5 × 10−3

𝑉𝑅𝑅𝐿 = 0.258 𝑚𝑚/𝑠
- The machining time required:

𝑑𝑒𝑝𝑡ℎ 5
𝒕= = = 𝟏𝟗. 𝟑𝟖 𝒔
𝑉𝑅𝑅𝐿 0.258
Volumetric removal rate calculation:
𝑉𝑅𝑅 = 𝐴 × 𝑉𝑅𝑅𝐿
𝑽𝑹𝑹 = 4 × 4 × 0.258 = 𝟒. 𝟏𝟐𝟖 𝒎𝒎𝟑 /𝒔

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34) Material removal rate in AJM is 0.3 mm3/sec. calculate MRR/impact if the mass
flow rate of abrasive is 4 gm/min, density is 1.5 gm/CC and grit size is 23 microns
Also calculate the indentation radius.

Calculation of the material removed per impact:

- The mass of one grit (grain):
𝜋 3 𝜋
𝑚𝑔 = 𝑑𝑔 𝜌𝑔 = (23 × 10−6 )3 × 1.5 × 1003 = 9.555 × 10−9 𝑔𝑚
6 6
- Number of impacts N:
𝐴𝑏𝑟𝑎𝑠𝑖𝑣𝑒 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 4
𝑁= = = 418628990.1 𝑖𝑚𝑝𝑎𝑐𝑡/𝑚𝑖𝑛
𝑚𝑔 9.555 × 10−9

- Material removed per impact Γ:

0.3 × 60
𝜞= = 4.299 × 10−8 𝑚𝑚3 /𝑖𝑚𝑝𝑎𝑐𝑡 = 𝟒𝟐. 𝟗𝟗𝟕 𝝁𝒎𝟑 /𝒊𝒎𝒑𝒂𝒄𝒕
418628990.1

indentation radius calculation:

2
𝐼𝑑𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑉𝑜𝑙𝑢𝑚𝑒 = 𝜋𝑟 3 = 𝛤 = 4.299 × 10−8
3

𝒓 = 0.00273 𝑚𝑚 = 𝟐. 𝟕𝟑𝟖 𝒎𝒊𝒄𝒓𝒐𝒏

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Sheet No (2) problems:

31) It is required to drill a hole of 10 mm diameter and 20 mm depth in a hard alloy
using the following conditions:

Calculate the following:

a. Machining time b. Tool diameter c. Machining current d. Machining gap

Calculation of machining time:

𝑑𝑒𝑝𝑡ℎ 20
𝒕= = = 𝟏𝟎 𝒎𝒊𝒏
𝑓𝑒𝑒𝑑 2
Calculation of tool diameter:
𝑫𝒕 = 𝐷ℎ − 𝑜𝑣𝑒𝑟𝑠𝑖𝑧𝑒 = 10 − 2 = 𝟖 𝒎𝒎
Calculation of machining current:
- Volumetric removal rate:

𝑉 (𝜋/4) × 102 × 20
𝑉𝑅𝑅 = = = 157.08 𝑚𝑚3 /𝑚𝑖𝑛
𝑡 10
- Machining current:
Ƞ𝑐 𝜀 𝐼
𝑉𝑅𝑅 =
𝐹𝜌
157.08 × (96500/600) × 0.0084
𝑰= = 𝟏𝟎𝟎 𝑨
42.44/2
Calculation of machining gap:
Ƞ𝑐 𝜀(𝑣 − ∆𝑣)𝑘 (42.44/2) × 20 × 0.032
𝒚𝒆 = = = 𝟎. 𝟓𝟎𝟑 𝒎𝒎
𝐹𝜌𝑎 (96500/60) × 0.0084 × 2

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33) Calculate the MRR and the electrode tool feed rate in the ECM of an iron surface
that has 25 × 25 mm2 in cross section using NaCl solution. The machining gap
between the tool and workpiece is 0.25 mm. The applied voltage is 12 V DC. The
specific resistance of the electrolyte is 3.0 Ω cm, then estimate the electrolyte flow
rate if the specific heat of the electrolyte is 0.997 Cal/g °C. The ambient
temperature is 35 °C, the electrolyte boiling temperature is 95 °C, and the density
of electrolyte is 1.0 g/cm3, Faraday’s constant is 96500 A s.

