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‫كل عام وانتم بخير‬

‫بالتوفيق والنجاح لكم جميعا أبناءنا الطلبة والطالبات‬

MACHINING EQUIPMENT
‫مع داتت شغيل‬
PRE 314

Production Department
3rd Year

Dr. Shokria Abbas Ahmed

 MACHINING EQUIPMENT

Traditional Processes Non-Traditional Processes

Dr. Aly Elmasry  Mechanical Energy Processes

 Electrochemical Machining
Processes
 Thermal Energy Processes
 Chemical Machining

Dr. Shokria Abbas Ahmed

DIFINATION OF NONTRADITIONAL
PROCESSES

A group of processes that remove excess

material by various techniques involving
mechanical, thermal, electrical, or chemical
energy (or combinations of these energies) but
do not use a sharp cutting tools as it needs to be
used for traditional manufacturing processes.
Why Nontraditional Processes are Important?

 Need to machine new materials having high strength and

hardness, such as nimonic alloys and alloys with alloying
elements such as tungsten, molybdenum, and columbium are
difficult to machine by the traditional methods.
 Need for unusual and/or complex part (Fig.1) geometries
that cannot easily be accomplished by conventional
machining.
 A very high accuracy is desired besides the complexity of
the surface to be machined.
 Need to avoid surface damage that often accompanies
conventional machining.
Machining of Complex Shaped Workpieces

Fig.1
 Classification of Nontraditional
Processes by Type of Energy Used
 Mechanical ‑ erosion of work material by a high
velocity stream of abrasives or fluid (or both) is the
typical form of mechanical action
 Electrochemical energy to remove material (reverse of
electroplating)
 Thermal – thermal energy usually applied to small
portion of work surface, causing that portion to be
removed by fusion and/or vaporization
 Chemical – chemical etchants selectively remove
material from portions of workpart, while other portions
are protected by a mask
 CLASSIFICATION OF NONTRADITIONAL
MACHINING
Non-traditional Machining Methods are classified according to the major
energy sources employed in machining.
I. Mechanical Energy Processes
⎯ Abrasive Jet Machining (AJM)
⎯ Ultrasonic Machining (USM)
⎯ Water Jet Machining (WJM)
⎯ Abrasive Water Jet Machining (AWJM)
II. Electrochemical Energy Processes
⎯ Electrochemical Machining (ECM)
⎯ Electrochemical Grinding (ECG)
⎯ Electrochemical Deburring (ECD)
III. Thermal Energy Processes
⎯ Electro-discharge machining (EDM)
⎯ Laser Beam Machining (LBM)
⎯ Electron Beam Machining (EBM)
IV. Chemical Energy Processes
⎯ Chemical Milling (CHM)
⎯ Photochemical Milling (PCM)
 CLASSIFICATION OF
NONTRADITIONAL MACHINING
 Characteristics of Non Traditional Machining
(NTM) Processes
 Material removal may occur with chip formation or even no chip formation may
take place. For example in AJM, chips are of microscopic size and in case of
Electrochemical machining material removal occurs due to electrochemical
dissolution at atomic level.
 No lay pattern on work surface, no direct physical contact between the tool and
the workpiece .
 In NTM, there may not be a physical tool present. For example in laser jet
machining, machining is carried out by laser beam. However in Electrochemical
Machining there is a physical tool that is very much required for machining.
 In NTM, the tool need not be harder than the work piece material. For example,
in EDM, copper is used as the tool material to machine hardened steels.
 Tool forces do not increase as the work material gets harder.
 Economic metal removal rate does not decrease as the work material gets harder.
 Performance depends on thermal, electrical and chemical properties of
workpiece materials.
 Uses different kinds of energy in direct form.
SELECTION OF PROCESS:

The correct selection of the non-traditional

machining methods must be based on the
following aspects.
I.Physical parameters of the process
II.Shape to be machined
III.Process capability
IV.Economics of the processes
I. PHYSICAL PARAMETER OF THE PROCESS

The physical parameters of the different NTM are given in

the Table 1.0 which indicates that PAM and ECM require
high power for fast machining. EBM and LBM require
high
voltages and require careful handling of equipment. EDM
and USM require medium power. EBM can be used in
vacuum and PAM uses oxygen and hydrogen gas.
Table 1
II. Shapes Cutting Capability

