Unconventional Machining

Unit-1 Introduction and Mechanical Energy Based Process

1. Identify why unconventional mechanical machining process is not popular?

Unconventional machining process is not so effective on soft metals like aluminum,
because accuracy cannot be maintained due to more metal removal rate.

2. List the importance of unconventional machining process.

• It provides a good surface.
• Complex shapes can be made easily
• It has longer tool life.
• The rate of metal removal is high.

3. Quote the requirements that demand the use of nontraditional machining processes.
• To machine high steel alloys.
• To generate desired complex surfaces and.
• To achieve high accuracy and surface finish.

4. Classify modern machining processes on the basis of the type of energy employed.

According to the type of energy used:

• Mechanical
• Electro-chemical
• Electro thermal
• Chemical

5. Articulate the requirements that demand the use of advanced machining process.

Advanced machining processes are the material-removing processes different from

conventional machining processes, in which a well-guided wedge-shaped tool removes the
material in the form of chips by producing contact stresses. There are a variety of ways in which
material is removed using these processes
6. Summarize the advantages of unconventional machining process.

Advantages of unconventional machining process

• It has good accuracy.

• It provides a good surface.
• Complex shapes can be made easily.
• It has longer tool life.
• The rate of metal removal is high.

7. Quote the unconventional machining process which uses mechanical energy.

The four main mechanical energy based unconventional machining processes are:
1. Abrasive Jet Machining (AJM)
2. Water Jet Machining (WJM)
3. Abrasive Water Jet Machining (AWJM)
4. Ultrasonic Machining (USM)

8. Distinguish between traditional and non-traditional machining.

S. No Conventional Process Un Conventional Process

1. The cutting tool and work piece are There is no physical contact between the
always in physical contact with tool and work piece, In some
relative motion with each other, which nontraditional process tool wear exists.
results in friction and tool wear

2. Capital cost and maintenance cost is Capital cost and maintenance cost is
low high.

3. Surface finish and tolerances are High surface finish (up to 0.1 micron)
limited by machining inaccuracies. and tolerances (25 Microns)can be
achieved.

4. High metal removal rate. Low material removal rate.

9. Summarize the limitation of traditional machining processes.

• The surface finish level is not quite high.

• High tolerance or close tolerance cannot be achieved.
• Difficult to obtain complex shapes.
• High wastage of material.
• The degree of accuracy and precision are not in best position.

10. Analyze, why abrasive jet machining is not recommended to machine ductile materials?

While machining ductile materials by AJM, the hard abrasive grits may get embedded on the
soft machined surface. This obstructs cut quality as well as properties and appearance of
machined surface.

11. Demonstrate, why reuse of abrasives is not recommended in abrasive jet machining
process?

Reuse of abrasives is not recommended since the cutting ability of abrasive decrease after the
usage and also the contamination of wear materials clogging the nozzle and the cutting unit
orifice.

12. List the different type of abrasives used in AJM.

• Aluminum oxide (Al2O3)

• Silicon carbide (SiC)
• Glass beads,
• Crushed glass
• Sodium bicarbonate
• Uniform particles of sand,
• Steel grit,
• Copper slag,
• Walnut shells,
• Powdered abrasives are used.

13. Summarize the applications of WJM

Applications

• WJM is used on metals, paper, cloth, leather, rubber, plastics, food, and ceramics.
 • It is a versatile and cost-effective cutting process that can be used as an alternative to
traditional machining methods.
• It completely eliminates heat-affected zones, toxic fumes, recast layers, work hardening
and thermal stresses.
• It is the most flexible and effective cleaning solution available for a variety of industrial
needs.
• In general the cut surface has a sandblast appearance.
• Moreover, harder materials exhibit a better edge finish.
• Typical surface finishes ranges from 1.6 μm Root Mean Square (RMS) to very coarse
depending on the application.
• Tolerances are in the range of ± 25 μm on thin material.
• Both the produced surface roughness and tolerance depend on the machining speed.

14. Select any four process variables that control the material removal rate in AJM process

• Carrier Gas,
• Jet Velocity,
• Stand of distance,
• Mixing ratio.

