Aditya College of Engineering .

Madanapalle

MACHINE TOOLS – Part - 2

( UBMTS )

By:
Amar Gandhi
Faculty ,Dept. of Mechanical Engineering
 Unit Built Machine Tools (UBMTS)
 Unit built machine tools are custom built with modular type
construction.
 Different functional parts of the machine like
spindle head, feed units, slide ways, facing units,
tool turrets, etc are available as standard parts and these
modules are assembled to obtain the required configuration.
These machines may have multiple drilling heads, milling
heads, tool turrets etc, performing machining simultaneously
on complex parts like automobile rear axle, chassis etc.
Multiple Spindle :
 Machining heads and multiple spindle heads are
specialized tool holders that mount on machine tool
spindles.
 Multi-spindle heads carry multiple tools at the same time
for performing simultaneous machining operations.
 Most machining and multiple spindle heads cannot be
shared, except in the case of identical-hole patterns in a
family of parts.
 Machining and multiple spindle heads are designed for
use with most drilling machinery and can double or triple
drilling operations by simultaneously drilling,
countersinking, reaming, or tapping two or more holes in
one operation.
 Hydraulic power unit :(Hydraulic Power Pack)

 Hydraulic power units (It is a self-contained system that

generally includes a motor, a fluid reservoir, and a pump.
 It works to apply the hydraulic pressure needed to drive
motors, cylinders, and other complementary parts of
given hydraulic system.
 Non-conventional Machining Processes
 It is similar to conventional process but the cutting
tool do not touch the work piece while removing
excesses material from it .
 Classification Of Non-conventional Processes
 1.Mechanical processes
a) Ultrasonic machining (USM)
b) Abrasive jet machining (AJM)
2. Thermal processes
a) Electric discharge machining (EDM)
b) Laser beam machining (LBM)
3. Electrical processes
a) Electro - chemical machining (ECM)
b) Electro – chemical grinding (ECG)
4. Chemical processes
a) Chemical Milling (CHM)
b) Chemical Blanking (CHB)
Ultrasonic Machining (USM)
Ultrasonic Machining (USM)
 Ultrasonic machining removes material in the
form of chips, and has the advantage that it is
suitable for conducting as well as non conducting
materials.
 Principle:
WORKING PRINCIPLE :
 In ultrasonic machining metal removal is effected with the
help of abrasive grains which are made to impinge
repeatedly upon the work piece by a tool vibrating at
ultrasonic frequency in the range of 15-30 KHz.
 The amplitude of vibrations is very small ranging from 0.1
mm to 0.03 mm.
 The abrasive grains are mixed with fluid (usually water )
to form slurry and are carried to the gap between work
piece and tool.
Ultrasonic Machining Equipment :

 Ultrasonic Machining Equipment :

1. Oscillator with out put amplifier
2. Transducer
3. Tool holder
4. Tool
5. Work fixture
6.Circulating system of abrasive
Working :
 Working :
 The oscillator and amplifier coverts 50 Hz power supply
into high frequency (15 KHz to 30KHz ) power which
intern is converted into mechanical vibrations with the
help of magneto strictive or piezo-electrical transducer.
 The tool is made from tough material and is connected to
the tool holder which is attached to transducer.
 Steel is cold rolled state is the best material for the tool ,
because the tool wear is small ,metal removal rate is high
and can be manufactured economically.
 The cross section area of the tools ranges from 0.02mm to
80 mm.
 A work fixture is provided on the work table to hold the
work piece in position.
Contd…
 The abrasive particles are mixed with water to form slurry,
and the abrasive slurry must be continuously circulated
between the tool and work piece in order to bring fresh
grains into the action at work- tool gap.
 Slurry acts as a coolant and dissipate heat from the tool
and work piece.
 The most commonly used abrasives are boron carbide
,silicon carbide and aluminum oxide. Boron carbide is
economical and gives good machining rates.
 Metal removal rate is high with coarse grains while fine
grades are used for finishing.
 Advantages:
✓ No heat is generated during machining.
✓ It has an ability to machine very hard materials.
✓ Good surface finish and high accuracy may be easily
obtained.
✓ Complex shapes can be obtained.
✓ Conducting as well non conducting materials can be
machined.
 Disadvantages:
➢ Low metal removal rate.
➢ High rate of tool wear.
➢ The power consumption is high.
➢ Abrasive slurry need to be replaced periodically.
 Applications :

❖Making wire drawing dies of tungsten and diamond.