Calculation of Tool feed rate a:

- The chemical equivalent weight 𝜀 :
𝐴 55.85
𝜀= = = 27.925 𝑔𝑚
𝑍 2
- The machining constant 𝐶𝑎 :
Ƞ𝑐 𝜀(𝑣 − ∆𝑣)𝑘 1 × 27.925 (12 − 0)(1/3)
𝐶𝑎 = = = 1.465 × 10−4 𝑐𝑚2 /𝑠
𝐹𝜌 96500 × 7.9
- Machining gap at equilibrium:
𝐶𝑎 1.465 × 10−4 × 102
𝑦𝑒 = → 𝒂= = 𝟎. 𝟎𝟓𝟖𝟔 𝒎𝒎/𝒔
𝑎 0.25
Calculation of Material removal rate MRR:
- Material removal rate:
𝑴𝑹𝑹 = 𝑎 𝐴 = 0.0586 × 25 × 25 = 𝟑𝟔. 𝟔𝟐𝟓 𝒎𝒎𝟑 /𝒔
Calculation of the electrolyte flow rate:
- Temperature change can be calculated as:
𝑎𝜌 29
𝑦𝛬 9
𝑎𝜌 2 𝑦𝛬
∆𝑇 = 2.23 × 10 [ ] [ ] → 𝑄𝑒 = 2.23 × 10 [ ] [ ]
Ƞ𝑐 𝜀 𝑘𝑄𝑒 𝜌𝑒 𝑐𝑒 Ƞ𝑐 𝜀 𝑘 ∆𝑇 𝜌𝑒 𝑐𝑒
- the electrolyte flow rate 𝑄𝑒 be calculated as:
2
0.0586 × 7.9 × 10−2
9
0.25 × 25 × 25
𝑄𝑒 = 2.23 × 10 [ ] [ ]
1 × 27.925 1
(30) (95 − 35) × 1 × 10−2 × 0.997

𝑸𝒆 = 𝟒𝟖𝟎𝟐𝟒𝟒. 𝟗𝟐 𝒎𝒎𝟑 /𝒔 = 𝟎. 𝟒𝟖 𝑳/𝒔𝒆𝒄

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35) A nimonic alloy of a density 7.85 g/cm3 is to be machined by ECM using NaCl
solution of conductivity 0.02 Ω−1 mm−1 to remove a stock of 200 g. If 200 A current
and 15 V were used that caused a current density of 80 A/cm2, Faraday’s constant
is 96500 A s, Calculate:
a. The chemical equivalent of nimonic alloy (54 % Ni – 21 % Cr – 20 % Co – 3% Ti –
2 % Al), use the minimum valence for each metal.
b. The equilibrium gap.
c. The tool feed rate used.
d. The time required for the job If the cathode area is 30 mm × 30 mm.

Calculation of the chemical equivalent:

