Mech Vi Non Traditional Machining (10me665) Notes

Non Traditional Machining
10ME665
NON-TRADITIONAL MACHINING
Subject Code: 10ME665
IA Marks: 25
Hours/Week: 04
Exam Hours: 03
Total Hours: 52
Exam Marks: 100

PART A
UNIT - 1 Introduction:History, Classification, comparison between conventional and Nonconventional machining process selection.
05 Hours
UNIT - 2 Ultrasonic Machining (USM):Introduction, equipment, tool materials & tool size,
abrasive slurry, cutting tool system design:- Effect of parameter: Effect of amplitude and
frequency and vibration, Effect of abrasive grain diameter, effect of applied static load, effect of
slurry, tool & work material, USM process characteristics: Material removal rate, tool wear,
Accuracy, surface finish, applications, advantages & Disadvantages of USM.
08 Hours
UNIT - 3 Abrasive Jet Machining (AJM):Introduction, Equipment, Variables in AJM: Carrier
Gas, Type of abrasive, size of abrasive grain, velocity of the abrasive jet, mean number. abrasive
particles per unit volume of the carrier gas, work material, standoff distance (SOD), nozzle
design, shape of cut. Process characteristics-Material removal rate, Nozzle wear, Accuracy &
surface finish. Applications, advantages & Disadvantages of AJM. Water Jet Machining:
Principal, Equipment, Operation, Application, Advantages and limitations of water Jet
machinery
07 Hours
UNIT - 4 Electrochemical Machining (ECM):Introduction, study of ECM machine, elements
of ECM process : Cathode tool, Anode work piece, source of DC power, Electrolyte, chemistry
of the process, ECM Process characteristics Material removal rate, Accuracy, surface finish,
ECM Tooling: ECM tooling technique & example, Tool & insulation materials, Tool size
Electrolyte flow arrangement, Handling of slug, Economics of ECM, Applications such as
Electrochemical turning, Electrochemical Grinding, Electrochemical Honing, deburring,
Advantages, Limitations.
06 Hours
PART B
UNIT - 5 Chemical Machining (CHM): Introduction, elements of process, chemical blanking
process : Preparation of work piece, preparation of masters, masking with photo resists, etching
for blanking, accuracy of chemical blanking, applications of chemical blanking, chemical milling
(contour machining): process steps masking, Etching, process characteristics of CHM: material
removal rate, accuracy, surface finish, Hydrogen embrittlement, advantages & application of
CHM.
06 Hours
DEPARTMENT OF MECHANICAL ENGG, SJBIT
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UNIT - 6 Electrical Discharge Machining (EDM): Introduction, mechanism of metal removal,

dielectric fluid, spark generator, EDM tools (electrodes) Electrode feed control, Electrode
manufacture, Electrode wear, EDM tool design, choice of machining operation, electrode
material selection, under sizing and length of electrode, machining time. Flushing; pressure
flushing, suction flushing, side flushing, pulsed flushing synchronized with electrode movement,
EDM process characteristics: metal removal rate, accuracy, surface finish, Heat Affected Zone.
Machine tool selection, Application, EDM accessories / applications, electrical discharge
grinding, Traveling wire EDM.
08 Hours
UNIT - 7 Plasma Arc Machining (PAM): Introduction, equipment, non-thermal generation of
plasma, selection of gas, Mechanism of metal removal, PAM parameters, process characteristics.
Safety precautions, Applications, Advantages and limitations.
05 Hours
UNIT - 8 Laser Beam Machining (LBM): Introduction, equipment of LBM mechanism of
metal removal, LBM parameters, Process characteristics, Applications, Advantages &
limitations. Electron Beam Machining (Ebm): Principles, equipment, operations, applications,
advantages and limitation of EBM.
07 Hours
TEXT BOOKS:
1. Modern machining process, Pandey and Shan, Tata McGraw Hill 2000
2. New Technology, Bhattacharya 2000
REFERENCE BOOKS:
1. Production Technology, HMT Tata McGraw Hill. 2001
2. Modern Machining Process, Aditya. 2002
3. Non-Conventional Machining, P.K.Mishra, The Institution of Engineers (India) Test book
series, Narosa Publishing House 2005.
4. Metals Handbook: Machining Volume 16, Joseph R. Davis (Editor), American Society of
Metals (ASM)
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CONTENT
1. Introduction
04-07
2. Ultrasonic Machining (USM)
08-14
3. Abrasive Jet Machining (AJM)
15-21
4. Electrochemical Machining (ECM)
22-26
5. Chemical Machining (CHM)
27-32
6. Electrical Discharge Machining (EDM)
33-36
7. Plasma Arc Machining (PAM)
37-40
8. Laser Beam Machining (LBM)
41-45
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UNIT-1
1.1 Introduction
Manufacturing processes can be broadly divided into two groups and they are primary
manufacturing processes and secondary manufacturing processes. The former ones provide basic
shape and size to the material as per designers requirement. Casting, forming, powder
metallurgy are such processes to name a few. Secondary manufacturing processes provide the
final shape and size with tighter control on dimension, surface characteristics etc. Material
removal processes are mainly the secondary manufacturing processes. Material removal
processes once again can be divided into mainly two groups and they are Conventional
Machining Processes and Non-Traditional Manufacturing Processes. Examples of
conventional machining processes are turning, boring, milling, shaping, broaching, slotting,
grinding etc. Similarly, Abrasive Jet Machining (AJM), Ultrasonic Machining (USM), Water Jet
and Abrasive Water Jet Machining (WJM and AWJM), Electro discharge Machining (EDM) are
some of the Non Traditional Machining (NTM) Processes.
1.2 History of Non Traditional processes
Although, the non conventional machining processes have created a revolution in the field of
machining technology by the development of idea of various processes were initiated as early as
in nineteen- twenties in USSR.
1920 The initiation was first made by Gussev towards the end of 1920 in USSR. He suggested a
method of machining by combination of Chemical and mechanical means. His work is basis for
all Electro Chemical processes known today.
1941 Burgess, American Scientist had demonstrated the possibility of ECM process by drawing
a sharp contrast between the mechanical and electrolyte methods in metal removal
1942 The idea of Ultrasonic machining was invented by Balamuth at the He invented at the time
of investigation of dispersion of solids in Liquids with the help of a vibrating magne-tostrictive
nickel tube However, the origination of the process was made by Rosenberg
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1943 DM was developed by B R Lazarenko and N I Lazarenko in USSR. They first developed
the idea of spark erosion machining. In the early nineteen-sixties, the idea of Ultrasonic
machining began to to develop widely in USSR and basis of this development was laid on
extensive investigation that took place in the mechanism of ultrasonic machining and in the
design of Magneto-strictive transducers, converters and wave guides.
1950 The basis of laser machining was established by the process which Which were developed
by Basov, Prokhorov and Fabrikanth in USSR in 1950.
1950 Electro chemical Grinding has practically been developed in about 1950.
1960 The concept of whirling jet machining was innovated.
1.3 Classification of NTM processes

