ASSIGNMENT

MACHINING
PROCESSES
LAEEQ AHMAD DANISH
REG#1221830135
 4TH SEMESTER
BS TECH IN MECHANICAL
ELECTRON BEAM
MACHINING
DEFINITION:
Electron beam machining is one of the several industrials
processes that use electron beam.
ELECTRON BEAM
MACHINING
USES:
 Electron beam machining is used for variety of high-
precision cutting application
on any known material application include drilling of
extremely small diameter holes-down to 0.05mm diameter,
drilling of holes to very high depth to diameter ratios more
than 100:1, and cutting of slots that are about 0.001 in wide.
ELECTRON BEAM
MACHINING
This process is ideal for micromachining and in generally
limited to cutting operation thin parts in the range 0.25 to
6.3 mm thick.
 It must be carried out in vacuum chamber.
 Limitations include the high energy required and expensive
equipments.
ELECTRON BEAM
MACHINING
LASER BEAM MACHINING

 Laser beams are used for a variety of industrial applications,

including heat treatment, welding, measurements as well as
scribing, cutting and drilling.
 Laser beam uses the light energy from a laser to remove
material by vaporization and ablation.
LASER BEAM MACHINING

 It is used to perform various types of drilling, slitting,

slotting, scribing, and marking operations.
 Drilling small holes is possible down to 0.025mm
 For larger holes laser beam is controlled to cut down the
sides of holes.
LASER BEAM MACHINING
WATER JET CUTTING

 Water jet cutting uses a fine, high pressure, high pressure,

highly velocity stream of water directed at the work surface
to cause cutting of the work, as illustrated in figure below.
To obtain the fine stream of water a small nozzle opening of
diameter 0.1 to 0.4 mm is used. To provide the stream with
sufficient energy for cutting, pressure up to 400MPa are
used and jet reaches velocities up to
WATER JET CUTTING

are used and jet reaches velocities up to 900 m/s.

 The fluid is pressurized to the desired level by a hydraulic
pump, the nozzle unit consist of a holder made of stainless
and a jewel nozzle made of sapphire, ruby or diamond.
Diamond lasts the longest, but cost the most.
WATER JET CUTTING

 ADVANTAGES OF WJC
1. No crushing or burning of the work surface typical in
other mechanical or thermal processes.
2. Minimum material loss because of narrow cut slit.
3. No environmental pollution.
4. Ease of automating process.
WATER JET CUTTING

LIMITATIONS
The limitation of WJC is that the process is not suitable for
cutting brittle materials, e.g Glass, because of their tendency
to crack during cutting.
WATER JET CUTTING
ULTRASONIC MACHINING

 INTRODUCTION
 Ultrasonic machining is one of the processes that uses
mechanical energy to remove the materials from surfaces of
work part.
 Hard and brittle material, such as glass, ceramics and quartz
crystals, are getting more and more attentions in the recent
years due to their superior properties
ULTRASONIC MACHINING

like high hardness, high strength, chemical stability, and low

density.
 Hence there is crucial need for developing precision and
efficient micromachining techniques for these materials.
ULTRASONIC MACHINING

 DEFINITION
 Ultrasonic machining is a non-traditional process in which
abrasives contained in a slurry are driven at high velocity
against the work by a tool vibrating at low amplitude and
high frequency. The amplitudes are around 0.075mm and
frequencies are approximately 20,000Hz.
ULTRASONIC MACHINING
ULTRASONIC MACHINING

 ADVANTAGES
 Used for machining hard and brittle metallic alloys,
semiconductors, glass, ceramics, carbides etc.
 Used for machining round, square, irregular shaped holes
and surface impressions.
 Machining, wire drawing, punching or small blanking dies.
ULTRASONIC MACHINING

 DISADVANTAGES
 Low material removal rate (MRR).
 Rather high tool wear.
 Low depth of hole.
 Unnecessary large grain sizes causes defect.
CHEMICAL MACHINING
PROCESS
 DEFINITION
 Chemical machining (CHM) is a non-traditional process in
which material is removed by means of strong chemical
etchant.
CHEMICAL MACHINING
PROCESS
 STEPS OF CHEMICAL MACHINING
1- CLEANING:
The first step is cleaning so that material will be removed
uniformly from the surface to be etched.
2-MASKING:
A protective coating called a maskant is applied to
certain portion of parts of surface.
CHEMICAL MACHINING
PROCESS
3-ETCHING:
This is the material removal step. The part is immersed
in an etchant that chemically attached to those parts of
surface that are not masked.
4-DEMASKING:
The maskant is removed from the part.
CHEMICAL MACHINING
PROCESS
 TYPES OF CHEMICAL MACHINING PROCESS
CHEMICAL MILLING:
This is first process to be commercialized. It is still used
largely in aircraft industry to remove materials from aircraft
wings and fuselage panel for weight reduction.
Metallurgical damage from chemical milling is very small,
CHEMICAL MACHINING
PROCESS
perhaps around 0.005mm (0.0002in) CHEMICAL
BLANKING:
Chemical blanking use chemical erosion to cut very thin
sheet metal parts down to 0.025mm (0.01 in) thick and /or
for intricate cutting patterns. It produces burr free parts ,an
advantage over conventional shearing operation.
CHEMICAL MACHINING
PROCESS
CHEMICAL MACHINING
PROCESS
CHEMICAL ENGRAVING:
Chemical engraving is a chemical machining process for
making name plates and other flat panels that have lettering
and/or artwork on one side. The sequence in chemical
engraving is similar to other processes except that a filling
operation follows etching.
CHEMICAL MACHINING
PROCESS
PHOTOCHEMICAL MACHINING:
PCM is employed in metalworking when close tolerances
and/or intricate pattern are required on flat parts.
CHEMICAL MACHINING
PROCESS