Neel Nadpara

HW# 5
Due: Wed, Nov. 18
ME 3217: HW 5
QUALITATIVE PROBLEMS

1) Explain why the mechanical properties of work piece materials are not significant in
most of the processes described in this chapter.

In the machining processes that we studied previously, the cutting procedure was done by
shearing or mechanically deforming the material in order to remove it. Thus, the
mechanical properties (hardness, yield strength, strength, ductility, toughness, impact
resistance) of the workpiece material became significantly important especially in
reference to the mechanical properties of the cutting tool (cutting tools need high hot
hardness, impact resistance, etc.). However, in the advanced machining processes
described within this chapter, these properties become less important since the cutting
operation is not performed by mechanical deformation. Instead, the processes used use
other methods such as chemical attack with chemical machining (CM) or
electrodischarge with electrical discharge machining (EDM) to remove material off the
workpiece. Therefore, the impacts of the mechanical properties are not important; one
such example is hot hardness which is required for cutting tools that are removing
material for hard workpieces in conventional machining. However, in an alternative
process such as chemical machining the material removal is done by chemical reaction
meaning that the hot hardness is no longer even a factor in the cutting operation.

2) List the processes that can produce shaped holes, that is, holes that are not circular.

The processes that can produce non-circular holes include ECM, EDM, Wire EDM,
LBM, EBM, WJM (for non-metals), AWJM, and AJM.

3) Why has electrical-discharge machining become so widely used in industry?

Due to the need for special materials for various engineering applications with high
strength, hardness, toughness and other extreme material properties it becomes necessary
to develop processes that allow for material removal on workpieces with these extreme
mechanical properties. One such process is electrical-discharge machining (EDM) which
uses erosion of metals by means of spark discharges. Since EDM relies on electrical
properties and it allows for material removal in numerous configurations it is widely used
in industry to manufacture parts that would otherwise be too difficult to make using
traditional means such as machining where tool wear would be excessive for certain
 workpiece materials. However, this process also has a number of disadvantages such as
high cost, a low material removal rate (MRR), and surface damage which can greatly
reduce fatigue life of certain parts.

4) Which of the advanced machining processes would cause thermal damage? What is
the consequence of such damage to work pieces?

Certain advanced manufacturing processes utilize high levels of heat that can obviously
cause thermal damage. The processes that are likely to cause thermal damage include
EDM, laser beam machining, and electron beam machining. The thermal effect is to
make the material develop a heat affected zone as welding often does to metals. The heat
affected zone is the area of the base metal which is not melted and has had its
microstructure and properties altered due to the heating and cooling of the workpiece.
This in turn can hinder the hardness or ductility of a material.

5) Which of the processes described in this chapter require a vacuum? Explain why?

The only process that requires a vacuum is electron beam machining. This is due to the
fact that the electron beam gun used in this process requires a vacuum in order to operate.

6) What is the purpose of the abrasives in electrochemical grinding?

The abrasives in electrochemical grinding serve two purposes. First, they serve as
insulators between the wheel and the workpiece. Second, they mechanically remove
electrolytic products from the working area.

7) Which of the processes described in this chapter are suitable for producing very
small and deep holes? Explain.

The process best suited for producing very small holes would be electron beam
machining since the process is very precise and the surface finish is quite good. This is
important since certain processes would leave rough edges that would have to be further
machined or the hole generated would be larger than desired. However, the part must be
able to fit within the vacuum chamber and the process can cause heat afflicted zones on
the workpiece. EDM and Wire EDM are also suited to this since they are also precise
processes that can generate holes.
QUANTITATIVE PROBLEMS

1) A 254 mm deep hole that is 25.4 mm in diameter is being produced by electro-

chemical machining. A high production rate is more important than machined
surface quality. Estimate the maximum current and the time required to
perform this operation.
2) If the operation in Q1 were performed on an electrical-discharge machine, what
would be the estimated machining time?
3) A 0.800” thick copper plate is being machined by wire EDM. The wire moves at
a speed of 4 ft/min and the kerf width is 0.0625”. What is the required power?
Note that it takes 1550 J (2100 ft-lb) to melt one gram of copper