Classification of NTM processes is carried out depending on the nature of energy used for
material removal.
1. Mechanical Processes
a) Abrasive Jet Machining (AJM)
b) Ultrasonic Machining (USM)
c) Water Jet Machining (WJM)
d) Abrasive Water Jet Machining (AWJM)
2. Electrochemical Processes
a) Electrochemical Machining (ECM)
b) Electro Chemical Grinding (ECG)
c) Electro Jet Drilling (EJD)
3. Electro-Thermal Processes
a) Electro-discharge machining (EDM)
b) Laser Jet Machining (LJM)
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c) Electron Beam Machining (EBM)

4. Chemical Processes
a. Chemical Milling (CHM)
b. Photochemical Milling (PCM)
1.4 Comparison between conventional and Non-conventional machining process selection.

Sl
Conventional Process
No.
1
The cutting tool and work piece arealways in
physical contact withrelative motion with each
other,which results in friction and toolwear.
2
Material removal rate is limited bymechanical
properties of workmaterial.
6
7
8
9
10
Non Conventional Process
There is no physical contact betweenthe tool and

work piece, In some nontraditional process tool
wear exists.
NTM can machine difficult to cut andhard to cut
materials
liketitanium,ceramics,nimonics,SST,composites,se
miconductingmaterials
Relative motion between the tooland work is Many NTM are capable of producingcomplex 3D
typically rotary orreciprocating. Thus the shape shapes and cavities
ofwork is limited to circular or flatshapes. In spite
of CNC systems,production of 3D surfaces is still
adifficult task.
Machining of small cavities , slits ,blind holes or Machining of small cavities, slits andProduction of
through holes aredifficult
non-circular, micro sized,large aspect ratio, shall
entry angleholes are easy using NTM
Use relative simple and inexpensivemachinery and Nontraditional processes requiresexpensive tools
readily availablecutting tools
and equipment as wellas skilled labour, which
increase theproduction cost significantly
Capital cost and maintenance cost islow
Capital cost and maintenance cost ishigh
Traditional processes are wellestablished and Mechanics of Material removal of Someof NTM
physics of processis well understood
process are still under research
Conventional process mostly usesmechanical Most NTM uses energy in direct formFor example
energy
: laser, Electron beam inits direct forms are used in
LBM andEBM respectively.
Surface finish and tolerances arelimited by High surface finish(up to 0.1 micron)and
machining inaccuracies
tolerances (25 Microns)can beachieved
High metal removal rate.
Low material removal rate.
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1.5 Applications
Some of the applications of NTM are given below:
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UNIT-2
2.1 Introduction
Ultrasonic Machining is a non-traditional process, in which abrasives contained in aslurry are
driven against the work by a tool oscillating at low amplitude (25-100 microns) and high
frequency (15-30kHz).
2.2 Equipment:
Ultrasonic Machining consists of :
1. High Power sine wave generator
2. Magneto-strictive Transducer
3. Tool Holder
4. Tool
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High power sine wave generator

This unit converts low frequency (60 Hz) electrical power to high frequency (20kHz) electrical
power.
Transducer
The high frequency electrical signal is transmitted to traducer which converts it into high
frequency low amplitude vibration. Essentially transducer converts electrical energy to
mechanical vibration. There are two types of transducer used
1. Piezo electric transducer
2. Magneto-stricitve transducer.
Piezo electric transducer: These transducer generate a small electric current when they are
compressed. Also when the electric current is passed though crystal it expands. When the current
is removed, crystal attains its original size and shape. Such transducers are available up to 900
Watts. Piezo electric crystals have high conversion efficiency of 95%.
Magneto-strictive transducer: These also change its length when subjected to strong magnetic
field. These transducers are made of nickel, nickel alloy sheets. Their conversion efficiency is
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about 20-30%. Such transducers are available up to 2000 Watts. The maximum change in length
can be achieved is about 25 microns.
Tool holder OR Horn.
The tool holder holds and connects the tool to the transducer. It virtually transmits the energy
and in some cases, amplifies the amplitude of vibration. Material of tool should have good
acoustic properties, high resistance to fatigue cracking. Due measures should be taken to avoid
ultrasonic welding between transducer and tool holder. Commonly used tool holders are Monel,
titanium, stainless steel. Tool holders are more expensive, demand higher operating cost.
Tool
Tools are made of relatively ductile materials like Brass, Stainless steel or Mild steel so that Tool
wear rate (TWR) can be minimized. The value of ratio of TWR and MRR depends on kind of
abrasive, work material and tool materials.
2.3 Process parameters
1. Amplitude of vibration ( 15 to 50 microns)
2. Frequency of vibration ( 19 to 25 kHz).
3. Feed force (F) related to tool dimensions
4. Feed pressure
5. Abrasive size
6. Abrasive material
Al203, SiC, B4C, Boron silicarbide, Diamond.
7. Flow strength of the work material

