Assignment

Advance Manufacturing Processes

By Vaibhav M.
Enroll No. 171E021
May 8, 2020
Que 1) Explain the nontransferred and transferred mode of plasma arc.
What are the advantages of each?
Ans. The plasma arc welding is method wherever a coalescence is gener-
ated with the temperature which is developed from a special setup between a
tungsten alloy electrode and the water-cooled nozzle (Non transferred ARC
) or between a tungsten alloy electrode and the job (transferred ARC). In
this type of winding, there are three types of gas supplies being utilized
namely plasma gas, shielding gas, and a back-purge gas. Plasma gas sup-
plies throughout the nozzle turn into ionized. The shielding gas supplies
throughout the external nozzle and protects the join from the environment.
Back-Purge gas is mainly used when particular materials are being used.

Plasma ARC Welding Types

1) Transferred PAW
The transferred PAW method uses direct polarity DC current. And in this
method, the tungsten electrode can be allied to the –ve terminal and the
metal can be allied to the +ve terminal. The arc produces among tungsten
electrode as well as work portion. In this kind of method, both arc and
plasma moved toward the work portion, which will enhance the heating ca-
pacity of the method. This type of PAW can be used to join solid sheets.
2) Non-transferred PAW
The Non-transferred PAW method used direct polarity DC current. And
in this method the tungsten electrode can be connected to the –ve and the
nozzle can be connected to the +ve pole. The arc generates among the
nozzle as well as tungsten electrode within the torch, which will enhance
the ionization of the gas within the torch. And the torch will transfer the
ionized gas for further procedure. This type of PAW can be used to join
thin sheets.

Advantages of PAW
• Power consumption is low

• Welding speed is high, so it can simply utilize to join thick and hard
workpieces.

• Penetration rate and strong arc are high.

• It can function at little amperage.

• The arc arrangement doesn’t affect by the distance among tool as well
as the workpiece.

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 • By using this method, the more steady arc can be produced.

Disadvantages of PAW

• The process is noisy.

• Equipment cost is high.

• High expertise labor required.

• Radiation is more.

Applications of PAW

• PAW can be used in industries like aerospace as well as marine

• PAW is used to join stainless tubes and pipes

• This type of welding is mostly applicable for electronic industries.

• PAW is mainly used to fix tools, mold and die.

• PAW is used to coating otherwise welding on the turbine blade.

Que 2) Make a comparison between LBM and EBM processes on the basis
of their applications and limitations.
Ans. Electron Beam Machining – Advantages and Limitations
EBM provides very high drilling rates when small holes with large aspect
ratio are to be drilled. Moreover it can machine almost any material irre-
spective of their mechanical properties. As it applies no mechanical cutting
force, work holding and fixturing cost is very less. Further for the same
reason fragile and brittle materials can also be processed. The heat affected
zone in EBM is rather less due to shorter pulses. EBM can provide holes of
any shape by combining beam deflection using electromagnetic coils and the
CNC table with high accuracy. However, EBM has its own share of limita-
tions. The primary limitations are the high capital cost of the equipment and
necessary regular maintenance applicable for any equipment using vacuum
system. Moreover in EBM there is significant amount of non-productive
pump down period for attaining desired vacuum. However this can be re-
duced to some extent using vacuum load locks. Though heat affected zone
is rather less in EBM but recast layer formation cannot be avoided.

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Applications

• Drill fine gas orifices less than 0.002 mm in space nuclear reactors,

• turbine blades for supersonic aero-engines.

• To produce wire drawing dies, light-ray orifices and spinnerets to pro-

duce synthetic fibres.

• Produce metering holes in injector nozzles in diesel engines

Laser Beam Machining – Limitations

• High initial capital cost

• High maintenance cost

• Not very efficient process

• Presence of Heat Affected Zone – specially in gas assist CO2 laser

cutting

• Thermal process – not suitable for heat sensitive materials like alu-
minium glass fibre laminate.

Applications

• Material removal – drilling, cutting and tre-panning

• Welding

• Cladding

• Alloying

Drilling micro-sized holes using laser in difficult – to – machine materials is

the most dominant application in industry. In laser drilling the laser beam
is focused over the desired spot size. For thin sheets pulse laser can be used.
For thicker ones continuous laser may be used.

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Que 3) Describe the mechanism of material removal of EBM process with
suitable diagram.
Ans. Working:

• First electron gun produces high velocity electron particles. These

electron particles move towards anode which is placed after cathode
tube.

• Now this high intense electron beam passes through magnetic lenses.
There are a series of lenses which take care of only convergent electron
passes through it. It absorb all divergent electron and low energy
electron. It provides a high quality electron beam.

• This electron beam now passes through electromagnetic lens and de-
flecting coil. It focus the electron beam at a spot.

