Non Traditional Machining Processes

(Thermal & Chemical)

Manufacturing Processes
ME-3401
 Lecture Outline
• NTM Processes Using Thermal Energy
– Electric Discharge Machining
– Electric Discharge Wire Cutting
• NTM Processes using Chemicals
– Mechanics and Chemistry of Chemical Machining
– Masking Methods
• The cut and peel
• Photographic resist method
• Screen resist method
– Etchant Material
– Undercut
 Solidification processes

Particulate processing
Shaping processes
Deformation processes

Material removal
Processes
operations Property enhancing
Heat treatment
processes
Cleaning & surface treatment
Surface enhancement &
protection Processes
Manufacturing Coating and deposition processes
processes
Welding
Permanent joining
Brazing and soldering
processes
Assembly Adhesive bonding
operations
Threaded fasteners
Mechanical fastening
Permanent fastening methods
 Turning and related operations

Drilling and related Operations

Conventional Machining
Milling Operations

Other Machining Operations

Grinding Operation
Material Removal Processes Abrasive Machining
Other abrasive Operations

Mechanical energy processes

Electrochemical machining
Nontraditional Machining
Thermal energy process

Chemical machining
 NTM Processes Using Thermal Energy
Material removal processes based on thermal energy are
characterized by very high local temperatures—hot enough to remove
material by fusion or vaporization.
Because of the high temperatures, these processes cause physical
and metallurgical damage to the new work surface.
Processes of commercial importance are:
1. Electrical discharge machining (EDM)
2. Electrical discharge Wire Cutting (EDWC)
3. Electron beam machining
4. Laser beam machining
Electric Discharge Machining (EDM)
 Electric Discharge Machining (EDM)
• EDM is one of the most widely used non-
traditional machining processes.
• The shape of the finished work surface is
produced by a formed electrode tool.
• The sparks occur across a small gap between
tool and work surface.
• The EDM process must take place in the
presence of a dielectric fluid, which creates a
path for each discharge as the fluid becomes
ionized in the gap.
• The discharges are generated by a pulsating
direct current (DC) power supply connected to
the work and the tool.
 Electric Discharge Machining (EDM)
• Once the power supply is turned on, thousands of DC impulses per
second cross the gap, begin the erosion process.
• The spark temperatures generated can range from 7760° to 11,649°
Celsius so that small portion of the workpiece is suddenly melted
and removed. The flowing dielectric flushes away the small particle.
• Two important process parameters in EDM are discharge current
and frequency of discharges. As either of these parameters is
increased, metal removal rate increases.
• Surface roughness is also affected by current and frequency. The
best surface finish is obtained in EDM at high frequencies and low
discharge currents
 Electric Discharge Machining (EDM)
• Electrodes are made of graphite, copper, brass, copper tungsten, silver
tungsten and other materials.
• The selection of the electrodes depends on the type of power supply circuit
available, the type of work material, and whether roughing or finishing is to
be done.
• Graphite is generally preferred for any applications because of its melting
characteristics. In fact it does not melt and vaporizes at very high
temperatures.
• Dielectric fluids used in EDM include hydro carbon oils, kerosene and
distilled water. The dielectric serves as an insulator in the gap except when
ionization occurs in the presence of a spark. Its other functions are to flush
debris out of the gap and to remove heat from tool and workpart
 Electric Discharge Machining (EDM)
• Applications of electric discharge machining include both tool fabrication
and parts production.
• Most of the tooling equipment's are made by EDM, including molds for
plastic injection molding, extrusion dies, wire drawing dies, forging dies
and sheet metal dies.
• EDM is also used for certain parts production. Examples include delicate
parts that are not rigid to with stand conventional cutting forces, hole
drilling where the axis of the hole is at an angle to the surface and
production machining of hard metals.
Electric Discharge Wire Cutting (EDWC)
Electric Discharge Wire Cutting (EDWC)
• Electric discharge wire cutting commonly called wire EDM is a special
form of electric discharge machining that uses small diameter wire as
the electrode to cut a narrow kerf in the work.
• The cutting action in wire EDM is achieved by thermal energy from
electric discharges between the electrode wire and the workpiece.
• The workpiece is fed continuously and slowly past the wire in order to
achieve the desired cutting path. NC is used to control the work part
motion during cutting.
Electric Discharge Wire Cutting (EDWC)
Electric Discharge Wire Cutting (EDWC)
• As it cuts, the wire is continuously advanced between a supply pool and a
take-up pool to present a fresh electrode of constant diameter to the work.
• As in EDM, wire EDM must also be carried out in the presence of
dielectric.
• This is applied by nozzles directed at the tool–work interface, or the
workpart is submerged in a dielectric bath
 Turning and related operations

Drilling and related Operations

Conventional Machining
Milling Operations

Other Machining Operations

Grinding Operation
Material Removal Processes Abrasive Machining
Other abrasive Operations

Mechanical energy processes

Electrochemical machining
Nontraditional Machining
Thermal energy process

Chemical machining
 Mechanics and Chemistry of Chemical
Machining
The chemical machining process consists of several steps.
The steps are:
1. Cleaning. The first step is a cleaning operation to ensure that material will
be removed uniformly from the surfaces to be etched.
2. Masking. A protective coating called a maskant is applied to certain
portions of the part surface.
Maskant materials include neoprene, polyvinylchloride, polyethylene, and
other polymers.
This maskant is made of a material that is chemically resistant to the
etchant (the term resist is used for this masking material).
It is therefore applied to those portions of the work surface that are not to
be etched.
 Mechanics and Chemistry of Chemical
Machining
3. Etching. This is the material removal step. The part is
immersed in an etchant that chemically attacks those
portions of the part surface that are not masked.
The usual method of attack is to convert the work material
(e.g., a metal) into a salt that dissolves in the etchant and is
thereby removed from the surface.
When the desired amount of material has been removed, the
part is withdrawn from the etchant and washed to stop the
process.
4. Demasking. The maskant is removed from the part.
The Chemical Machining Process
 Expected Learning
• NTM Processes Using Thermal Energy
– Electric Discharge Machining
– Electric Discharge Wire Cutting
• NTM Processes using Chemicals
– Mechanics and Chemistry of Chemical Machining