8. Flow strength of the tool material
9. Contact area of the tool
10. Volume concentration of abrasive in water slurry
11. Tool
a. Material of tool
b. Shape
c. Amplitude of vibration
d. Frequency of vibration
e. Strength developed in tool
12. Work material
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a. Material
b. Impact strength
c. Surface fatigue strength
13. Slurry
a. Abrasive hardness, size, shape and quantity of abrasive flow
b. Liquid Chemical property, viscosity, flow rate
c. Pressure
d. Density
2.4 Process capability
1. Can Machine work piece harder than 40 HRC to 60 HRC like carbides, ceramics,
tungsten glass that cannot be machined by conventional methods
2. Tolerance range 7 micron to 25 microns
3. Holes up to 76 micron have been drilledhole depth upto 51mm have been achieved
easily. Hole depth of 152mm deep is achieved by special flushing techniques.
4. Aspect ratio 40:1 has been achieved
5. Linear material removal rate -0.025 to 25mm/min
6. Surface finish -0.25 micron to 0.75 micron
7. Non directional surface texture is possible compared to conventional grinding
8. Radial over cut may be as low as 1.5 to 4 times the mean abrasive grain size.
2.5 Applications
1. Machining of cavities in electrically non-conductive ceramics
2. Used to machine fragile components in which otherwise the scrap rate is high
3. Used for multistep processing for fabricating silicon nitride (Si3N4) turbine blades
4. Large number of holes of small diameter. 930 holes with 0.32mm has been reported (
Benedict, 1973) using hypodermic needles
5. Used for machining hard, brittle metallic alloys, semiconductors, glass, ceramics,
carbides etc.
6. Used for machining round, square, irregular shaped holes and surface impressions.
7. Used in machining of dies for wire drawing, punching and blanking operations
8. USM can perform machining operations like drilling, grinding and milling operations on
all materials which can be treated suitably with abrasives.
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9. USM has been used for piercing of dies and for parting off and blankingoperations.
10. USM enables a dentist to drill a hole of any shape on teeth without any pain
11. Ferrites and steel parts , precision mineral stones can be machined using USM
12. USM can be used to cut industrial diamonds
13. USM is used for grinding Quartz, Glass, and ceramics
14. Cutting holes with curved or spiral centre lines and cutting threads in glass and mineral or
metallo-ceramics
2.6 Advantages
1. It can be used machine hard, brittle, fragile and non-conductive material
2. No heat is generated in work, therefore no significant changes in physical structure of
work material
3. Non-metal (because of the poor electrical conductivity) that cannot be machined by EDM
and ECM can very well be machined by USM.
4. It is burr less and distortion less processes.
5.
It can be adopted in conjunction with other new technologies like EDM,ECG,ECM.
2.7 Disadvantages
1. Low Metal removal rate
2. It is difficult to drill deep holes, as slurry movement is restricted.
3. Tool wear rate is high due to abrasive particles. Tools made from brass, tungsten carbide,
MS or tool steel will wear from the action of abrasive grit with a ratio that ranges from
1:1 to 200:1
4. USM can be used only when the hardness of work is more than 45 HRC.
2.8 Material removal models in USM
Theoretical analysis and experimental results have revealed that USM is a form of abrasion and
material removal in the form of small grains by four mechanisms
i.
Throwing of abrasive grains
ii.
Hammering of abrasive grains
iii.
Cavitations in the fluid medium arising out of ultrasonic vibration of tool.
iv.
Chemical erosion due to micro agitation
Material removal due to throwing and hammering is significant and MR due to cavitations and
chemical erosion can be ignored.
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Abrasive particles are assumed to be spherical in shape having diameter dg. Abrasive particles
move under high frequency vibrating tool. There are two possibilities whenthe tool hit the
particle.
If the size of the particle is small and gap between the tool and work is large, then particle
will be thrown by tool to hit the work piece.
If the size of the particle is large and gap between tool and work is small, then particle is
hammered over the work surface.
From the geometry
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UNIT-3
3.1 Definition
In abrasive jet machining, a focused stream of abrasive particles, carried by high pressure air or
gas is made to impinge on the work surface through a nozzle and the work material is made to
impinge on the work surface through a nozzle and work material is removed by erosion by high
velocity abrasive particles.
3.2 Abrasive Jet Machining Equipment
In Abrasive Jet Machining (AJM), abrasive particles are made to impinge on the work material at
a high velocity. The high velocity abrasive particles remove the material by micro-cutting action
as well as brittle fracture of the work material.
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A schematic layout of AJM is shown above. The gas stream is then passed to thenozzle through a
connecting hose. The velocity of the abrasive stream ejected through the nozzle is generally of
the order of 330 m/sec.
Abrasive jet Machining consists of
1. Gas propulsion system
2. Abrasive feeder
3. Machining Chamber
4. AJM Nozzle
5. Abrasives
3.3 Gas Propulsion System
Supplies clean and dry air. Air, Nitrogen and carbon dioxide to propel the abrasive particles. Gas
may be supplied either from a compressor or a cylinder. In case of a compressor, air filter cum
drier should be used to avoid water or oil contamination of abrasive powder. Gas should be nontoxic, cheap, easily available. It should not excessively spread when discharged from nozzle into
atmosphere. The propellant consumption is of order of 0.008 m3/min at a nozzle pressure of 5bar
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and abrasiveflow rate varies from 2 to 4 gm/min for fine machining and 10 to 20 gm/min
forcutting operation.
Abrasive Feeder.
Required quantity of abrasive particles is supplied by abrasive feeder. The filleted propellant is
fed into the mixing chamber where in abrasive particles are fed through a sieve. The sieve is
made to vibrate at 50-60 Hz and mixing ratio is controlled by the amplitude of vibration of sieve.
The particles are propelled by carrier gas to a mixing chamber. Air abrasive mixture moves
further to nozzle. The nozzle imparts high velocity to mixture which is directed at work piece
surface.
Machining chamber
It is well closed so that concentration of abrasive particles around the working chamber does not
reach to the harmful limits. Machining chamber is equipped with vacuum dust collector. Special
consideration should be given to dust collection system if the toxic material (like beryllium) are
being machined.
AJM nozzle
AJM nozzle is usually made of tungsten carbide or sapphire ( usually life 300 hours for
sapphire , 20 to 30 hours for WC) which has resistance to wear. The nozzle is made of either
circular or rectangular cross section and head can be head can be straight, or at a right angle. It is
so designed that loss of pressure due to the bends, friction etc is minimum possible. With
increase in wear of a nozzle, the divergence ofjet stream increases resulting in more stray cutting
and high inaccuracy.
3.4 Process parameters
For successful utilization of AJM process, it is necessary to analyze the following process
criteria.
1. Material removal rate
2. Geometry and surface finish of work piece
3. Wear rate of the nozzle
However, Process criteria are generally influenced by the process parameters as enumerated
below:
Abrasives
a) material Al2CO3 SiC Glass beads Crushed glass Sodium bi carbonate
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b) shape irregular/regular
c) Size 10 to 50 microns
d) Mass flow 2-20 gm/min
Carrier Gas
a) Composition Air, CO2, N2

b) Density 1.3 kg/m3
c) Velocity - 500 to 700 m/s
d) Pressure - 2 to 10 bar
e) Flow rate - 5 to 30 microns
Abrasive Jet
a) Velocity - 100 to 300 m/s
b) Mixing ratio Volume flow rate of abrasives/Volume flow rate of gas
c) Standoff distance SOD- 0.5 to 15mm.
d) Impingement angle 60 to 90 deg
Nozzle
a) Material WC/Sapphire
b) Diameter 0.2 to 0.8 mm
c) Life 300 hours for sapphire, 20 to 30 hours for WC
3.5 Applications
1. This is used for abrading and frosting glass more economically as compared to etching or
grinding
2. Cleaning of metallic smears on ceramics, oxides on metals, resistive coating etc.