• The high intense electron beam impinges on the work piece where
kinetic energy of electrons convert into thermal energy.

• The material is removed from contact surface by melting and vapor-

ization due to this high heat generated by conversion of kinetic energy
into thermal energy. This whole process take place in a vacuum cham-
ber otherwise these electron collide with air particle between path and
loses its kinetic energy.

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Que 4) Discuss the factors that influence the quality of cut in PAM.
Ans. Operating Parameters
Quality of cut and metal removal rate are largely dependent upon proper
attention to operating variables. Several factors contribute to the quality
and speed of cuts made by the plasma arc process, including cutting-tip
nozzle selection, power level, gas type and mixture, gas flow rate, traverse
speed, standoff distance, thickness of material, type of materials, impinge-
ment angle, and equipment design.
• Nozzle size: The highest quality plasma cut is usually obtained when
maximum thermal intensity is used. To achieve this, the smallest, or
next to the smallest, nozzle size that is capable of operating at a power
level suitable for the speed and thickness involved is used. Nozzle size
for cutting usually ranges from 0.80 to 6.30 mm in diameter.
• Power: Direct current up to 200 kW and 50-1000 A is employed in
plasma arc cutting operations.
• Gas mixture composition: A proportion of 10
• Gas flow rate: For any particular nozzle size, an increase in plasma
gas (primary) flow permits an increase in current. This increases the
power density of the flame and permits greater speed with less taper
on the kerf walls. Primary gas flow rates usually range between 0.40-
5.60 m3 /hr. Secondary gasses are pressurized to flow at up to 11.3
m3 /hr.
• Standoff distance: Due to the columnar shape of the plasma jet, a wide
range of tip-to-workpiece spacing is allowable. This permits machine
cutting along warped or irregular surfaces. General consideration in-
clude:
– Better quality cuts usually result from a short standoff distance
since arc divergence is less and the thermal intensity of the arc is
greater.
– Excessively close standoff distance can promote arcing due to the
accumulation of slag drops on the tip.
– Increased power input is necessary when the standoff distance is
great.
– Standoff distance can range from 6.5-76.2 mm

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Que 5) Explain the working principle of wire-EDM. Find the condition for
maximum power delivery to the discharging circuit in EDM.
Ans. CNC wire cut EDM machine puts impulse voltage between electrode
wire and workpiece through impulse source, controlled by servo system, to
get a certain gap, and realize impulse discharging in the working liquid be-
tween electrode wire and workpiece. Numerous tiny holes appears due to
erosion of impulse discharging, and therefore get the needed shape of work-
piece. Electrode wire is connecting to cathode of impulse power source, and
workpiece is connecting to anode of impulse power source. When workpiece
is approaching electrode wire in the insulating liquid and gap between them
getting small to a certain value, insulating liquid was broken through; very
shortly, discharging channel forms, and electrical discharging happens. And
release huge high temperature instantaneously, up to more than 10000 de-
gree centigrade, the eroded workpiece is cooling down swiftly in working
liquid and flushed away.

Three basic conditions that wire cut EDM work correctly:

1. The gap between electrode wire and workpiece should be certainly main-
tained in a required range. Within this range, not only impulse power can
break through insulating liquid to create spark discharging, but also the
eroded workpiece can be flushed away after discharging process. If gap is
too big, insulating liquid can’t be break through,, and there will be no spark
discharging; if gap is too small, short circuit is easy to happen, no spark
discharging neither.
2. The procedure should happen in the liquid with insulate capacity, for
example saponification and deionized water, the liquid could act as medium
of discharging channel and provide cooling and flushing.
3. Electrical discharging should be short time impulse discharging,. As
with short discharging time, the released heat won’t affect inside material of
workpiece, and limits energy to a tiny field and keep characteristics of cool
machining of wire cut EDM machine.

Part 2
Charging voltage and charging current:
Vo − Vct
ict = (1)
Rc
dVct
ict = C (2)
dt
where, Vo is the supply voltage, and Vct is the charged voltage of the con-

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denser at time t. Rc is charging resistance and C is capacitance of the
condenser.
so,
dVct 1
= dt (3)
Vo − Vct Rc C
Now, integrate both sides,
t
ln(Vo − Vct ) = − + K1 (4)
Rc C
where, K1 is a constant of integration. Use the boundary condition (Vct =
0att = 0) to evaluate K1 .It gives

K1 = lnVo (5)

Substitute the value of K, in Eq. 4 and simplify to get

 
Vct = Vo 1 − e−t/Rc c (6)

