PROSES MANUFAKTUR

Ultrasonic Machining
Plasma Arc Machining

ALEXANDER SEBAYANG, S.T., M.T.

 INTRODUCTION
Mechanical
Engineering

Design Manufacturing Thermal

Primary
Manufacturing

Secondary
Manufacturing
• What is Manufacturing?
INTRODUCTION
Types of Manufacturing Processes:
• Manufacturing processes can be broadly divided
into two groups
1. Primary manufacturing processes
2. Secondary manufacturing processes.
• The Primary manufacturing process provides
basic shape and size to the material as per
designer’s requirement. For example: Casting,
forming, powder metallurgy processes provide INTRODUCTION
the basic shape and size.
• The Secondary manufacturing processes provide
the final shape and size with tighter control on
dimension, surface characteristics etc. Most of
Material removal processes are mainly the
secondary manufacturing processes.
Material removal processes can be further divided
into mainly two groups
1. Conventional Machining Processes
2. Non-Traditional Manufacturing Processes
Examples of conventional machining processes
are turning, boring, milling, shaping,
broaching, slotting, grinding etc.
Examples of non conventional ( or also called non
traditional or unconventional) are
INTRODUCTION
1. Abrasive Jet Machining (AJM),
2. Ultrasonic Machining (USM),
3. Water Jet and Abrasive Water Jet Machining
(WJM and AWJM),
4. Electro-discharge Machining (EDM) ,
5. Electro Chemical Machining (ECM).
• Generally macroscopic chip formation by shear
deformation
• Material removal takes place due to application
of cutting forces – energy domain can be
CONVENTIONAL
classified as mechanical
• Cutting tool is harder than work piece at room
MACHINING
temperature as well as under machining
conditions
PROCESS
CONVENTIONAL
MACHINING
PROCESS
COMPARISON
Conventional
Generally macroscopic chip
formation by shear deformation. chip formation or even no chip
Chip Formation
Tool There may be a physical tool
present. for example a cutting
tool in a Lathe Machine,
Non Conventional
Material removal may occur with
formation may take place. For
example in AJM, chips are of
microscopic size and in case of
Electrochemical machining
material removal occurs due to
electrochemical dissolution at
atomic level
There may not be a physical tool
present. For example in laser jet
machining, machining is carried
out by laser beam. However in
Electrochemical Machining there
is a physical tool that is very
much required for machining.
 Conventional
Cutting tool is harder than work
piece at room temperature as
well as under machining
conditions
Characteristic of Tool
Material removal takes place due
to application of cutting forces –
energy domain can be classified
Material Removal Process as mechanical
Non Conventional
There may not be a physical tool
present. For example in laser jet
machining, machining is carried
out by laser beam. However in
Electrochemical Machining there
is a physical tool that is very much
required for machining.
Mostly NTM processes do not
necessarily use mechanical energy
to provide material removal. They
use different energy domains to
provide machining. For example,
in USM, AJM, WJM mechanical
energy is used to machine
material, whereas in ECM
electrochemical dissolution
constitutes material removal.
 Conventional Non
Conventional
Conventional Whereas
machining unconventional
involves the machining does
Tool Contact direct contact of not require the
tool and work – direct contact of
piece tool and work
piece.

Lower accuracy Higher accuracy

and surface and surface
Surface Finish finish. finish.
 Conventional Non Conventional
Suitable for every type of material Not Suitable for every type of
Material Economy economically. material economically
Tool life is less due to high surface Tool life is more
Tool Life contact and wear.

Material Wastage Higher waste of material due to Lower waste of material due to low
high wear. or no wear.
Noise Level Noisy operation mostly cause Quieter operation mostly no sound
sound pollutions pollutions are produced.