3. AJM is useful in manufacture of electronic devices , drilling of glass wafers, de burring
of plastics, making of nylon and Teflon parts permanent marking on rubber stencils,
cutting titanium foils
4. Deflating small castings, engraving registration numbers on toughened glass used for car
windows
5. Used for cutting thin fragile components like germanium, silicon etc.
6. Register treaming can be done very easily and micro module fabrication for electrical
contact, semiconductor processing can also be done effectively.
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7. Used for drilling, cutting, deburring etching and polishing of hard and brittle materials.
8. Most suitable for machining brittle and heat sensitive materials like glass, quartz,
sapphire, mica, ceramics germanium , silicon and gallium.
9. It is also good method for deburring small hole like in hypodermic needles and for small
milled slots in hard metallic components.
3.6 Advantages of AJM
1. High surface finish can be obtained depending upon the grain sizes
2. Depth of damage is low ( around2.5 microns)
3. It provides cool cutting action, so it can machine delicate and heat sensitive material
4. Process is free from chatter and vibration as there is no contact between the tool and work
piece
5. Capital cost is low and it is easy to operate and maintain AJM.
6. Thin sections of hard brittle materials like germanium, mica, silicon, glass and ceramics
can be machined.
7. It has the capability of cutting holes of intricate shape in hard materials.
3.7 Disadvantages of AJM
1. Limited capacity due to low MRR. MRR for glass is 40 gm/minute

2. Abrasives may get embedded in the work surface, especially while machining soft
material like elastomers or soft plastics.
3. The accuracy of cutting is hampered by tapering of hole due to unavoidable flaring of

abrasive jet.
4. Stray cutting is difficult to avoid

5. A dust collection system is a basic requirement to prevent atmospheric pollution and
health hazards.
6. Nozzle life is limited (300 hours)

7. Abrasive powders cannot be reused as the sharp edges are worn and smaller particles can
clog the nozzle.
8. Short standoff distances when used for cutting, damages the nozzle.
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3.8 Machining characteristics

Following are the AJM process criteria
1. Material removal rate
2. Geometry and surface finish of work piece
3. wear rate of the nozzle
Process criteria are generally influenced by the process parameters
The characteristics of above process parameters on process criteria are as follows
1. Effect of abrasive flow rate and grain size on MRR
It is clear from the figure that at aparticular pressure MRR increase with increase of abrasive
flow rate and is influenced by size of abrasive particles. But after reaching optimum value, MRR
decreases with further increase of abrasive flow rate. This is owing to the fact that Mass flow rate
of gas decreases with increase of abrasive flow rate and hence mixing ratio increases causing a
decrease in material removal rate because of decreasing energy available for erosion.
2. Effect of exit gas velocity and abrasive particle density

The velocity of carrier gas conveying the abrasiveparticles changes considerably with the change
of abrasive particle density as indicated in figure. The exit velocity of gas can be increased to
critical velocity when the internal gas pressure is nearly twice the pressure at exit of nozzle for
the abrasive particle density is zero. If the density ofabrasive particles is gradually increased exit
velocity will go on decreasing for the same pressure condition. It is due to fact that Kinetic
energy of gas is utilized for transporting the abrasive particle
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3. Effect of mixing ratio on MRR

Increased mass flow rate of abrasive will result in a decreased velocity of fluid and will
therebydecreasesthe available energy for erosion and ultimately the MRR. It is convenient to
explain to this fact by term MIXING RATIO.
4. Effect of Nozzle pressure on MRR

The abrasive flow rate can be increased by increasing the flow rate of the carrier gas. This is only
possible by increasing the internal gas pressure as shown in the figure. As the internal gas
pressure increases abrasive mass flow rate increase and thus MRR increases. As a matter of fact,
the material removal ratewill increase with the increase in gas pressureKinetic energy of the
abrasive particles is responsible for the removal of material by erosion process. The abrasive
must impinge on the work surface with minimum velocity for machining glass by SIC particle is
found to be around 150m/s.
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UNIT 4
4.1 Introduction
Electrochemical Machining (ECM) is a non-traditional machining (NTM) process belonging to
electrochemical category. ECM is opposite of electrochemical or galvanic coating or deposition
process. Thus ECM can be thought of a controlled anodic dissolution at atomic level of the work
piece that is electrically conductive by a shaped tool due to flow of high current at relatively low
potential difference through an electrolyte which is quite often water based neutral salt solution.
Fig. 1 schematically shows the basic principle of ECM.
4.2 Equipment
The electrochemical machining system has the following modules:
Power supply
Electrolyte filtration and delivery system
Tool feed system
Working tank
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4.3 Modelling of material removal rate

Material removal rate (MRR) is an important characteristic to evaluate efficiency of a nontraditional machining process.
In ECM, material removal takes place due to atomic dissolution of work material.
Electrochemical dissolution is governed by Faradays laws.
The first law states that the amount of electrochemical dissolution or deposition is proportional to
amount of charge passed through the electrochemical cell, which may be expressed as:
mQ,
Where m = mass of material dissolved or deposited
Q = amount of charge passed
The second law states that the amount of material deposited or dissolved further depends on
Electrochemical Equivalence (ECE) of the material that is again the ratio atomic weigh and
valency. Thus
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4.4 Applications
1. ECM can be used to make disc for turbine rotor blades made up ofHSTR alloys
2. ECM can be used for slotting very thin walled collets
3. ECM can be used for copying of internal and external surfaces, cuttingof curvilinear
slots, machining of intricate patterns, production of longcurved profiles, machining of
gears and chain sprockets, production ofintegrally bladed nozzle for use in diesel
locomotives, production ofsatellite rings and connecting rods, machining of thin large
diameterdiaphragms.
4. ECM principle has be employed for performing a number of machiningoperations
namely, turning, treplaning, broaching, grinding, fine holedrilling, die sinking, piercing,
deburring,plunge cutting etc.
5. ECM can also be used to generate internal profile of internal cams.
4.5 Advantages
ECM offers impressive and long lasting advantages.
1. ECM can machine highly complicated and curved surfaces in a singlepass.
2. A single tool can be used to machine a large number of pieces withoutany loss in its
shape and size. Theoretically tool life is high
3. Machinability of the work material is independent of its physical andmechanical
properties. The process is capable of machining metals andalloys irrespective of their
strength and hardness.
4. Machined surfaces are stress and burr free having good surface finish
5. It yields low scrap, almost automatic operation, low overall machiningtime, and reduced
inventory expenses.
6. There is no thermal damage and burr free surface can be produced.
4.6 Disadvantages
1. High capital cost of equipment
2. Design and tooling system is complex
3. Hydrogen libration at the tool surface may cause hydrogen embrittlementof the surface.
4. Spark damage may become sometimes problematic
5. Fatigue properties of the machined surface may reduce as compared toconventional
techniques (by 20%)
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6. Non-conductive material cannot be machined.