The various NTM have some special shape cutting

capability as given below:
Micro-machining and drilling: LBM and EBM
Cavity sinking and standard hole Drilling: EDM
and USM
Fine hole drilling and contour machining: ECM
Clean, rapid cuts and profiles: PAM
Shallow pocketing: AJM
III. Process capability
 EDM which achieves higher accuracy has the lowest
specific power requirement.
 ECM can machine faster and has a low thermal surface
damage depth.
 USM and AJM have very low material removal rates
(MRR) combined with high tool wear and are used non
metal cutting.
 LBM and EBM are, due to their high penetration depth
can be used for micro drilling, sheet cutting and welding.
 CHM is used for manufacture of PCM and other shallow
components.
 Some Observations
 EDM has the lowest specific power requirement and can
achieve sufficient accuracy.
 ECM has the highest metal removal rate, MRR.
 USM and AJM have low MRR and combined with high
tool wear, are used for non-metal cutting.
 LBM and EBM have high penetration rates with low
MRR and, therefore, are commonly used for micro
drilling, sheet cutting, and welding.
 CHM is used for manufacturing PCB and other shallow
components.
 PAM can be used for clean, rapid cuts and profiles in
almost all plates up to 20 cm thick with 5 ̊to 10 ̊̊ taper.
 Limitations of NTM
 Expensive set up, low MRR and skilled labor
required.
 The limitation of electrical machining methods is
that the work material must be an electrical
conductor. Also, consumption of electrical energy
is very large.
 The NTM which have not been proved
commercially economical are: USM, AJM, CHM,
EBM and PAM.
 Problem
 How will you decide to recommend specific advanced machining
processes for A) cutting a glass plate into two pieces, B) making a
hole in a mild steel workpiece?
Solution:
A) Cutting of a glass plate into two pieces:
 Glass is electrically non-conductive hence certain processes (ECM,
EDM, PAM, EBM) are ruled out because they can’t be employed
for electrically non-conductive workpieces.
 LBM can be ignored being an expensive process.
 Chemical machining need not be considered because it is for very
special applications.
 WJM is usually for comparatively softer materials.
 AJM, AWJM and USM can be applied. Which one to use will also
depend on the size of the workpiece, and the kind of the accuracy
required.
Continue solution

B) In case of a hole in M.S., one can proceed as follows:

Moresuitable for comparatively harder materials, one can drop AJM,
USM and AWJM.
Being electrically conductive, ECM, EDM, LBM, EBM, and PAM
can be employed. At this point, one should know the requirements of
the hole in terms of dimensions, tolerances and surface integrity. If it
is not a micro hole one can easily adopt ECM or EDM. If high surface
integrity is required, ECM should be used, and so on.

Thus, by elimination process one should arrive at the particular

process to be used.
Question 1
Which of the following processes has very
high material removal rate efficiency?
a.Electron beam machining
b.Electrochemical machining
c.Electro discharge machining
d.Plasma arc machining
Question 2
Arrange the processes in the increasing order of their maximum material
removal rate.
•Electrochemical Machining (ECM)
•Ultrasonic Machining (USM)
•Electron Beam Machining (EBM)
•Laser Beam Machining (LBM) and
•Electric Discharge Machining (EDM)
USM, LBM, EBM, EDM, ECM
EBM, LBM, USM, ECM, EDM
LBM, EBM, USM, ECM, EDM
LBM, EBM, USM, EDM, ECM
Question 3
Consider the following statements in relation to the unconventional machining
processes:
1. Different
forms of energy directly applied to the piece to have shape transformation or
material removal from work surface.
2. Relative motion between the work and the tool is essential.
3. Cutting tool is not in physical contact with work piece.

1. 1 and 2 only
2. 1, 2 and 3 only
3. 2 and 3 only
4. 1 and 3 only
Question 4
Which one of the following statements is correct in
respect of unconventional machining processes?
The cutting tool is in direct contact with the job.
The tool material needs to be harder than the job
material.
The tool is never in contact with the job.
There has to be a relative motion between the tool
and the job.
Question 5
Match List I (Processes) with List II (Tolerances obtained) and
select the correct answer using the codes given below the Lists:
Processes
A.Plasma arc machining
B.Laser beam machining
Tolerance obtained
C.Abrasive jet machining
D.Ultrasonic machining 1. 7.5 micron
A B C D
a.4 1 3 2 2.25 micron
b.3 2 4 1
c.4
d.3
2
1
3
4
1
2
3.50 micron
4.125 micron
I. Mechanical Energy Processes