Cost Lower capital cost Higher Capital Cost

 Conventional Non
Conventional
Equipment Easy set-up of Complex set-up
Setup equipment. equipment.
Operator level Skilled or un- Skilled operator
skilled operator required.
may required
Process Generally they Generally they
are manual to are fully
operate. automated
process.
Efficiency They cannot be Can be used to
used to produce produce
prototype parts prototype parts
very efficiently very efficiently
and And
economically. economically.
Spare Parts Easily Available Not so easily
available
 ULTRASONIC MACHINING
• Introduction.
• Equipment.
• Tool Materials and Tool Size and Abrasive Slurry.
• Cutting tool system design
• Effect of parameter: Effect of amplitude and frequency and vibration.
• Effect of abrasive grain diameter.
• Effect of applied static load.
• Effect of slurry, tool and work material.
• USM process characteristics: Material removal rate, tool wear, Accuracy, surface finish, applications,
• Advantages & Disadvantages of USM.
 What is the Difference between Frequency,
Wavelength and Amplitude?
 Frequency tells us how many waves pass
through a point at a second.
 Wavelength tells us the length of those waves.
 Amplitude tells us how big the wave is. INTRODUCTION
 In USM, abrasives contained in a slurry are
driven against the work by a tool oscillating at
low amplitude (25-100 microns) and high
frequency (15-30 kHz).
 The machining zone (between the tool and the
work piece) is flooded with hard abrasive
particles generally in the form of water based
slurry.
 As the tool vibrates over the work piece,
abrasive particles acts as indenter and indent
both work and tool material .
 Abrasive particles , as they indent , the work
PRINCIPLE
material would remove the material from both
tool and work piece.
 In Ultrasonic machining material removal is due
to crack initiation, propagation and brittle
fracture of material.
EQUIPMENT
• Ultrasonic Machining consists of :
1. High Power sine wave generator.
2. Magneto-strictive Transducer. EQUIPMENT
3. Tool Holder.
4. Tool.
 This unit converts low frequency (50 Hz)
electrical power to high frequency (20kHz)
High Power Sine
electrical power. Wave Generator
• The high frequency electrical signal is
transmitted to traducer which converts it into
high frequency low amplitude vibration.
• Essentially transducer converts electrical energy
to mechanical vibration. There are two types of
transducer used
1. Piezo electric transducer
2. Magneto-stricitve transducer.
 These transducer are made of nickel , nickel
alloy sheets.
 Their conversion efficiency is about 20-30%.
 Such transducers are available up to 2000
Watts.
 The maximum change in length can be achieved
is about 25 microns.
 The tool holder holds and connects the tool to
the transducer. It virtually transmits the energy
and in some cases, amplifies the amplitude of
vibration.
 Material of tool should have good acoustic
properties, high resistance to fatigue cracking.
 Due measures should be taken to avoid
ultrasonic welding between transducer and tool
holder.
 Commonly used tool holders are Monel,
titanium, stainless steel.
 Tool holders are more expensive, demand
higher operating cost.
 Tools are made of relatively ductile materials
like Brass, Stainless steel or Mild steel so that
Tool wear rate (TWR) can be minimized.
 The value of ratio of TWR and MRR depends on
kind of abrasive, work material and tool
materials.
 Mechanism of
Material Removal
The following are the Material Removal Models
used in USM
1. Throwing of abrasive grains.
2. Hammering of abrasive grains.
Material Removal
3. Cavitations in the fluid medium arising out of Models in USM
ultrasonic vibration of tool.
4. Chemical erosion due to micro –agitations.
• MRR increases with slurry concentration.
• Slurry saturation occurs at 30 to 40%
abrasive/water mixture.
• Material Removal rate drops with increasing
viscosity.
• The pressure with which the slurry is fed into Effect of Slurry,
the cutting zone affects MRR .
• In some cases MRR can be increased even ten Tool and Work
times by supplying the slurry at increased
pressure. Material
• The shape of the tool affects the MRR. Narrower
rectangular tool gives more MRR compared to
square cross section.
 Conical tool gives twice MRR compared to
cylindrical tool.
 The brittle behavior of material is important in
determining the MRR.
 Brittle material can be cut at higher rates than
ductile materials.
 Machining of cavities in electrically non-
conductive ceramics
 Used to machine fragile components in which
otherwise the scrap rate is high
 Used for multistep processing for fabricating
silicon nitride (Si3N4) turbine blades
 Large number of holes of small diameter could APPLICATIONS
be machined. 930 holes with 0.32mm has been
reported ( Benedict, 1973) using hypodermic
needles
 Used for machining hard, brittle metallic alloys,
semiconductors, glass, ceramics, carbides etc.
 Used for machining round, square, irregular
shaped holes and surface impressions.
 Used in machining of dies for wire drawing,
punching and blanking operations
 USM can perform machining operations like
drilling, grinding and milling operations on all
materials which can be treated suitably with
abrasives.
 USM has been used for piercing of dies and for
parting off and blanking operations.
 USM enables a dentist to drill a hole of any
shape on teeth without any pain
 Ferrites and steel parts , precision mineral
stones can be machined using USM
 USM can be used to cut industrial diamonds
 USM is used for grinding Quartz, Glass, ceramics
 Cutting holes with curved or spiral centre lines
and cutting threads in glass and mineral or
metallo-ceramics.
 It can be used machine hard, brittle, fragile and
non conductive material
 No heat is generated in work, therefore no
significant changes in physical structure of work
material
 Non-metal (because of the poor electrical
conductivity) that cannot be machined by EDM
ADVANTAGES
and ECM can very well be machined by USM.
 It is burr less and distortion less processes.
 It can be adopted in conjunction with other new
technologies like EDM,ECG,ECM.
 Low Metal removal rate.
 It is difficult to drill deep holes, as slurry
movement is restricted.
 Tool wear rate is high due to abrasive particles.
Tools made from brass, tungsten carbide, MS or
tool steel will wear from the action of abrasive
DISADVANTAGES
grit with a ratio that ranges from 1:1 to 200:1.
 USM can be used only when the hardness of
work is more than 45 HRC.