7. Blind holes cannot be machined in solid block in one stage
8. Corrosion and rust of ECM machine can be hazard
9. Space and floor area requirement are also higher than for conventionalmachining
methods. Some additional problems related to machine toolrequirements such as power
supply, electrolyte handling and tool feed servo
4.7 Process Parameters
1. Power supply
Type DC
Voltage 30V
Current - 40000A
Current Density 500 A/Cm2
2. Electrolyte
Type Nacl, NaNo3, Proprietary mixtures.
Temperature 26 to 50 deg.
Flow rate 16 LPM to 20 LPM
Velocity 1500 m/min to 3000 m/min
Inlet pressure 2200 kPa.
Outlet Pressure- 300 kpa
3. Working Gap
0.075 to 0.75mm
4. Side over cut
0.125 to 1mm
5. Feed rate
0.500 to 13 mm/min
6. Electrode material
Copper , Brass, Bronze
7. Tolerance
0.025mm (2D) and 0.050mm(3D)
8. Roughness
1.5 microns
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UNIT 5
5.1 Introduction
Chemical machining is one of the non-conventional machining processes where material is
removed by bringing it in contact of a strong chemical enchant. There are different chemical
machining methods base on this like chemical milling, chemical blanking, photochemical
machining, etc.
5.2 Working Principle of ECM
Electrochemical machining removes material of electrically conductor workpiece. The
workpiece is made anode of the setup and material is removed by anodic dissolution. Tool is
made cathode and kept in close proximity to the workpiece and current is passed through the
circuit. Both electrodes are immersed into the electrolyte solution. The working principle and
process details are shown in the Figure. This works on the basis of Faradays law of electrolysis.
The cavity machined is the mirror image of the tool. MRR in this process can easily be
calculated according to Faradays law.
Process details of ECM are shown in Figure and described as below:
Workpiece
Workpiece is made anode, electrolyte is pumped between workpiece and the tool. Material of workpiece
is removed by anodic dissolution. Only electrically conducting materials can be processed by ECM.
Tool
A specially designed and shaped tool is used for ECM, which forms cathode in the ECM setup. The tool
is usually made of copper, brass, stainless steel, and it is a mirror image of the desired machined cavity.
Proper allowances are given in the tool size to get the dimensional accuracy of the machined surface.
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Power Supply
DC power source should be used to supply the current. Tool is connected with the negative terminal and
workpiece with the positive terminal of the power source. Power supply supplies low voltage (3 to 4
volts) and high current to the circuit.
Electrolyte
Water is used as base of electrolyte in ECM. Normally water soluble NaCl and NaNO3 are used as
electrolyte. Electrolyte facilitates are carrier of dissolved workpiece material. It is recycled by a pump
after filtration.
Tool Feed Mechanism
Servo motor is used to feed the tool to the machining zone. It is necessary to maintain a constant gap
between the workpiece and tool so tool feed rate is kept accordingly while machining.
In addition to the above whole process is carried out in a tank filled with electrolyte. The tank is made of
transparent plastic which should be non-reactive to the electrolyte. Connecting wires are required to
connect electrodes to the power supply.
5.3 Tooling for CHM

Tooling for CHM is relatively inexpensive and simple to modify. Four different types of tools are
required: maskants, etchants, scribing templates, and accessories.
Maskants: Maskants are generally used to protect parts of theworkpiece where CD action is not
needed. Synthetic or rubber basematerials are frequently used. Table 3.1 shows the different
maskantsand etchants for several materials together with the etch rate and etchfactor. Maskants
should, however, possess the following properties:
1. Be tough enough to withstand handling
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2. Adhere well to the workpiece surface

3. Scribe easily
4. Be inert to the chemical reagent used
5. Be able to withstand the heat generated by etching
6. Be removed easily and inexpensively after etching
Etchants:Etchants (see below Table) are acid or alkaline solutionsmaintained within a controlled
range of chemical composition andtemperature. Their main technical goals are to achieve the
following:
1. Good surface finish
2. Uniformity of metal removal
3. Control of selective and intergranular attack
4. Control of hydrogen absorption in the case of titanium alloys
5. Maintenance of personal safety
6. Best price and reliability for the materials to be used in the constructionof the process
tank
7. Maintenance of air quality and avoidance of possible environmentalProblems
5.4 Accuracy and surface finish

In CHM, the metal is dissolved by the CD action. This machining phase takes place both at the
individual grain surfaces as well as at the grain boundaries. Fine grain size and homogenous
metallurgical structure are, therefore, necessary, for fine surface quality of uniform appearance.
Surfaces machined by CHM do not have a regular lay pattern. Based on the grain size,
orientation, heat treatment, and previously induced stresses, every material has a basic surface
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finish that results from CHM for a certain period of time. While surface imperfections will not be
eliminated by CHM, any prior surface irregularities, waviness, dents, or scratches will be slightly
altered and reproduced in the machined surface. The machining rate affects the surface
roughness and hence the tolerance produced. Generally, slow etching will produce a surface
finish similar to the original one. Figure 3.7 shows typical surface roughnesses for different
materials. The orientation of the areas being etched withrespect to the rolling direction or the
direction of the grain in the workpiece is also important for good CHM surfaces. The depth of
cut tolerance increases when machining larger depths at high machining rates.
Aluminum and magnesium alloys can be controlled more closely than steel, nickel, or titanium
alloys. An etching rate of 0.025 mm/mm with tolerances of 10 percent of the cut width can be
achieved depending on the workpiece material and depth of cut. The surface roughness is also
influenced by the initial workpiece roughness. It increases as the metal ion concentration rises in
the etchant. For low machining depths, <200 m, the roughness sharply increases with the depth
of cut, while at higher depths a slight change in the roughness is evident. Figure 3.7 shows the
dependence of the surface roughness and etch rate on the workpiece material. Typically, surface
roughnesses of 0.1 to 0.8 m, depending on the initial roughness, can be obtained. However,
under special conditions, roughnesses of 0.025 to 0.05 m become possible (Machining Data
Handbook, 1997). CHM can affect the mechanical properties of the machined parts when the
surface layers have different mechanical properties from those of the base metal. The removal of
such layers results in a change in the average mechanical properties of the finished parts. In this
regard surface conditions such as a titanium oxide layer (alpha case), decarburized layer, and
recast structure are easily removed by CHM, resulting in an improvement in the properties of the
finished parts. Some loss of fatigue properties has been reported after CHM of aluminum;
however, shot peening or grit blasting can restore it.
5.5 Material removal rate
The material removal or etch rate depends upon the chemical and metallurgicaluniformity of the
workpiece and the uniformity of the solutiontemperature. As shown in Figs.and, castings, having
thelargest grain size, show the roughest surface together with the lowest
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Figure 3.6 CHM average roughness of some alloys after removing 0.25 to 0.4 mm
Figure 3.7 surface roughnesses and etch rate of some alloys after removing 0.25 to 0.4 mm
5.6 Applications of ECM Process
There are large numbers of applications of ECMs some other related machining and finishing processes
as described below:
1. Electrochemical Grinding: This can also be named as electrochemical debrruing. This is used for
anodic dissolution of burrs or roughness a surface to make it smooth. Any conducting material
can be machined by this process. The quality of finish largely depends on the quality of finish of
the tool.
2. This is applied in internal finishing of surgical needles and also for their sharpening.
3. Machining of hard, brittle, heat resistant materials without any problem.
4. Drilling of small and deeper holes with very good quality of internal surface finish.
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5. Machining of cavities and holes of complicated and irregular shapes.