- Using percentage by weight method:
𝑛𝑧
1 𝐴𝑖
𝜀= ∑ ( ) 𝑋𝑖
100 𝑍𝑖
𝑖

1 58.7 51.99 58.9 47.9 26.9

= (( × 54) + ( × 21) + ( × 20) + ( × 3) + ( × 2))
100 2 2 2 3 3
𝜺 = 𝟐𝟕. 𝟖𝟓𝟔 𝒈
Calculation of the equilibrium gap:
(𝑣 − ∆𝑣)𝑘 (𝑣 − ∆𝑣)𝑘 (15 − 0) 0.02
𝐽= → 𝒚= = = 𝟎. 𝟑𝟕𝟓 𝒎𝒎
𝑦 𝐽 80 × 10−2
Calculation of the tool feed rate:
Ƞ𝑐 𝜀 1 × 27.9
𝒂 = 𝑉𝑅𝑅𝑠 𝐽 = 𝐽= × 80 = 𝟎. 𝟎𝟎𝟐𝟗𝟓 𝒄𝒎/𝒔 = 𝟎. 𝟎𝟐𝟗𝟓 𝒎𝒎/𝒔
𝐹𝜌 96500 × 7.85
Calculation of the time required:
- The volume removed of stock:
𝑚 200
𝑉= = = 25.4777 𝑐𝑚3
𝜌 7.85
- The depth of removed cavity:
𝑉 25.4777 × 1000
𝑑= = = 28.31 𝑚𝑚
𝐴 30 × 30
- Time required for the job:
𝑑 28.31
𝒕= = = 𝟗𝟓𝟗. 𝟔𝟏 𝒔 ≈ 𝟏𝟔 𝒎𝒊𝒏
𝑎 0.0295

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38) A circular hole of 12.5 mm diameter is to be machined in titanium alloy block by

using the current density of 6 A/mm2, estimate the time required for a hole depth
of 20 mm if the theoretical specific removal rate is 1.6 mm3/min A and the current
efficiency is 90 %. Compare this time with the time required for conventional
drilling at 300 rpm and a feed rate of 0.15 mm/rev.

Calculation of The machining time required (ECM):

- The linear volumetric removal rate:
𝑉𝑅𝑅𝐿 = 𝑉𝑅𝑅𝑠 𝐽 = 1.6 × 6 × (0.9) = 8.64 𝑚𝑚/𝑚𝑖𝑛

- Machining time:
𝑑𝑒𝑝𝑡ℎ 20
𝑇𝑖𝑚𝑒 = = = 𝟐. 𝟏𝟑 𝒎𝒊𝒏
𝑉𝑅𝑅𝐿 8.64

Calculation of The machining time required (drilling):

- Tool feed rate:
𝑓 = 300 × 0.15 = 45 𝑚𝑚/𝑚𝑖𝑛

- Machining time:
𝑑𝑒𝑝𝑡ℎ 20
𝑇𝑖𝑚𝑒 = = = 𝟎. 𝟒𝟒 𝒎𝒊𝒏
𝑓 45

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Advanced Machining Processes Tutorials

Sheet No (3) problems:

12) During EDM operation of a steel sheet, calculate the surface finish if the
capacitance used is 15 μF, the discharging voltage is 130 V, and K2 = 0.4.

Calculation of surface finish:

𝑹𝒂 = 𝑘2 𝑉𝑑 0.5 𝐶𝑎𝑝 −0.5 = 0.4 × 1300.5 × 15−0.5 = 𝟏. 𝟏𝟖 𝝁𝒎

14) A through square hole of 10 × 10 mm2 is to be drilled by EDM in 5 mm thickness

plate. Estimate the time required for the process. Assume Rc = 50 Ω, Cap = 10 μF,
Vsp = 200 V, Vd = 150 V, and K1 = 0.18 to obtain the volumetric removal rate.
Calculate the surface roughness if K2 = 0.5.

Calculation of time required for process:

- The volumetric removal rate:

1 1
𝑉𝑅𝑅 = 𝑘1 𝐶𝑎𝑝 𝑉𝑠𝑝 2 [ ]
𝑅𝑐 𝐶𝑎𝑝 ln ( 1
)
1 − (𝑉𝑑 /𝑉𝑠𝑝 )

1 1
= 0.18 × 2002 [ ] = 103.874 𝑚𝑚3 /𝑚𝑖𝑛
50 ln ( 1
)
1 − (150/200)

- The machining time:

𝑉 100 × 5
𝒕= = = 𝟒. 𝟖𝟏 𝒎𝒊𝒏
𝑉𝑅𝑅 103.874
Calculation of surface roughness:
𝑹𝒂 = 𝑘2 𝑉𝑑 0.5 𝐶𝑎𝑝 −0.5 = 0.5 × 1500.5 × 10−0.5 = 𝟏. 𝟗𝟒 𝝁𝒎

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13) It is required to drill a hole of 10 mm diameter by EDM in 5 mm HSS plate using

EDM RC circuit. If the required surface finish is 2 μm, determine the specifications
of the capacitor to be used. If the supply voltage is 200 V and the discharge voltage
is 150 V, use a resistance value of 50 Ω and the constant K1 and K2 as 0.04 and 0.6,
respectively, to calculate the time required for the job. What would be the
discharging current and discharge energy?

