UNCONVENTIONAL MACHINING

PROCESSES

MEMBERS:

JORGE FIDENCIO BRAVO ORDOÑEZ 1870524

DANIEL ESTEBAN CUASPUD ZUÑIGA 1871107
HENRY ALBEIRO ENRÍQUEZ PANTOJA 1748051
FERNANDO LAURENCIO GUERRA FAJARDO 1833855
 CONTENT

1. MECHANICAL ENERGY PROCESSES:

* Abrasive Ultrasonic Machining (USM)
* Rotary Ultrasonic Machining (RUM)
* Water Jet Cutting
* Abrasive Jet Cutting

2. ELECTROCHEMICAL MACHINING (ECM)

 ABRASIVE ULTRASONIC MACHINING (USM)

- Introduction
- History
- Operating principles
- Schematic diagram
- Applications
- Advantages and disadvantages
Introduction
Ultrasonic machining is a non-traditional machining
process to remove material.

This technique of material removal allows to

facilitate the manipulation of metals and other
materials, as well as creating designs with high
degrees of difficulty.

Particularly designed for the need to machine hard

and brittle materials, such as ceramics, glass and
carbides, it is also used successfully in stainless
steels and titanium.
History

- Prospects for the use of high-frequency sound

waves for machining were noted as early as 1927 by
Robert W. Wood
Wood and Loomis.

- The first USM patents appeared in 1945, filed by

Balamuth, while investigating the ultrasonic bite of
abrasive powders.

Alfred Lee Loomis

 Operating principles

- This type of machining allows drilling and surface roughing.

- An abrasive fluid circulates between the tool and the workpiece, against the working
direction and in line with its longitudinal axis.

- This process removes material from the part to achieve a specific shape in it, for this
the tool penetrates the part with a vibration at very high frequencies (15-30 KHz) and
very low amplitude (25-100 µm).

- Direct contact between tool and workpiece does not occur.

- Abrasive fluid causes material roughing due to tool vibrations.

- Material removal occurs by creating microcracks in the workpiece (brittle break).

- The fluid is recirculated from the cutting area and its cooling takes place during the
journey.
Schematic diagram

https://prezi.com/0tc6_17nxknc/mecanizado-ultrasonico/
For this machining there are mainly two types of machines:

- Underpowered machines: for precision work or nano fabrication.

- High power machines: for most operations.

The machine has the following elements:

Electronic oscillator

- Transforms the 50 Hz frequency of the conventional line into 20000-30000 Hz.

- Supplies the high frequency electrical signal to the transducer.

Transducer

- Converts the supplied electrical signal into high frequency, low amplitude mechanical
vibration.
- There are two types of transducers.
• Piezoelectric transducer:

- It contains a crystal in its system, which when circulating

a variant current in a sinusoidal form, it expands and
contracts, causing vibration.
- Power 900 W, efficiency 95%.

• Magneto-strictor transducer:

- Consisting of nickel sheets and an electrical system with connection to the oscillator.
- Varies its length when subjected to a high intensity magnetic field.
- Water-cooled.
- Power 2000 W, efficiency 30 %.

Acoustic horn

- It is coupled to the core of the magneto-strictor.

- Increases the intensity of vibrations by concentrating on its smaller base, which is in contact
with the tool.
Parameters

- Materials: good acoustic properties and high resistance to fatigue breakage.

* Titanium
* Monel
* Stainless steel
- Shape:
* Exponential
* Tapered
* Stepped
Tool (Sonotrode)

- Strongly attached to the minor base of the acoustic horn.

- Perfectly aligned with the working axis of the machine.
Parameters

- Materials: relatively ductile.

* Steel * Molybdenum
* Stainless Steel 303 * Brass

- Vibration frequency:
* 15 - 30 KHz
* Related to the dimensions of the workpiece

- Vibration amplitude:
* 25 - 100 µm
* Related to the dimensions of the workpiece

- Geometry:
* Inverse to the geometry required in the workpiece

- Force developed in the tool:

* Related to the dimensions of the workpiece

- Wear ratio of material vs tool:

* 100: 1 glass, 1: 1 stainless steel
Abrasive fluid

- Composed of abrasive grains (20 - 60%) + water.

- Its function is to remove material due to
vibrations of the tool.
- It is pumped at a rate of 25 L / min.

Parameters

- Materials: extreme hardness.

* Boron carbide (good in general)
* Silicon carbide (glass, ceramics)
* Corundum
* Diamond (precious stones)
* Cubic boron nitride

- Grain size:
* Less than the vibration amplitude
* Homogeneous size and shape
* Depends on the required operation
Workpiece

- Materials of great hardness, up to 60 HRC.