6. It is used for making inclined and blind holes and finishing of conventionally machined surfaces.
5.7 Advantages of ECM Process
Following are the advantages of ECM process:
1. Machining of hard and brittle material is possible with good quality of surface finish and
dimensional accuracy.
2. Complex shapes can also be easily machined.
3. There is almost negligible tool wear so cost of tool making is only one time investment for mass
production.
4. There is no application of force, no direct contact between tool and work and no application of
heat so there is no scope of mechanical and thermal residual stresses in the workpiece.
5. Very close tolerances can be obtained.
5.8 Disadvantages and Limitations of ECM
There are some disadvantages and limitations of ECM process as listed below:
1. All electricity non-conducting materials cannot be machined.
2. Total material and workpiece material should be chemically stable with the electrolyte solution
3. Designing and making tool is difficult but its life is long so recommended only for mass
production.
4. Accurate feed rate of tool is required to be maintained.
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UNIT 6
6.1 Introduction
The history of electro discharge machining (EDM) dates back to the daysof World Wars I and II
when B. R. and N. I. Lazarenko invented the relaxation circuit (RC). Using a simple servo
controller they maintainedthe gap width between the tool and the workpiece, reduced arcing,
andmade EDM more profitable. Since 1940, die sinking by EDM has beenrefined using pulse
generators, planetary and orbital motion techniques,computer numerical control (CNC), and the
adaptive control systems.
During the 1960s the extensive research led the progress of EDMwhen numerous problems
related to mathematical modeling were tackled.The evolution of wire EDM in the 1970s was due
to the powerful generators,new wire tool electrodes, improved machine intelligence, andbetter
flushing. Recently, the machining speed has gone up by 20 times,which has decreased machining
costs by at least 30 percent and improvedthe surface finish by a factor of 15. EDM has the
following advantages:
1. Cavities with thin walls and fine features can be produced.
2. Difficult geometry is possible.
3. The use of EDM is not affected by the hardness of the work material.
4. The process is burr-free.
6.2 Principles of EDM
Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to
remove metal by means of electric spark erosion. In this process an electric spark is used as the
cutting tool to cut (erode) the workpiece to produce the finished part to the desired shape. The
metal-removal process is performed by applying a pulsating (ON/OFF) electrical charge of highfrequency current through the electrode to the workpiece. This removes (erodes) very tiny pieces
of metal from the workpiece at a controlled rate.
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6.3 EDM Process

EDM spark erosion is the same as having an electrical short that burns a small hole
in a piece of metal it contacts. With the EDM process both the workpiece material and the
electrode material must be conductors of electricity.
The EDM process can be used in two different ways:
I.
A pre shaped or formed electrode (tool), usually made from graphite or

copper, is shaped to the form of the cavity it is to reproduce. The formed
electrode is fed vertically down and the reverse shape of the electrode is
eroded (burned) into the solid workpiece.
II.
A continuous-travelling vertical-wire electrode, the diameter of a small

needle or less, is controlled by the computer to follow a programmed path to
erode or cut a narrow slot through the workpiece to produce the required
shape.
6.4 Conventional EDM

In the EDM process an electric spark is used to cut the workpiece, which takes the shape
opposite to that of the cutting tool or electrode. The electrode and the workpiece are both
submerged in a dielectric fluid, which is generally light lubricating oil. A servomechanism
maintains a space of about the thickness of a human hair between the electrode and the work,
preventing them from contacting each other.
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In EDM ram or sinker machining, a relatively soft graphite or metallic electrode can be used to
cut hardened steel, or even carbide. The EDM process produces a cavity slightly larger than the
electrode because of the overcut.
6.5 Wire-Cut EDM
The wire-cut EDM is a discharge machine that uses CNC movement to produce the desired
contour or shape. It does not require a special shaped electrode, instead it uses a continuoustraveling vertical wire under tension as the electrode. The electrode in wire-cut EDM is about as
thick as a small diameter needle whose path is controlled by the machine computer to produce
the shape required.
6.6 Dielectric Fluids
Conventional EDM During the EDM process the workpiece and the electrode are submerged in
the dielectric oil, which is an electrical insulator that helps to control the arc discharge. The
dielectric oil, that provides a means of flushing, is pumped through the arc gap. This removes
suspended particles of workpiece material and electrode from the work cavity.
6.7 Flushing
One of the most important factors in a successful EDM operation is the removal of the metal
particles (chips) from the working gap. Flushing these particles out of the gap between the
workpiece to prevent them from forming bridges that cause short circuits.
6.8 Flushing Ram Type EDM
Flushing is the most important function in any electrical discharge machining operation.
Flushing is the process of introducing clean filtered dielectric fluid into the spark gap. Flushing
applied incorrectly can result in erratic cutting and poor machining conditions.
There are a number of flushing methods used to remove the metal particles efficiently while
assisting in the machining process. Too much fluid pressure will remove the chips before they
can assist in the cutting action, resulting in slower metal removal. Too little pressure will not
remove the chips quickly enough and may result in short-circuiting the erosion process
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6.9 Wire EDM Dielectric Fluids

The dielectric fluid must be circulated under constant pressure to flush (wash) away the metal
particles and assist in the machining or erosion process. If red sparks occur during the cutting
operation, the water supply is inadequate. To overcome this problem, increase the flow of water
until blue sparks appear.
6.10 The Servo Mechanism
Both wire and vertical EDM machines are equipped with a servo control mechanism that
automatically maintains a constant gap of about the thickness of a human hair between the
electrode and the workpiece. It is important for both machine types that there is no physical
contact between the electrode and the workpiece, otherwise arcing could damage the workpiece
and break the wire. The servomechanism advances the electrode into the workpiece as the
operation progresses and senses the work-wire spacing and controls it to maintain the proper arc
gap which is essential to a successful machining operation.
6.11 Advantages of EDM
Conventional EDM machines can be programmed for vertical machining, orbital, vectorial,
directional, helical, conical, rotational, spin and indexing machining cycles. This versatility gives
Electrical Discharge Machines many advantages over conventional machine tools.
i.
Any material that is electrically conductive can be cut using the EDM process.
ii.
Hardened workpieces can be machined eliminating the deformation caused by heat