Ultrasonic machining
Water jet cutting
Abrasive water jet cutting
Abrasive jet machining
Ultrasonic Machining (USM)
Abrasives contained in a slurry are driven at high velocity
against work by a tool vibrating at low amplitude and
high frequency
 Tool oscillation is perpendicular to work surface
 Tool is fed slowly into work
 Shape of tool is formed in part
USM Applications
 Hard, brittle work materials such as ceramics, glass, and
carbides
 Also successful on certain metals, such as stainless steel
and titanium
 Shapes include non-round holes, holes along a curved
axis
 “Coining operations” - pattern on tool is imparted to a
flat work surface
USM Products
Water Jet Cutting (WJC)
Uses a fine, high pressure, high velocity stream of
water directed at work surface for cutting
WJC Applications
 Usuallyautomated by CNC or industrial robots to
manipulate nozzle along desired trajectory

 Used to cut narrow slits in flat stock such as plastic,

textiles, composites, floor tile, carpet, leather, and
cardboard

 Not suitable for brittle materials (e.g., glass)

 WJC advantages: no crushing or burning of work

surface, minimum material loss, no environmental
pollution, and ease of automation
 Abrasive Jet Machining (AJM)
 High velocity stream of gas containing small abrasive
particles
AJM Application Notes
 Usually performed manually by operator who directs
nozzle
 Normally used as a finishing process rather than cutting
process
 Applications: deburring, trimming and deflashing,
cleaning, and polishing
 Work materials: thin flat stock of hard, brittle materials
(e.g., glass, silicon, mica, ceramics)
Abrasive Jet Machining: Machined products
Abrasive Water Jet Cutting (AWJC)
 When WJC is used on metals, abrasive particles must be
added to jet stream usually
 Additional process parameters: abrasive type, grit size,
and flow rate
◦ Abrasives: aluminum oxide, silicon dioxide, and
garnet (a silicate mineral)
◦ Grit sizes range between 60 and 120
◦ Grits added to water stream at about 0.25 kg/min (0.5
lb/min) after it exits nozzle
Water jet (WJ) and Abrasive Water jet (AWJ)
Cutting
Abrasive Water
jet (AWJ) and
Water jet (WJ)
examples
II. Electrochemical Machining
Processes
 Electrical energy used in combination with chemical
reactions to remove material
 Reverse of electroplating
 Work material must be a conductor
 Processes:
◦ Electrochemical machining (ECM)
◦ Electrochemical grinding (ECG)
◦ Electrochemical deburring (ECD)
Electrochemical Machining (ECM)
Material removal by anodic dissolution, using electrode
(tool) in close proximity to the work but separated by a
rapidly flowing electrolyte
Electrochemical Deburring (ECD)
Adaptation of ECM to remove burrs or round sharp
corners on holes in metal parts produced by
conventional through‑hole drilling
Electrochemical Grinding (ECG)
Special form of ECM in which a grinding wheel with
conductive bond material is used to augment anodic
dissolution of metal part surface
Electrochemical Machining Products
III. Thermal Energy Processes

Very high local temperatures

 Material is removed by fusion or vaporization
Physicaland metallurgical damage to the new
work surface
In some cases, resulting finish is so poor that
subsequent processing is required
Thermal Energy Processes
Electric discharge machining
Electric discharge wire cutting
Electron beam machining
Laser beam machining
Plasma arc machining
Electric Discharge Processes
Metal removal by a series of discrete electrical discharges
(sparks) causing localized temperatures high enough to
melt or vaporize the metal
 Can be used only on electrically conducting work
materials
 Two main processes:
1. Electric discharge machining
2. Wire electric discharge machining
Electric Discharge Machining (EDM)

Electric discharge machining (EDM): (a) overall setup, and (b)

close‑up view of gap, showing discharge and metal removal
EDM Applications
 Tooling for many mechanical processes: molds for
plastic injection molding, extrusion dies, wire drawing
dies, forging and heading dies, and sheetmetal stamping
dies
 Production parts: delicate parts not rigid enough to
withstand conventional cutting forces, hole drilling
where hole axis is at an acute angle to surface, and
machining of hard and exotic metals
Electric Discharge Machining (EDM) Products
Wire EDM
Special form of EDM that uses small diameter
wire as electrode to cut a narrow kerf in work

Electric discharge wire cutting (EDWC), also called wire EDM

Wire EDM Parts
Laser Beam Machining (LBM)
Uses the light energy from a laser to remove
material by vaporization and ablation
Examples of holes produced in nonmetallic parts
by LBM.
Plasma Arc Cutting (PAC)
Uses a plasma stream operating at very high
temperatures to cut metal by melting
IV. Chemical Machining (CHM)
Material removal through contact with a strong
chemical etchant
Processes include:
◦ Chemical milling
◦ Chemical blanking
◦ Chemical engraving
◦ Photochemical machining
Allutilize the same mechanism of material
removal