The time required by the condenser to attain 0.638 times of its charging
voltage (= 0.638Vo ) is called “ time constant” (τ = Rc C). Substitute the
value Vct from Eq. 6 in Eq. 1 and simplify to get Eq. 7.
Vo  −t/Rc c 
ict = e (7)
Rc
The energy delivered to the discharging circuit at any time t is given by

dEn = ict Vct dt

Substituting the values of Vcl and icl from Eqs. 6 and 7 respectively in the
above equation, we get
Vo  −t/Rc c   
dEn = e Vo 1 − e−t/Rc c (8)
Rc
Integrate Eq. 8 to get

V2 τ
 
En = o −τ e−t/τ + e−2t/τ + K2 (9)
Rc 2

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where, t = Rc C. K2 is a constant, and can be evaluated by using the
boundary condition En = 0 at t = 0. Substitute the value of K2 in 9 to get

V 2 τ 1 1 −2x
 
En = o + e − ex (10)
Rc 2 2
Suppose the energy En is delivered to the discharging circuit For time τc = t
then the average power delivered Pavg is given by

En V 2 1 1 −2x
 
Pavg = = o + e − ex (11)
τc Rc x 2 2

where, x = τc /τ . The condition for the maximum power to be delivered to

the discharging circuit is given by
dPavg
=0 (12)
dx
After solving Eq. 12, we get x = 1.26. Substitute this value of x in Eq. 6.

Vct = Vo (1 − e−1.26 ) ≈ 0.72Vo (13)

Que 6) Explain the following processes including material removal mecha-

nism, machining setup and their applications:
(a) Ion beam machining (b) Chemical Machining
Ans. (a) Ion beam machining
Ion-beam machining or etching is generally a surface finishing process in
which the material removal takes place by sputtering of ions. The process
is different from electric discharge, electron beam, laser and plasma arc ma-
chining in that the process does not depend on heating of the workpiece to
the point of evaporation.
This sputter etching mechanism is very simple. It consists in bombarding the
work with accelerated ions which collide with the surface atoms of the work.
Each bombarding ions, as a result of collisions, dislodges surface atoms by
transferring kinetic energy from itself to the atoms of the surface layer.It
consists of an electron gun which discharges free electrons into a chamber
filled with argon gas. The gas is then ionized by the electrons. The top of
the chamber is called an Ion-Beam generating apparatus. At the other end,
the workpiece is fixed to a table which can be oscillated and rotated so that

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different points on the work surface can be subjected to ion-beam.
Accuracy
Practical etching rates vary up to 2000 A (2 x 10-4 mm) per min. The
accuracy of the etching process is considerably high mainly due to the small
amount of material removal. Tolerances in the vicinity of + 50 Å (+ 5 x
10-mm) are possible.
Applications of Ion-Beam Machining
It is applied mostly in micro-machining (etching) of electronic components
like computer parts, figuring optical surfaces and for the precision fabrica-
tion of fine wire dies in refractory materials. Typical materials that can
be etched include glass, alumina, quartz, crystals, silica, agates, porcelain,
cermets. and numerous metals and oxides.

Advantages

• The process is almost universal.

• No chemical reagents or etching compounds are required.

• There is no undercutting as with another chemical etching process.

• Etching rates are easily controlled.

Disadvantages

• It is relatively expensive.

• Etching rates are slow.

• Although virtually no heat is generated there is little possibility of

some thermal or radiation damage.

(b) Chemical Machining

Working Principle of CHM
The main working principle of chemical machining is chemical etching. The
part of the workpiece whose material is to be removed, is brought into the
contact of chemical called enchant. The metal is removed by the chemical
attack of enchant. The method of making contact of metal with the enchant
is masking. The portion of workpiece where no material is to be removed,
is mashed before chemical etching
Process Details of CHM

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Cleaning
The first step of the process is a cleaning of workpiece, this is required to
ensure that material will be removed uniformly from the surfaces to be pro-
cessed.
Masking
Masking is similar to masking action is any machining operation. This is
the action of selecting material that is to be removed and another that is
not to be removed. The material which is not to be removed is applied
with a protective coating called maskant. This is made of a materials are
neoprene, polyvinylchloride, polyethylene or any other polymer. Thinkers
of maskent is maintained upto 0.125 mm. The portion of workpiece having
no application of maskent is etched during the process of etching.
Etching
In this step the material is finally removed. The workpiece is immersed in
the enchant where the material of workpiece having no protective coating is
removed by the chemical action of enchant. Enchant is selected depending
on the workpiece material and rate of material removal; and surface finish
required. There is a necessity to ensure that maskant and enchant should
be chemically in active. Common enchants are H2 SO4 , F eCl3 , HN O3 . Se-
lection of enchant also affects MRR. As in CHM process, MRR is indicated
as penetration rates (mm/min).
Demasking
After the process is completed demasking is done. Demasking is an act of
removing maskent after machining.

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