P204 EDM ECM Machining

Chapter 27
Advanced Machining Processes
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Parts Made by Advanced Machining Processes
(a)
(b)
Figure 27.1 Examples of parts produced by advanced machining processes. (a)

Samples of parts produced from waterjet cutting. (b) Turbine blade, produced by
plunge EDM, in a fixture to produce the holes by EDM. Source: (a) Courtesy of Omax
Corporation. (b) Courtesy of Hi-TEK Mfg., Inc.
General
Characteristics
of Advanced
Machining
Processes
Chemical Milling
Figure 27.2 (a) Missile skin-panel section contoured by chemical milling to improve the
stiffness-to-weight ratio of the part. (b) Weight reduction of space-launch vehicles by the
chemical milling of aluminum-alloy plates. These panels are chemically milled after the
plates first have been formed into shape by a process such as roll forming or stretch forming.
The design of the chemically machined rib patterns can be modified readily at minimal cost.
Chemical-Machining
Figure 27.3 (a) Schematic illustration of the chemical-machining process. Note that no
forces or machine tools are involved in this process. (b) Stages in producing a profiled
cavity by chemical machining; note the undercut.
Surface
Roughness
and
Tolerances
in
Machining
Figure 27.4 Surface roughness and tolerances obtained in various machining processes. Note
the wide range within each process (see also Fig. 23.13). Source: Machining Data Handbook,
3rd ed. Copyright © 1980. Used by permission of Metcut Research Associates, Inc.
Parts Made by Chemical Blanking
Figure 27.5 Various parts made by chemical blanking. Note the

fine detail. Source: Courtesy of Buckbee-Mears, St. Paul.
Electrochemical Machining
Figure 27.6 Schematic illustration of the electrochemical machining process.
Parts Made by Electrochemical Machining
Figure 27.7 Typical parts made by electrochemical machining. (a) Turbine blade
made of nickel alloy of 360 HB. Note the shape of the electrode on the right. (b) Thin
slots on a 4340-steel roller-bearing cage. (c) Integral airfoils on a compressor disk.
Knee Implants
Figure 27.8 (a) Two total knee replacement systems showing metal implants
(top pieces) with an ultra-high molecular-weight polyethylene insert (bottom
pieces). (b) Cross-section of the ECM process as applies to the metal implant.
Source: Courtesy of Biomet, Inc.
Electrochemical-Grinding Process
Figure 27.9 (a) Schematic illustration of the electrochemical-grinding process.

(b) Thin slot produced on a round nickel-alloy tube by this process.
Electrical-Discharge Machining Process
Figure 27.10 (a) Schematic illustration of the electrical-discharge machining process. This is one of the
most widely used machining processes, particularly for die-sinking applications. (b) Examples of cavities
produced by the electrical-discharge machining process, using shaped electrodes. Two round parts (rear)
are the set of dies for extruding the aluminum piece shown in front (see also Fig. 19.9b). (c) A spiral
cavity produced by EDM using a slowly rotating electrode similar to a screw thread. (d) Holes in a fuel-
injection nozzle made by EDM; the material is heat-treated steel. Source: (b) Courtesy of AGIE USA Ltd.
Stepped Cavities Produced by EDM Process
Figure 27.11 Stepped cavities produced with a square electrode by the EDM
process. The workpiece moves in the two principle horizontal directions (x – y), and
its motion is synchronized with the downward movement of the electrode to produce
these cavities. Also shown is a round electrode capable of producing round or
elliptical cavities. Source: Courtesy of AGIE USA Ltd.
The Wire EDM Process
Metal removal rate :

MRR = 4 ×10 4 ITw−1.23
where
I = current in amperes
Tw = melting temperature of workpiece, °C
Figure 27.12 Schematic illustration of the

€
wire EDM process. As many as 50 hours of
machining can be performed with one reel of
wire, which is then discarded.
Wire EDM
(a) (b)
Figure 27.13 (a) Cutting a thick plate with wire EDM. (b) A computer-
controlled wire EDM machine. Source: Courtesy of AGIE USA Ltd.
Laser-Beam
Machining (LBM)
Figure 27.14 (a) Schematic

illustration of the laser-beam
machining process. (b) and (c)
Examples of holes produced in
nonmetallic parts by LBM. (d)
Cutting sheet metal with a laser
beam. Source: (d) Courtesy of
Rofin-Sinar, Inc.
General Applications of Lasers in Manufacturing
Electron-Beam Machining Process
Figure 27.15 Schematic illustration of the electron-beam

machining process. Unlike LBM, this process requires a vacuum,
so workpiece size is limited to the size of the vacuum chamber.
Water-Jet
Cutting
Process
Figure 27.16 (a) Schematic illustration of the water-jet machining process. (b) A
computer-controlled water-jet cutting machine cutting a granite plate. (c) Examples of
various nonmetallic parts produced by the water-jet cutting process. (Enlarged on next
slide). Source: Courtesy of Possis Corporation
Nonmetallic Parts Made by Water-Jet Cutting
Enlargement of Fig. 27.16c. Examples of various nonmetallic parts produced by

the water-jet cutting process. Source: Courtesy of Possis Corporation
Abrasive-Jet Machining
(b)
Figure 27.17 (a) Schematic illustration of the abrasive-jet machining process. (b)
Examples of parts produced through abrasive-jet machining, produced in 50-mm (2-in.)
thick 304 stainless steel. Source: Courtesy of OMAX Corporation.
Case Study: Stent Manufacture
Figure 27.18 The Guidant MULTI-LINK Figure 27.19 Detail of the 3-3-3
TETRATM coronary stent system. MULTI-LINK TETRATM pattern.
Figure 27.20 Evolution of

the stent surface. (a)
MULTI-LINK TETRATM after
lasing. Note that a metal
slug is still attached. (b)
After removal of slag. (c)
After electropolishing.

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Chapter 27

Advanced Machining Processes

Figure 27.1 Examples of parts produced by advanced machining processes. (a)

Figure 27.5 Various parts made by chemical blanking. Note the

Figure 27.6 Schematic illustration of the electrochemical machining process.

Figure 27.9 (a) Schematic illustration of the electrochemical-grinding process.

Metal removal rate :

Figure 27.12 Schematic illustration of the

Figure 27.14 (a) Schematic

Figure 27.15 Schematic illustration of the electron-beam

Enlargement of Fig. 27.16c. Examples of various nonmetallic parts produced by

Figure 27.20 Evolution of

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