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MACHINING
PROCESS
UNIT 1:INTRODUCTION
CONVENTIONAL PROCESS
piece is harder.
This process is also called as traditional process
UNCONVENTIONAL
PROCESS
There will be no physical contact
CLASSIFICATION OF UCMP
1.Shape of material
Electrical
Electro
chemical
Chemical
Mechanical
Thermal
CLASSIFICATION OF UCMP
2.MECHANISM INVOLVED
EROSION
IONIC DISSOLUTION
VAPORISATION
CLASSIFICATION OF UCMP
3.MATERIAL REMOVAL
Hydrostatic
pressure
High current
density
High voltage
Ionised material
CLASSIFICATION OF UCMP
4.Medium of energy transfer
High voltage
particles
Electroyte
Electron
Hot gases
LASER BEAM
MACHINING(LBM)
PLASMA ARC
MACHINING(PAM)
ELECTRON BEAM
MACHINING(EBM
)
ION BEAM
MACHINING(IBM)
PHYSICAL
SHAPES TO BE
MACHINED
Machining
characteristics
Economic
Considerations
1.PHYSICAL
PARAMETERS
Some of the physical parameters of UCMP are listed in the
table
2.SHAPES TO BE
MACHINED
UCMP applications are also been seen in the size
and shape of the materials
3.MACHINING CHARACTERISTICS
or Process CAPABILITIES
Process capabilities
are analyzed on the
following aspects
Metal removal rate
obtained
Tolerance maintained
Surface finish obtained
Depth of surface
damage
Power required for
machining
4.PROCESS ECONOMY
LIMITATIONS OF UCMP
Some of the limitations of UMP are
UCMP are more expensive
Metal removal rate is slow
AJM,CHM,PAM,EBM are not commercially
economical process
ADVNTAGES OF UCMP
It increases productivity
Reduces No of rejected components
Close tolerance is possible
Harder and difficult to machine materials can
UNIT 2
MECHANICAL ENERGY BASED PROCESS
Principle of AJM
High velocity abrasive gas jet
(150 ~ 300 m/s)
nozzle
Stand off
distance (0.5
~15 mm)
work piece
AJM PROCESS
Work material - hard and brittle
(glass,quartz,ceramics,mica,etc.,)
Abrasive
- Al2O3,SiC,glass
powder,dolomite
Size
- around 25 um
Flow rate
- 2-20 g/min
Medium
- N2 or Co2 or Air
Velocity
-125-300m/s
Pressure
- 2 to 8 kg/cm2
Nozzle mtrl - tungsten carbide or synthatic
sapphire
Life of nozzle
- Tungesten carbide 12 to 20
hrs
Nozzle tip clearance - 0.25 to 15 mm
Tolerance
- 0.05 mm
cleaning,etc..,
MRR PROCESS
PARAMETERS
Mass flow rate
Abrasive grain size
Gas pressure
Velocity of abrasive particles
Mixing ratio
Nozzle tip clearance.
Mixing ratio
rate of
Gas pressure
GAS PRESSURE
Stand Of Distance
Advantages of AJM
Suitable for cutting all materials
There is no direct contact between the tool
Disadvantages of AJM
Material removable rate is slow
Soft material cannot be machined
Machining accuracy is poor
Nozzle wear rate is high
Abrasive powder cannot be reused
Requires some kind of dust collection system.
Applications of AJM
m/cing of hard and brittle materials
Fine drilling and micro welding
m/cing of semiconductors
Cleaning and polishing of plastics, nylon and
Teflon components
Surface etching and surface preparation
in the material.
Pressure level of the jet is about 400MPa.
Advantages
- no heat produced
- cut can be started anywhere without the need
for predrilled holes
- burr produced is minimum
- environmentally safe and friendly
manufacturing.
Application used for cutting composites, plastics,
fabrics, rubber, wood products etc. Also used in
food processing industry.
ULTRASONIC MACHINING
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