* Ceramics * Titanium
* Glass * Germanium
* Carbides * Precious stones
* Stainless steels

Fixture
- Where the workpiece is fixed.
- It is inside a tank where part of the abrasive fluid is found.

Pump
- Recirculates the abrasive fluid already decanted.

Numerical control
- It was implemented from the 70s-80s.
- Allows full control of the different parameters of the machine.
Applications
- In is mainly used for:
* Drilling
* Profiling
* Coining
* Piercing of dies

Some examples
- Used for machining round, square, irregular
shaped holes and surface impressions.
- It is widely used at NASA to process
materials that cannot be processed
otherwise.
- Precision parts, close to nanotechnology.
- Used in the aerospace and aeronautical
sector.
- Ceramic molds.
- Ceramic chips.
- Automotive industry.
- Optical industry.
Advantages
- It allows the mechanization of materials that without these operations would be practically
impossible (ceramic, dielectric, 60 HRC)
- Allows you to make precision parts, close to nanotechnology
- Allows better tolerances (7 – 25 µm)
- Does not produce a directional surface finish
- Surface finishes of 0.2 µm are achieved
- Cutting force and heat are reduced due to continuous separation between tool and
workpiece

Disadvantages
- It is a more expensive process than conventional ones
- High tool wear occurs due to abrasive grains
- Drilling deep holes is difficult since the entry of abrasive fluid is restricted
References
https://books.google.com.co/books?id=gilYI9_KKAoC&printsec=frontcover&hl=es#v=onepage&q&f=true

https://www.bjultrasonic.com/shop/ultrasonic-horn/?lang=es

https://es.slideshare.net/pablop010/mecanizado-por-ultrasonidos

https://www.bullentech.com/animation/

https://es.slideshare.net/edwinalexissemianriobeltran/maquinado-ultrasonido

https://www.youtube.com/watch?v=1f5yMLuT9Wc
 Rotary ultrasonic machining

Among the unconventional machining processes that are being developed for
machining these ceramics, Rotary Ultrasonic Machining (RUM-Rotary Ultrasonic
Machining) stands out for being an efficient and economically viable process for
machining hard and brittle materials .
RUM is a process that consists of removing material using a superabrasive tool by
combining three movements: rotation, ultrasonic axial vibration (frequency of the
order of 20 Khz.) And advance against the part. On the other hand, a stream of coolant
is pumped through the tool, removing chips from the cutting area, avoiding dulling and
cooling the process.
Regarding the material removal mechanism, the RUM is a hybrid process that combines
the starting mechanisms of diamond grinding and traditional ultrasound machining
(USM), improving both processes
The continuous separation between
tool and part thanks to this ultrasonic
vibration means that, compared to
traditional methods, the cutting forces
are reduced and the heat generation is
less. This translates into a protection of
the tool and the part, increasing
productivity by up to 5 times that of
said conventional processes, and
obtaining surface finishes even less
than 0.2mm.
Likewise, the presence of a series of
intelligent control algorithms help to
fully optimize the cutting process, so
the ADR monitors the torque (the tool
is protected) and the ACC controls the
force in the axial direction by means of
acoustic signals (it protects
piezoelectric).
 General advantages
• Reduction of the cutting efforts, of the thermal load to the piece and with it the wear of the
tool due to the shorter contact time of each abrasive grain with the piece material, inherent
to the ultrasonic movement.
• The overlapping of movements, rotation and rotation, results in higher starting rates than in
the case of conventional processes such as grinding (up to 5 times higher).
• Great surface finish due to the lower forces of the process, being able to obtain surfaces
with roughness less than 0.2 µm Ra until the polishing is suppressed.
• The ultrasonic movement together with the internal and external coolant makes the tool
undergo a self-cleaning process, thus avoiding the dulling phenomenon and facilitating its
regeneration.
• The process produces a superficial layer of residual compression stresses, thus increasing
fatigue life.
• Hard and brittle materials can be treated by carrying out small cutting operations, from
0.5mm as well as various operations in a single machine, namely drilling and milling: holes
of great depth, contoured, grooved, planned or complex surfaces.
 Advantages of RUM over diamond grinding
and traditional ultrasound machining
• It is 10 times faster.
• Drilling small holes is easier, and its accuracy improves markedly.
• There is less pressure on the tool and less wear rate.
• No need to use abrasive fluid.
• Compared to grinding, the advantages are as follows :
• Produces lower cutting forces (65% -70%) and tool wear.
• Surface roughness is improved (29%).
• There is no thermally affected area, or chemical alterations on the surface
of the piece.
• A layer of residual compression stresses is created that could increase the
fatigue life of the machined component.
 APLICACIONES