treatment.
iii.
X, Y, and Z axes movements allow for the programming of complex profiles using
simple electrodes.
iv.
Complex dies sections and molds can be produced accurately, faster, and at lower costs.
v.
The EDM process is burr-free.
vi.
Thin fragile sections such as webs or fins can be easily machined without deforming the
part.
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UNIT 7
7.1 Introduction
When the temperature of a gas is raised to about 2000C, the gas moleculesbecome dissociated
into separate atoms. At higher temperatures,30,000C, these atoms become ionized. The gas in
this stage is termedplasma. Machining by plasma was adopted in the early 1950s as an
alternativemethod for oxy-gas flame cutting of stainless steel, aluminum,and other nonferrous
metals. During that time the process limitationsregarding the low cutting speed, poor machining
quality, and the unreliableequipment were clear. Recently machining of both metallic and
nonconductivematerials has become much more attractive. An importantfeature of plasma beam
machining (PBM) is that it is the only fabricatingmethod that works faster in stainless steel than
it does in mild steel.
7.2 Working Principle of PAM
In this process gases are heated and charged to plasma state. Plasma state is the superheated and
electrically ionized gases at approximately 5000oC. These gases are directed on the workpiece in
the form of high velocity stream. Working principle and process details are shown in below
Figure.
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Process Details of PAM

Details of PAM are described below.
Plasma Gun
Gases are used to create plasma like, nitrogen, argon, hydrogen or mixture of these gases. The
plasma gun consists of a tungsten electrode fitted in the chamber. The electrode is given negative
polarity and nozzle of the gun is given positive polarity. Supply of gases is maintained into the
gun. A strong arc is established between the two terminals anode and cathode. There is a
collision between molecules of gas and electrons of the established arc. As a result of this
collision gas molecules get ionized and heat is evolved. This hot and ionized gas called plasma is
directed to the workpiece with high velocity. The established arc is controlled by the supply rate
of gases.
Power Supply and Terminals
Power supply (DC) is used to develop two terminals in the plasma gun. A tungsten electrode is
inserted to the gun and made cathode and nozzle of the gun is made anode. Heavy potential
difference is applied across the electrodes to develop plasma state of gases.
Cooling Mechanism
As we know that hot gases continuously comes out of nozzle so there are chances of its
overheating. A water jacket is used to surround the nozzle to avoid its overheating.
Tooling
There is no direct visible tool used in PAM. Focused spray of ho0t, plasma state gases works as a
cutting tool.
Workpiece
Workpiece of different materials can be processed by PAM process. These materials are
aluminium, magnesium, stainless steels and carbon and alloy steels. All those material which can
be processed by LBM can also be processed by PAM process.
7.3 Material removal rate
During PBM absorbing the heat energy from the plasma jet directed to theworkpiece activates
metal removal. The plasma torch blows the molten andevaporated metal away as a fine spray or
vapor. The resulting cuttingrates and hence the machinability depend on the workpiece
beingmachined as well as the type of the cutting and shielding gases that determinethe maximum
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temperature transfer rates. The maximum machiningspeed, as an index of machinability for dual
gas plasma of carbonsteel, stainless steel, and aluminum, is shown in below Figuresshows the
power consumption factor needed in plasma beam rough turningof some alloys. A low factor
indicates either low energy required orhigh removal rates. The machining speed is found to
decrease withincreasing the thickness of the metal or the cut width in case of beveling.As the
power is increased, the efficient removal of melted metal isfound to need a corresponding rise in
the gas flow rate. During plasmamachining of 12-mm-thick steel plate using 220 kW the
machining speedis 2500 mm/min, which is 5 times greater than that for oxy-gas cutting.
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7.4 Accuracy and surface quality

The edges of the workpieces cut by PBM are often beveled. McGeough (1988) reported that the
right side of the plasma arc relative to the cutting direction produces a square edge to within 3.
The left-handedge is beveled to about 15 due to the clockwise swirling of the machininggas.
Owing to the high rate of heat transfer the depth of fused metalextends to about 0.18 mm below
the cut surface. The high machiningspeed does not allow the heat to penetrate more than a few
microns from the edges of the cut which produces little or no distortion in the cut workpiece.
The cut edge of the material tends to be harder than the base material. Afurther heat-affected
zone (HAZ) of thickness 0.25 to 1.12 mm has been reported. Additionally due to the rapid
cooling, cracks may arise beyond the heat-affected zone to 1.6 mm. A clean, smooth surface is
produced by PBM. Large tolerances of 1.6 mm can be achieved. Finish cuts are, therefore,
required when narrow tolerances are required.
7.5 Applications of PAM

The chief application of this process is profile cutting as controlling movement of spray focus
point is easy in case of PAM process. This is also recommended for smaller machining of
difficult to machining materials.
7.6 Advantages of PAM Process

Advantages of PAM are given below:
i.
It gives faster production rate.
ii.
Very hard and brittle metals can be machined.
iii.
Small cavities can be machined with good dimensional accuracy.
7.7 Disadvantages of PAM Process

i.
Its initial cost is very high.
ii.
The process requires over safety precautions which further enhance the initial cost of the
setup.
iii.
Some of the workpiece materials are very much prone to metallurgical changes on
excessive heating so this fact imposes limitations to this process.
iv.
It is uneconomical for bigger cavities to be machined.
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UNIT 8
8.1 Introduction
Laser-beam machining is a thermal material-removal process that utilizes a high-energy,
coherent light beam to melt and vaporize particles on the surface of metallic and non-metallic
workpieces. Lasers can be used to cut, drill, weld and mark. LBM is particularly suitable for
making accurately placed holes. A schematic of laser beam machining is shown in below Figure.
Different types of lasers are available for manufacturing operations which are as follows:
CO2 (pulsed or continuous wave): It is a gas laser that emits light in the infrared region.
It can provide up to 25 kW in continuous-wave mode.
Nd:YAG: Neodymium-doped Yttrium-Aluminum-Garnet (Y3Al5O12) laser is a solidstate laser which can deliver light through a fibre-optic cable. It can provide up to 50 kW
power in pulsed mode and 1 kW in continuous-wave mode.
8.2 Working Principle of LBM
LBM uses the light energy of a laser beam to remove material by vaporization and ablation. The
working principle and the process details (setup) are indicated in Figure 5.6. In this process the
energy of coherent light beam is focused optically for predecided longer period of time. The
beam is pulsed so that the released energy results in an impulse against the work surface that
does melting and evaporation. Here the way of metal removing is same as that of EDM process
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but method of generation of heat is different. The application of heat is very finely focused in
case of LBM as compared to EDM.
Laser Tube and Lamp Assembly
This is the main part of LBM setup. It consists of a laser tube, a pair of reflectors, one at each
end of the tube, a flash tube or lamp, an amplification source, a power supply unit and a cooling
system. This whole setup is fitted inside a enclosure, which carries good quality reflecting
surfaces inside. In this setup the flash lamp goes to laser tube, that excites the atoms of the inside
media, which absorb the radiation of incoming light energy. This enables the light to travel to
and fro between two reflecting mirrors. The partial reflecting mirror does not reflect the total
light back and apart of it goes out in the form of a coherent stream of monochromatic light. This
highly amplified stream of light is focused on the workpiece with the help of converging lense.
The converging lense is also the part of this assembly.
Workpiece
The range of workpiece material that can be machined by LBM includes high hardness
and strength materials like ceramics, glass to softer materials like plastics, rubber wood, etc. A
good workpiece material high light energy absorption power, poor reflectivity, poor thermal
conductivity, low specific heat, low melting point and low latent heat.
Cooling Mechanism
A cooling mechanism circulates coolant in the laser tube assembly to avoid its
overheatingin long continuous operation.
Tool Feed Mechanism
There is no tool used in the LBM process. Focusing laser beam at a pre-decided point in
the workpiece serve the purpose of tool. As the requirement of being focused shifts during the
operation, its focus point can also be shifted gradually and accordingly by moving the
converging lense in a controlled manner. This movement of the converging lense is the tool feed
mechanism in LBM process.
8.3 Applications of LBM
LBM is used to perform different machining operations like drilling, slitting, slotting, scribing operations.
It is used for drilling holes of small diameter of the order of 0.025 mm. It is used for very thin stocks.
Other applications are listed below:
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i.
10ME665
Making complex profiles in thin and hard materials like integrated circuits and printed circuit
boards (PCBS).
ii.
Machining of mechanical components of watches.
iii.
Smaller machining of very hard material parts.
8.4 Advantage of laser cutting