Calculation of capacitance:
𝑹𝒂 = 𝑘2 𝑉𝑑 0.5 𝐶𝑎𝑝 −0.5
2 0.5 2
𝑘2 𝑉𝑑 0.5 0.6 × 150
𝑪𝒂𝒑 =( ) =( ) = 𝟏𝟑. 𝟓 𝝁𝑭
𝑅𝑎 2
Calculation of time required for the job:
- The volumetric removal rate:

1 1
𝑉𝑅𝑅 = 𝑘1 𝐶𝑎𝑝 𝑉𝑠𝑝 2 [ ]
𝑅𝑐 𝐶𝑎𝑝 ln ( 1
)
1 − (𝑉𝑑 /𝑉𝑠𝑝 )

1 1
= 0.04 × 2002 [ ] = 23.08 𝑚𝑚3 /𝑚𝑖𝑛
50 ln ( 1
)
1 − (150/200)

- The machining time:

𝜋
𝑉 × 102 × 5
𝒕= = 4 = 𝟏𝟕. 𝟎𝟏 𝒎𝒊𝒏
𝑉𝑅𝑅 23.08
Calculation of discharging current:
𝑉𝑑 150
𝑰𝒅 = = =𝟑𝑨
𝑅𝑐 50
Calculation of discharging energy:
𝑬𝒅 = 0.5𝐶𝑎𝑝 𝑉𝑠𝑝 2 = 0.5 × 13.5 × 10−6 × 2002 = 𝟎. 𝟐𝟕 𝑱

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15) It is required to drill a hole of 5 mm diameter to a depth of 10 mm in a steel plate

using RC circuit and brass electrode. The surface finish required is 3 μm, sparking
time is 100 μs, and the constant K1 = 0.3, and K2 = 4,

- Determine the supply voltage if Cap = 120 μF and Rc = 100 Ω.

- Find out the time required for drilling.
- Calculate the volume removed by each spark.

Calculation of supply voltage:

- The discharge voltage:
2 2
𝑅𝑎 3
𝑉𝑑 = ( ) =( ) = 67.5 𝑉
𝑘2 𝐶𝑎𝑝 −0.5 4 × 120−0.5

- The supply voltage:

𝑽𝒔𝒑 = 𝑉𝑑 /0.72 = 𝟗𝟑. 𝟕𝟓 𝑽
Calculation of time required:
- The volumetric removal rate:

1 1
𝑉𝑅𝑅 = 𝑘1 𝐶𝑎𝑝 𝑉𝑠𝑝 2 [ ]
𝑅𝑐 𝐶𝑎𝑝 ln ( 1
)
1 − (𝑉𝑑 /𝑉𝑠𝑝 )

1 1
= 0.3 × 93.752 [ ] = 20.713 𝑚𝑚3 /𝑚𝑖𝑛
100 ln ( 1
)
1 − (67.5/93.75)

- The machining time:

𝜋
𝑉 × 52 × 10
𝒕= = 4 = 𝟏𝟗. 𝟒𝟖 𝒎𝒊𝒏
𝑉𝑅𝑅 20.713
Calculation of volume removed by each spark:
20.713 100
𝒗𝒐𝒍𝒖𝒎𝒆/𝒔𝒑𝒂𝒓𝒌 = 𝑉𝑅𝑅 × 𝑡𝑠𝑝𝑎𝑟𝑘 = ( ) × ( 6 ) = 𝟑. 𝟒𝟓 × 𝟏𝟎−𝟓 𝒎𝒎𝟑
60 10

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