• Automotive industry:
brake discs, injection
nozzles, injection mold
inserts ...; in materials
such as Silicon Nitride,
Alumina, carbide,
tempered steel
(55HRc) ...
• Semiconductor
industry: inserts
(Wafer), cooling
elements ... in
materials such as
Silicon, Hyaline
Quartz .
• Medical
industry:
joints, dental
crowns ...; in
various
ceramic
materials such
as Zirconia,
Alumina ...
• Optical industry:
concave and convex
lenses, mirrors ...; in
materials such as
Sapphire, Silicon,
Zerodur and various
glasses.
• Various: anti-wear guides,
pyrometry, welding nozzles,
thermal insulators ...; also in
ceramic materials.
All these applications have one
element in common: the
superior properties of high
hardness, mechanical
resistance to wear, low
density, resistance to abrasion
at high temperatures, optical
capacities, etc.
video
 References
• https://es.wikipedia.org/wiki/Mecanizado_ultras%C3%B3nico
• https://www.interempresas.net/MetalMecanica/Articulos/10438-El-
mecanizado-por-ultrasonidos-rotatorio-y-el-mecanizado-mixto-
fresado-laser.html
• https://www.interempresas.net/MetalMecanica/Articulos/14736-
Mecanizado-por-ultrasonidos-rotatorio-de-ceramicas-tecnicas-
estudio-del-proceso.html
• https://www.youtube.com/watch?v=fEvo5jarIW4
WATER JET CUTTING - ABRASIVE
 History
Dr. Norman Franz was
looking for new ways to
saw trees and transform
them into woods, he
becomes the first person
to study ultra high
pressure (UHP) as a
cutting tool.
 Operation
In general, this method works by forcing a certain
flow of highly pressurized water through a hole of
a very small diameter (nozzle), thus forming a
thin jet of very high speed. This jet impacts the
material with great force in a very small area,
which causes small cracks that with the
persistence of the impact of the jet "erodes" the
material, so we talk about "micro-erosion".
 System with water and
abrasive
There are two systems that use the
principle described above, the one that
uses only water and is used to cut all
kinds of soft materials, such as: wood,
food, plastics, etc. And the other system
of similar characteristics but that only
differs in the entry of an abrasive to the
jet, to allow the cutting of hard materials
such as: steels, titanium, alloys, etc.
 The Method on which the cut is based
Researchers of this subject have relied on the fundamental laws of
physics and fluid mechanics to interpret the phenomena that
occur here. For example, the jet impacts the material with a
certain Kinetic energy Ea and leaves the material with an Eex.
energy, which must be less than the initial one for the cut to occur.
The difference of these two energies is the dissipated energy Edis.,
product of impact, friction, etc., in the cut.
Edis = Ea - Eex (1)
Critical pressure. pressure between the success of the cut and the
failure of the cut.
 Pressure Generator Systems
• There are two main systems in place to generate the necessary
pressure
• Plunger pumps
• The so-called "pressure intensifier."
 Plunger pumps
They usually have three plungers connected
to a crankshaft and powered by an electric
motor. They can generate low and medium
pressures (up to 344 Mpa in recent designs)
without problems.
Advantage. is very efficient in the above
pressures.
Disadvantage. is that on these pressures it
becomes unsafe and produces significant
variability in the delivery flow.
 El llamado “intensificador de presión”.
It consists mainly of a cylinder with difference in diameters and a piston with equal
difference. The normal pressures they can generate are above 400Mpa and have
reached 690Mpa on some modern equipment.
Advantage. it lies in the high pressure it can generate and that it can feed several
injectors simultaneously.
Disadvantage. its low efficiency due to the hydraulic system it has, since it loses
power due to the heat it needs to dissipate through an exchanger system, in
addition to needing a pressure accumulator due to its great delivery variability.
WATER CHORO WITH ABRASIVE
 Abrasive
• What is an abrasive material? This is called
any type of mineral substance used in artisanal
and industrial processes to work with other
materials or pieces determined by different
mechanical processes, in order to give it
another finish, texture or shape.
• How do they act? Abrasive products act by
ripping material from the substrate by friction.
Examples of abrasive materials
The most commonly used abrasives are:

