Unconventional machining process
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Unconventional machining uses indirect energy sources like abrasives, laser beams, or electrical discharges to machine materials instead of direct contact between a tool and workpiece. It can machine hard materials and complex shapes without tool wear issues. Some common unconventional machining methods are abrasive jet machining, ultrasonic machining, electrochemical machining, electrical discharge machining, and laser beam machining. Each method uses a different indirect energy source to remove material from the workpiece.
Unconventional machining process
- 2. In ordinary machining we use harder tool to work on work piece, this limitations is overcome by unconventional machining, unconventional machining is directly using some sort of indirect energy For machining. Conventional machining involves the direct contact of tool and work -piece, whereas unconventional machining does not require the direct contact of tool and work piece. Conventional machining has many disadvantages like tool wear which are not present in Non-conventional machining. DEFINITION
- 3. Mechanical Processes Abrasive Jet Machining (AJM) Ultrasonic Machining (USM) Abrasive Water Jet Machining (AWJM) Electrochemical Processes Electrochemical Machining(ECM) Electro Chemical Grinding (ECG) Electro discharge machining(EDM) Wire electrical discharge machining(WEDM) Laser Beam Machining (LBM) Electron Beam Machining (EBM) CLASSIFICATION
- 4. It is the material removal process where the material is removed by high velocity stream of air/gas or water and abrasive mixture . An abrasive is small, hard particle having sharp edges and an irregular shape . High velocity jet is aimed at a surface under controller condition . Abrasive Jet Machining (AJM)
- 5. Abrasive Jet Machining (AJM)
- 6. Abrasive Water Jet Machining (AWJM) Used light energy from a laser to remove material by vaporization and ablation Energy is concentrated optically Laser emits either continuous or pulsed light beam
- 7. Abrasive Water Jet Machining (AWJM)
- 8. Ultrasonic Machining (USM) In the process of Ultrasonic Machining, material is removed by micro-chipping or erosion with abrasive particles. •In USM process, the tool, made of softer material than that of the work piece, is oscillated by the Booster and electrode at a frequency of about 20 kHz with an amplitude of about 25.4 um (0.001 in). •The tool forces the abrasive grits, in the gap between the tool and the work piece, to impact normally and successively on the work surface, thereby machining the work surface.
- 10. Non-conventional machining system in which metal is removed by electrochemical process Characterized as ‘Reverse Electroplating’ means it removes metal instead of adding it Normally used for mass production and for hard materials that are difficult to machine using conventional processes Electrochemical Machining (ECM)
- 12. Electro Chemical Grinding (ECG) • Electrochemical grinding is a variation of ECM that combines electrolytic activity with the physical removal of material by means of electrically charged wheels • ECG can produce burr free and stress free parts without heat or metallurgical caused by mechanical grinding , eliminating the need for secondary machining operations • Like ECM, (ECG) generates little or no heat that can distort delicate components
- 13. Electro Chemical Grinding (ECG)
- 14. Laser Beam Machining •Laser beam machining (LBM) is one of the most widely used thermal energy based non-contact type advance machining process which can be applied for almost whole range of material. •As the name suggest it uses LASER (Light Amplification by Stimulated Emission of Radiation ) for operations. •Laser is a coherent and amplified beam of Light.
- 16. Electron beam welding(EBM) • Electron beam is generated in an electron beam gun. Electron beam gun provides high velocity electrons over a very small spot size. • Electron Beam Machining is required to be carried out in vacuum. • Otherwise the electrons would interact with the air molecules, thus they would loose their energy and cutting ability. • Thus the work piece to be machined is located under the electron beam and is kept under vacuum. • The high-energy focused electron beam is made to impinge on the work piece with a spot size of 10 – 100 μm. •The kinetic energy of the high velocity electrons is converted to heat energy as the electrons strike the work material.
- 18. Electrical discharge machining(EDM) • The principle of EDM is also called electro discharge or spark erosion or electro erosion, is based on erosion of metals by spark discharges. • Since, when two current carrying conductors/wires are allowed to touch each other, an arc is produce. If we look closely at the point of contact b/w the two wires, we note that a small portion of metal has been eroded away, leaving a small crater.
- 20. Wire Electrical discharge machining(WEDM) • The principle used in the Wire cut EDM is same as that of EDM i.e. Thermal energy of spark is used to remove the material of the work piece. • It used wire of very small diameter 0.05 to 0.25mm as an electrode.