Roll no :17031A0335

1.Explain the principles and elements of EBM, also how the work table is protected from getting
damaged by electron beam?

Working Principle

In an electron beam machining, the electrons strike the workpiece with a high velocity. As
the electron strikes the workpiece, the kinetic energy of the electron changes into heat energy. The heat
energy so produced is used to melt and vaporize the materials from the w/p.

Construction of EBM :

It consists of an electron gun, diaphragm, focusing lens, deflector coil, work table, etc. enclosed in a
vacuum chamber, which carries a vacuum of the order 10-5 to IO-6 mm of mercury.

Electron-beam machining (EBM) is a process where high-velocity electrons concentrated into

a narrow beam that are directed towards the work piece, creating heat and vaporizing the material.
EBM can be used for very precise cutting or boring of a wide variety of metals. Surface finish is better
and kerf width is narrower than those for other thermal cutting processes.

EEBM process is best suitable for high melting point and high thermal conductivity materials.
 In an electron beam machining, the electrons strike the workpiece with a high velocity. As the
electron strikes the workpiece, the kinetic energy of the electron changes into heat energy. The heat
energy so produced is used to melt and vaporize the materials from the w/p. The whole process takes
place in vacuum.

2.Explain the production of laser beam and working principle of LBM Process?

Laser Beam Machining (LBM) is a form of machining process in which laser beam is used for
the machining of metallic and non-metallic materials. In this process, a laser beam of high energy is
made to strike on the workpiece, the thermal energy of the laser gets transferred to the surface of the
w/p (workpiece).

Principle of LBM:

It works on the principle that when a high energy laser beam strikes the surface of the
workpiece. The heat energy contained by the laser beam gets transferred to the surface of the w/p. This
heat energy absorbed by the surface heat melts and vaporizes the material from the w/p. In this way the
machining of material takes place by the use of laser beam.

How Laser is Produced

A high voltage power supply is applied across the flash tube. A capacitor is used to operate the flash
tube at pulse mode.

As the flash is produced by the flash tube, it emits light photons that contain energy.
This light photons emitted by the flash tube is absorbed by the ruby crystal. The photons absorbed by
the atoms of the ruby crystals excite the electrons to the high energy level and population inversion
(situation when the number of exited electrons is greater than the ground state electrons) is attained.

After short duration, this excited electrons jumps back to its ground state and emits a light photon. This
emission of photon is called spontaneous emission,

The emitted photon stimulates the excited electrons and they starts to return to the ground state by
emitting two photons. In this way two light photons are produced by utilizing a single photon. Here the
amplification (increase) of light takes place by stimulated emission of radiation.

Concentration of the light photon increases and it forms a laser beam.

100 % reflecting mirror bounces back the photons into the crystal. Partially reflecting mirror reflects
some of the photons back to the crystal and some of it escapes out and forms a highly concentrated
laser beam. A lens is used to focus the laser beam to a desired location.

3.Explain the working principle involved in plasma machining method?

Working principle of Plasma Arc Machining

PAM process uses ionized plasma to transfer heat. The plasma is obtained by forcing gas through an
electric arc generated between cathode and andode. The high temperature plasma jet melts the metal
and remove material from the workpiece.

In a plasma torch, known as the gun or plasmatron, a volume of gas such as H2, N2, 02, etc. is passed
through a small chamber in which a high-frequency spark (arc) is maintained between the tungsten
electrode (cathode) and the copper nozzle (anode), both of which are water-cooled.

4.Explain non-transferred and transferred modes of Plasma arc?

 Plasma arc welding is an arc welding process wherein coalescence is produced by the heat
obtained from a constricted arc setup between a tungsten/alloy tungsten electrode and the water-
cooled (constricting) nozzle (non-transferred arc) or between a tungsten/alloy tungsten electrode and
the job (transferred arc).

Hot ionized gases are commonly referred to as plasma. ... Ionized gas that conducts electricity
transfers an electric arc to the welding surface. The arc's extreme heat welds two metal pieces together.
Plasma arc welding is almost similar to the gas tungsten arc process.

Plasma is generated by subjecting a volume of gas to electron bombardment of an electric arc. The
anode heating due to direct electron bombardment plus convective heating from the high temp plasma
raises the matl to the molten point and the high velocity gas stream effectively blows the matl away.
5.Discuss in detail about the AJM process variables that influence the rate of material removal and
accuracy in the machining?

Process Parameters of Abrasive Jet machining (AJM) are factors that influence its Metal Removal
Rate (MRR). In a machining process, Metal Removal Rate (MRR) is the volume of metal removed from a
given work piece in unit time. ... Abrasive mass flow rate. Nozzle tip distance.

These factors are in turn affected by, •The abrasive Composition; strength; size; mass flow rate. The gas
Composition, pressure and velocity. The nozzle Geometry; material; distance to work; inclination to
work.

Explanation:

Materials like ceramics, glass, hard and super hard materials can be machined using Abrasive jet
machining. 5. In machining system of AJM, which is the medium of carrying the abrasive grains for
machining? Explanation: In AJM, different types of gases are used as the medium for carrying abrasives.

In AJM, it is considered that hard abrasive particles take part in material removal process, whereas
carrier gas helps to blow away removed particles from machining zone. ... Whereas, fine abrasives
reduce MRR but improve surface finish and accuracy.
6.Write the names of various elements of Abrasive Water Jet Machining (AWJM) and explain them in
brief?

Primary Components of the AWJM System

(i) Hydraulic pump.

A hydraulic pump is a mechanical source of power that converts mechanical power into hydraulic
energy (hydrostatic energy i.e. flow, pressure). It generates flow with enough power to overcome
pressure induced by the load at the pump outlet.

Hydraulic pumps are used in hydraulic drive systems and can be hydrostatic or hydrodynamic. A
hydraulic pump is a mechanical source of power that converts mechanical power into hydraulic energy.
It generates flow with enough power to overcome pressure induced by the load at the pump outlet.

(ii) Intensifier pump.

Intensifier pumps are called intensifiers because they use the concept of pressure intensification or
amplification to generate the desired water pressure. If you apply pressure to one side of a cylinder and
the other side of the cylinder is the same surface area, the pressure on the other side will be the same.

Hydraulic pressure intensifiers, sometimes referred to as hydraulic pressure boosters, generate a higher
pressure from a low-pressure hydraulic power source. They always work powered by a pump, which is
operating at a set pressure and from this the intensifier simply generates a higher output pressure.
(iii) Abrasive delivery system.

The Bulk Abrasive Delivery System is manufactured to the standards of ASME code or CE marking
status. ... The system uses compressed air to automatically transport garnet from the Bulk Abrasive
hopper to the 25 lb hopper located on the OMAX machine.

(iv) Cutting head.

In order to get the best waterjet cutting experience one of the most important aspects of the
Resato waterjet cutting machine is the cutting head. The 2D cutting head is a highly accurate cutting
head, suitable for both abrasive and pure water cutting. Resato also developed the 2,5D cutting head,
designed for the cutting of bevels and correcting the taper effect. In combination with the smart
software of the ACM waterjet cutting machine, a high cutting quality can be achieved. Our Resato
experts can help you make a quality decision about which cutting head would suit your needs best.

(v) Position control system.

In Position Control System the reference input will be an input signal proportional to desired
output. The feedback signal is a signal proportional to current output of the system. The error detector
compares the reference input and feedback signal and if there is a difference it produces an error signal.

(vi) Catcher unit.

• “Catcher” is used to absorb the residual energy of the AWJ and dissipate the same. Acts as a reservoir
for collecting the machining debris entrained in the water jet.