o Garnet
o Aluminium Oxide
o Olivine
o Silica Sand
 Equipment
There is currently a wide variety
of equipment on the market,
which allow a large number of
work to be carried out. Small
sized equipment to perform very
precise and delicate work,
medium-sized equipment for
small industries and large
equipment to meet high job
demands.
 o No abrasive
o Rubber
Applications o Vehicle upholstery
o Polypropylene
o Carton
o Paper
o Gum
o Fiberglass
o Abrasive
o Carbon steel
o Aluminum
o Titanium
o Brass
o Stainless steel.
 Advantages and Disadvantages of cutting
with water run – abrasive
oAdvantages. oDisadvantages.
oIt does not produce heat and is a oIn materials of large thicknesses
very environmentally friendly and high hardness, the time
process since it does not generate required to be cut can be very long.
pollution or gases.
oAs there are no cutting tools there
is no problem of wear of it.
oExcellent quality cut.
oThe same machine can cost a
variety of materials.
oThere is no heat material
deformation.
VÍDEO 1
VÍDEO 2
Referencias
• https://prezi.com/82zephnniypp/maquinado-por-chorro-de-agua-y-
abrasivo/
• https://es.slideshare.net/DiegoEVR/materiales-abrasivos-31601354
GRACIAS POR SU ATENCIÓN
ELECTROCHEMICAL
MACHINING (ECM)

Tomado de https://www.google.com/search?q=mecanizado+electroquimico+PIESAS
History
• Michael Faraday discovered the principles of anode metal machining and has
been considered the father of the expanded science of electro-magnetism ever
since. His first metallurgical investigations from 1818 to 1824 brought forward the
events that have led to the widespread use of steel alloys today.
• Electrochemical Machining (ECM) as a technological method, originated from the
electrolytic polishing process that was developed in 1911 by the famous Russian
chemist E. Shpitalsky. However, the modern history of electrochemical machining
(ECM) was traced from the Gussef patent in 1929, a leading visionary invention
that fairly accurately captures the operating characteristics of the ECM
procedure. What the Russian researcher did was develop the first procedure for
machining metal anodically, and it left him a special place in the history of ECM.
• In the 1960s and 1970s, technology generated growing interest, especially in
Western Europe and the Soviet Union. The first industries to augur potential and
initiate technological exploration were the Aerospace (eg gas turbines) and Tool
Manufacturing industries.
What is the ECM?
ECM corresponds to the English initials of electrochemical metal
machining and, as opposed to erosion, it is a smooth
electrochemical removal of material without spark formation. For
this, the positive part is polarized as an anode and the negative
tool as a cathode by means of a direct or pulsed current source.

Copiado de https://www.google.com/search?q=maquinado+electroquimico&rlz
Tomado de https://www.google.com/search?q=electrolisis&tbm Copiado de https://www.google.com/search?q=maquinado+electroquimico&rlz
Advantage
1. There are no thermal changes in the piece
2. They produce pieces with very complex geometry.
3. Very tight tolerances
4. No burr
5. Does not cause tool wear
6. Hard and soft materials are machined just as easily
7. There are no mechanical efforts
Disadvantages
• 1. The design and construction of the cutting tool can be complicated
and somewhat expensive
• 2. A large amount of electrical energy is consumed
• 3. Cannot obtain lower living angles
Components of the process
• 1. Machine
• 2. Electro liter
• 3. Power supply
• 4. Electrode or tool
• 5. Processing part (anode)
• 6. Electrolyte circulation system
Parameters
• Continuous voltage from 6 to 35 V
• Current from 10 to 10,000 A
• Current density of 2.3 to 3.1 A / mm2
• Penetration rate of up to more than 2.5 mm / min in hard alloys
Examples of work
• 1. Forgings
• 2. Turbine wheels
• 3. With integrated blades
• 4. Hard and resistant materials
• 5. Deep and shallow holes
• 6. Various profiles
• 7. Roughing all kinds of fish
Bibliografía
• http://electrochemicalmachining.com/es/el-proceso/historia-del-
procedimiento
• https://prezi.com/m3ydj0xaxid6/mecanizado-electroquimico/
• https://www.emag.com/es/tecnologias/ecm-mecanizado-
electroquimico-de-metales.html
Links para mas informacion
• https://www.youtube.com/watch?v=rb8yyGFAons
• https://www.youtube.com/watch?v=HmxSTfzKKxc
• https://www.youtube.com/watch?v=0_Ha_cfCDCg
• https://www.youtube.com/watch?v=i-0aEPtEzwY