1. No limit to cutting path as the laser point can move any path.
2. The process is stress less allowing very fragile materials to be laser cut without any
support.
3. Very hard and abrasive material can be cut.
4. Sticky materials are also can be cut by this process.
5. It is a cost effective and flexible process.
6. High accuracy parts can be machined.
7. No cutting lubricants required
8. No tool wear
9. Narrow heat effected zone
8.5 Limitations of laser cutting

1 Uneconomic on high volumes compared to stamping
2 Limitations on thickness due to taper
3 High capital cost
4 High maintenance cost
5 Assist or cover gas required
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Electron Beam Machining

8.6 Introduction
The earliest work of material removal utilizing an electron beam wasattributed to Steigerwald
who designed a prototype machine in 1947.Electron beam machining (EBM) has been used in
industry since the1960s, initially in nuclear and aerospace welding applications. Drillingsmall
holes, cutting, engraving, and heat treatment are a set of modernapplications used in
semiconductor manufacturing as well as micromachiningareas.
8.7 Principles, equipment and operation ofElectron Beam Machining
The main components of EBM installation, shown in Fig. 5.43 arehoused in a vacuum chamber,
evacuated to about 104 torr. The tungsten filament cathode is heated to about 2500 to 3000C in
order to emit electrons. A measure of this effect is the emission current, the magnitude of which
varies between 20 and 100 mA. Corresponding current densities lie between 5 and 15 A/cm2.
Emission current depends on the cathode material, temperature, and the high voltage that is
usually about 150 kV. Such a high voltage accelerates a stream of electrons in the direction of
the workpiece. After acceleration, electrons, focused by the field, travel through a hole in the
anode. The electron beam isthen refocused by a magnetic or electronic lens system so that the
beam is directed under control toward the workpiece. The electrons the velocity (228 103
km/s) imparted by the acceleration voltage until they strike the workpiece, over a well-defined
area, typically 0.25 mm in diameter.
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The kinetic energy of the electrons is then rapidly transmitted intoheat, causing a corresponding
rapid increase in the temperature of the workpiece, to well above its boiling point, thus causing
material removal by evaporation. With power densities of 1.55 MW/mm2 involved in EBM,
virtually all engineering materials can be machined by this machining technique. Accurate
manipulation of the workpiece coupled with the precise control of the beam is reported by
McGeough (1988) to yield a machining process that can be fully automated.
8.8 Advantages Electron Beam Machining

i.
Drilling is possible at high rates (up to 4000 holes per second).
ii.
No difficulty is encountered with acute angles.
iii.
Drilling parameters can easily be changed during machining.
iv.
No limitation is imposed by workpiece hardness, ductility, and surfacereflectivity.
v.
No mechanical distortion occurs to the workpiece since there is no contact.
vi.
The process is capable of achieving high accuracy and repeatabilityof 0.1 mm for
position of holes and 5 percent for the hole diameter.
vii.
The process produces the best surface finish compared to otherprocesses.
viii.
The cost is relatively small compared to other processes used to producevery small holes.
8.9 Disadvantages Electron Beam Machining

i.
High capital equipment cost
ii.
Long production time due to the time needed to generate a vacuum
iii.
The presence of a thin recast layer
iv.
Need for auxiliary backing material
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Non Traditional Machining

Subject Code: 10ME665

Exam Marks: 100

Non Traditional Machining

UNIT - 6 Electrical Discharge Machining (EDM): Introduction, mechanism of metal removal,

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

2. Ultrasonic Machining (USM)

3. Abrasive Jet Machining (AJM)

4. Electrochemical Machining (ECM)

5. Chemical Machining (CHM)

6. Electrical Discharge Machining (EDM)

7. Plasma Arc Machining (PAM)

8. Laser Beam Machining (LBM)

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

Non Traditional Machining

1960 The concept of whirling jet machining was innovated.

1.3 Classification of NTM processes

Non Traditional Machining

c) Electron Beam Machining (EBM)

1.4 Comparison between conventional and Non-conventional machining process selection.

Non Conventional Process

There is no physical contact betweenthe tool and

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

High power sine wave generator

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

Al203, SiC, B4C, Boron silicarbide, Diamond.

7. Flow strength of the work material

Non Traditional Machining

Non Traditional Machining

It can be adopted in conjunction with other new technologies like EDM,ECG,ECM.

Throwing of abrasive grains

Hammering of abrasive grains

Cavitations in the fluid medium arising out of ultrasonic vibration of tool.

Chemical erosion due to micro agitation

Non Traditional Machining

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

a) Composition Air, CO2, N2

2. Cleaning of metallic smears on ceramics, oxides on metals, resistive coating etc.

Non Traditional Machining

1. Limited capacity due to low MRR. MRR for glass is 40 gm/minute

3. The accuracy of cutting is hampered by tapering of hole due to unavoidable flaring of

4. Stray cutting is difficult to avoid

6. Nozzle life is limited (300 hours)

DEPARTMENT OF MECHANICAL ENGG, SJBIT

Non Traditional Machining

3.8 Machining characteristics