Non-Traditional Manufacturing Processes

Chemical Machining (CM)

Electrochemical Machining (ECM)
Electro-Discharge Machining (EDM)
Laser cutting
Ultrasonic Machining (USM)
Water-Jet and Abrasive Water-Jet Machining

Chemical Machining
Etching:
Chemical reaction between reagent (in gas, solution, or paste form)
and workpiece.

Main uses:
- Shallow, wide cavities on plates, forgings, castings reduce weight
- Electronics manufacturing (wafer fabrication)
- Hydrogen Flouride, Hydrofloric acid: etching of glass

Photo-Chemical Machining

(i) Clean

(ii) Apply resist

(iii) UV exposure

(iv) Development

(v) Etching

(v) Stripping

Main uses:
- Flat springs, metal bookmarks, encoder wheels, lead frames for IC chips,
sieves for medical applications, microwave oven filters, heat-sinks for PCBs

Electrochemical Machining (ECM)

Reverse of electro-plating (workpiece is anode)

Main uses:
- Dies and glass-making molds, turbine and compressor blades, Holes, Deburring

Due to low forces on tool,

ECM can be used to make
holes at very large angle to
a surface an example is
shown in the turbine nozzle
holes in the figure here.
[source: www.barber-nichols.com]

Electro-Discharge Machining (EDM)

Electrode EDM

- Sparks between electrode-workpiece

- Dielectric flushes the metal powder
- Inexpensive, precise, complex shapes
- Workpiece must be a conductor
[source: iprod.auc.dk]

Wire-cut EDM

[source: www.magnix.co.kr]

Laser cutting
Light Amplification by Stimulated Emission of Radiation

- High energy density (small focus area)

- Uses: Cutting, welding, precision holes
- Common lasers: CO2, Nd:YAG
- Continuous power or Pulsed (more precise)

Nd:YAG laser cut:

larger dia and
heat-affected zone

Microscope image of laser cut hole

Femtosecond laser cut:

smaller diameter,
lower thermal damage

Ultrasonic Machining
Main uses of USM:
- Welding plastics (package sealing)
- Wire-bonding (IC chips)
- Machining brittle materials
power
supply ~
Transducer

Up-down vibration of tool

hammers the abrasive particles
against workpiece, causing cutting

Nozzle

Abrasive
slurry

Water-Jet, Abrasive Water-Jet Machining

- Workpiece is fractured by impact from

high pressure (~400 MPa) water-jet
- No heat no thermal stress, damage

Common applications:
- Fast and precise cutting of fabrics
- Vinyl, foam coverings of car dashboard panels
- Plastic and composite body panels used in the interior of cars
- Cutting glass and ceramic tiles