❖Drilling non circular holes in hard materials.
❖Micro-drilling of holes up to 0.1mm diameter.
❖Welding , cleaning and de-burring operations.
❖Non – destructive testing.
ABRASIVE JET MACHINING (AJM)
In abrasive jet machining stream of gas mixed with fine
abrasive particles is directed to the work piece by suitable
nozzle .
The material is removed due to impingement of abrasive
particles .
PRINCIPLE:
The high velocity jet of gas containing abrasive particles is
directed on to the work surface through nozzle.
It causes the indentation of work piece which results in the
removal of work piece material.
Working :
 The abrasive particles (aluminum oxide ,silicon carbide,
sodium bicarbonate)and the carrier gas (air, carbon dioxide
and nitrogen) are thoroughly mixed in the mixing chamber
and a stream of abrasive mixed gas passes through a nozzle
on to the work piece.
 Due to repeated impact of abrasive particles, small particles
from work piece is removed and fresh surface is exposed to
the jet.
 The air is mostly used as carrier gas, and it must be filtered
to remove water ,oil and other contaminations.
 The nozzle pressure varies between 0.2 to 1.4 Mpa.
Working :
 Advantages :
 Can cut holes of intricate shapes in hard materials
 Good surface finish can be obtained
 Power consumption is low
 Capital cost is low
➢ Limitations :
 Low metal removal rate
 Machining accuracy is poor due to stray marks
 Nozzle wear is high
 Difficult to machine soft materials
 Applications:
✓ It is used in engineering applications such as cutting,
grooving , de-burring and cleaning of hard and brittle
materials.
✓ The process can also be used to machine thin sections and
intricate shapes in hard and brittle materials.
Electric Discharge Machining (EDM)
 Electric Discharge Machining (EDM)
Electrical discharge machining is also known as spark
erosion.
With the process soft or extremely hard work pieces such as
tungsten carbides can be machined.
Two forms of electric discharge machining are
1. EDM 2. wire EDM
❑Process description :
 The work is Placed in a tank, containing dielectric fluid and
the tool is mounted above the work piece.
 The constant gap between tool and work piece is maintained
by servo-system.
 The dielectric fluid is circulated through a pump at a pressure
of 0.2 N/mm.
Working Principle :
 In this process the metal is removed by intense heat of
electric spark .
 The tool and the work piece are submerged in dielectric
fluid.
 The spark discharges (flow of stream of electrons) are
created by maintaining sufficient potential difference
between tool and work piece, separated by a dielectric in a
very small gap.
 A large number of electrons emitted from tool
(cathode)impinges on work material (anode) and thus
develop a very high temperature.
 This temperature is sufficient to melt and even vapourise a
part of the metal.
Dielectric :
➢ The dielectric fluid commonly used are paraffin , kerosine
and transformer oil. Dielectric fluid should posses the
following characteristics.
▪ Must remain non conducting until critical voltage is
reached.
▪ Non- toxic and non corrosive
▪ Latent heat of vapourisation must be high
▪ High flash point
▪ Must have low viscosity to flow easily
❖The dielectric fluid has the following functions
➢ It concentrates the energy to a very narrow region
➢ It acts as a coolant and carries away eroded metal
EDM equipment:
1. work table
2. Tool holder
3. Servo control system
4. Dielectric tank
5. D.C. power
Working :
➢The work is placed in a tank, containing dielectric fluid,
and the tool is mounted above the work piece.
➢The constant gap between tool and work piece is
maintained by servo-system.
➢The dielectric fluid is circulated through a pump.
➢ The work is connected to positive terminal to form
anode and the tool is made cathode .
➢The current is varied within a wide range from 0.5to
400amps,at 40-300 D.C volts.
➢The circuit consists a capacitor in parallel with spark
gap.
Contd…
➢ At low voltage the dielectric acts as an insulator i.e spark
gap behaves as an open circuit.
➢ The spark generates localized heat which melts and
vapourise the metal to form crater on work surface.
➢ The condenser discharges , the de-ionizes of the dielectric
re establishes the insulating film, the current flow drops to
zero and the capacitor can be given charging again.
➢ The cycle is repeated at a frequency of 200-500000 Hz.
➢ Material removal is not confined to the work piece, the
tool is also wear out.
➢ Discharge is always takes place at the closest gap,
➢ The electrode is fed continuously to cut the desired shape.
 Advantages:
 Hardness is never a limitation for machining
 High degree of surface finish can be obtained
 The tool and work are not in contact , and no cutting force
acts upon the work
 Any complicated shapes can be produced on the work
piece
Disadvantages:
✓ The metal removal rate is low
✓ Only suitable for electrically conducting metals
✓ Excessive tool wear
✓ High specific power consumption
 Applications:

The process can be used economically for:

➢ Machining dies for forging, blanking, extrusion
➢ Drilling fine deep holes in fuel injector nozzle
➢ Machining hard alloys
➢ Producing intricate and irregular shaped profiles.
Laser Beam Machining (LBM)
Laser Beam Machining (LBM)
 Laser (light amplification by stimulated emission of
radiation) can be used as a tool for material processing
(welding, cutting , scribing and drilling etc.) laser
action can be obtained over the entire frequency
ranges from ultra violet to infrared.
 Laser commonly used in metal working have wave
lengths ranging from 0.6 to 10.6 mm.
 Principle of operation :

 A laser is a device that converts electrical energy into a highly

coherent light beam.
 The output from the laser is monochromatic light (light with a
single wave length ) which can be focussed to an extremely
high intensity by an optical system.
 This high intensity beam melts and vapourise the material to be
machined.
Process Description :
 The set up consists of a pair of mirrors which are placed
facing each other with laser in between them.
 One of them is perfectly reflecting while the other is
partially reflecting .
 There are several types of lasers (carbon dioxide gas,
liquid and solid state lasers) used for different purposes.
 The energy to the laser is supplied by flash lamps filled
by xenon, argon or crypton gas .
 The lamp is placed close to the laser so that maximum
amount of energy can be absorbed by the laser materials.
 The output from the laser is a monochromatic light beam
which can be focussed on the work piece by an optical
system .
 The high intensity beam melts and vapourise the material
to be machined.
 Advantages :
 Suitable for any materials due to high energy density
 Can be used for machining inaccessible areas
 Minimum heat affected zone
 No distortion of work
 Dissimilar metals can be welded easily
Disadvantages :
 Material removal rate is low
 Capital and operative cost is high
 High input energy is required
 Applications :
 LBM is a micromachining operation which can be used
for drilling , scribing, cutting ,and shaping .
 Holes as small as 0.025mm can be produced.
Chemical Machining
 Chemical Machining :
 Certain chemicals attack metals and etch them, there by
removing small amounts of materials from the surface
based on this, chemical machining was developed where
by the material is removed by using chemical re-agents or
etchants.
 Chemical machining is used for engraving metals and
hard stones. Production of printed circuit boards and
micro processor chips.
 Chemical machining may be classified as :
1) Chemical milling
2) Chemical blanking
chemical milling is used for producing shallow cavities
on plates , sheets , forgings and extrusion.
chemical blanking is similar to blanking of sheet metal
with the exception that the material is removed by
chemical dissolution rather than by shearing
 Chemical Milling :
 Chemical milling (CHM) involves removing the work
piece material by chemicals.
Principle of chemical milling :
➢ In chemical milling the part to be machined is immersed
in a chemical etchant that removes the desired metal.
➢ The areas not subjected to machining are protected by the
materials resistant to reactive solution.
 Process:
▪ The important features of chemical milling are shown
in fig.
▪ In chemical milling the work piece is first thoroughly
cleaned.
▪ All oils and grease must be completely removed and
dried.
▪ Portions which are not to be machined are coated or
covered with a materials resistant to the chemicals.
▪ These chemical resistant materials are called
Maskants and include materials like vinyl plastics
and neoprene rubber with a resin base.
▪
Contd…

▪ After maskant coating is cured , the maskant is cut and stripped

off over the portions to be machined with the help of a scribing
knife and a template.
▪ The work piece is then dipped completely into a tank
containing chemical etchant.
▪ This etchant attach exposed surface and dissolve away the
metal.
▪ After removing the material to a required depth, the work piece
is removed from the bath, de-masked and cleaned thoroughly.
▪ ACCURACY:
❖ Under optimum conditions, CHM is capable of producing
tolerance with in 0.01mm.
 Applications :
❖It is used in production of printed circuit boards,
engraving, machining air craft parts.
❖Advantages:
o The process is very efficient for making complex
surface on very large work piece .
o A number of parts or surfaces of a part may be
machined at a time.
o Delicate parts may be machined with out distortion.
o Disadvantages:
▪ Safety in handling and storing chemicals is essential.
▪ Needs adequate ventilation and good circulation of air.