15. EXPRESS THE DESIRABLE PROPERTIES OF CARRIER GAS IN AGM

• AJM USES A STREAM OF FINE GRAINED ABRASIVES (OF SIZE 10 TO 40

MICRONS) MIXED WITH AIR OR SOME

• OTHER CARRIER GAS AT HIGH PRESSURE. THIS STREAM IS DIRECTED ON

THE WORK SURFACE BY USING A SUITABLE NOZZLE

.• THE VELOCITY OF CARRIER GAS OR AIR IS UPTO 200 TO 400 M/SEC

16. COMPARE THE WJM AND AWJM.

17. LIST THE LIMITATION OF WJM. IT IS USED TO CUT SOFTER MATERIALS.

BUT AWJM CAN CUT HARDER MATERIAL OF LIMITED THICKNESS.

• VERY THICK MATERIAL CANNOT BE MACHINED BY THIS PROCESS

• THE INITIAL COST OF WJM IS HIGH.

18. ENUMERATE THE PROCESS CAPABILITIES OF AWJM.

IT IS BASED ON THE PRINCIPLE OF WATER EROSION. WHEN A HIGH-VELOCITY

JET OF WATER STRIKES THE SURFACE, THE REMOVAL OF MATERIAL TAKES
PLACE. PURE WATER JET IS USED TO MACHINE SOFTER MATERIALS. BUT TO CUT
HARDER MATERIALS, SOME ABRASIVE PARTICLES MIXED WITH THE WATER FOR
MACHINING AND IT IS CALLED AS AWJM (ABRASIVE WATER JET MACHINING).

19. QUOTE THE LIMITATION IN ULTRASONIC MACHINING.

1. LOW METAL REMOVAL RATE

2. IT IS DIFFICULT TO DRILL DEEP HOLES, AS SLURRY MOVEMENT IS

RESTRICTED.
3. 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 GRIT WITH A RATIO THAT RANGES FROM 1:1 TO 200:1

4. USM CAN BE USED ONLY WHEN THE HARDNESS OF WORK IS MORE THAN 45
HRC.

20. LIST THE FUNCTION OF TRANSDUCERS IN ULTRASONIC MACHINING.

THE FUNCTION OF THE TRANSDUCER IS TO CONVERT ELECTRICAL ENERGY INTO

MECHANICAL VIBRATION USING THE PRINCIPLE OF PIEZOELECTRIC OR
MAGNETOSTRICTION.

21. IDENTIFY THE RANGE OF FREQUENCY REQUIRED FOR ULTRASONIC.

AS THE APPLICATIONS OF ULTRASOUND PROLIFERATE, OPERATING WITHIN A

FREQUENCY RANGE FROM ABOUT 20 KHZ TO 1 GHZ AND ABOVE, THIS
DEFINITION, BASED ON WHAT ULTRASOUND DOES NOT DO RATHER THAN WHAT
IT DOES DO, HAS OFTEN RESULTED IN CONFUSION AND OBFUSCATION

22. DESCRIBE THE FUNCTIONS OF HORN IN ULTRASONIC MACHINING.

A HORN IS A WAVEGUIDE-FOCUSING DEVICE WITH A CROSS-SECTIONAL AREA

THAT DECREASES FROM THE TRANSDUCER END TO THE TOE END. IT AMPLIFIES
THE INPUT AMPLITUDE OF VIBRATIONS SO THAT AT THE OUTPUT END THE
AMPLITUDE IS SUFFICIENTLY LARGE FOR MACHINING.

23. CLASSIFY FEED MECHANISM.

24. WRITE THE IMPORTANCE OF SURFACE FINISHING IN MACHINING

OPERATION.

THE SURFACE FINISH CAN AFFECT THE ABILITY OF THE PART TO RESIST WEAR
AND FATIGUE; TO ASSIST OR DESTROY EFFECTIVE LUBRICATION; TO INCREASE
OR DECREASE FRICTION AND/ OR ABRASION WITH MATING PARTS; AND TO
RESIST CORROSION.

25. NAME THE UNCONVENTIONAL MACHINING PROCESS WHICH PRODUCE

BEST SURFACE FINISH.

• ABRASIVE JET MACHINING (AJM)

• ELECTRO CHEMICAL GRINDING (ECG)
• ULTRA SONIC MACHINING (USM)
• ELECTRO CHEMICAL DEBURRING (ECD)