8unconventional Machining Processes

8/8/2019 8unconventional Machining Processes

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DhruvLalitAashutosh


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HYDRODYNAMIC MACHININGHYDRODYNAMIC MACHINING

(WATER JET MACHINING)(WATER JET MACHINING)

# HIGH

VELOCITY# NARROW JET


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Advantages Disadvantages

y THE ABILITY TOCUT MATERIALWITHOUT INTERFERING THEMATERIALS INHERENT STRUCTURE ASTHERE IS NO HEAT AFFECTED ZONE

y IT DOSENT CHANGE THE PROPERTYOF MATERIAL

y USESLESSWATER

y WATERCAN BE RECYCLE FORCLOSELOOP SYSTEM

y MIN. INSIDE REDIUSAN ABRASICEJET CAN CUT ISABOUT 0.38MM,WHICH CAN BE REDUCED TO0.25MMM WITH SPECEL NOZZEL

y FOR THICK MATERIAL TOLERANCE ONHOLE MAKING BECOMEINCREASINGLY DIFFICULT.


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ApplicationApplication

TOCUT RUBBER, FOAM, PLASTICS, COMPOSITES, STONE, TILE, PAPER

GLASSCAN NOT BE CUT USING THIS PROCEDURE

THERE IS NOLIMITATION FOR THICKNESSOF MATERIAL,

IT CAN CUT OVER 45CM THICK


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ULTRASONIC MACHINING PROCESSULTRASONIC MACHINING PROCESS

# VIBRATING TOOL

# ABRASIVE SLURRY


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y ABRASICE SLURRY FREELY MOVESBETWEEN W.P. ANDVIBRATING TOOL

y VERY LITTLE HEAT IS PRODUCED

y TOOL NEVERCONTACT TOW.P.

y PREFERABLE FOR MACHINING EXTREMELY HARDANDBRITTLE MATERIALSUCH AS, GLASS, RUBY, CYRAMIC


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ELECTRO DISCHARGE MACHININGELECTRO DISCHARGE MACHININGPROCESS (EDM)PROCESS (EDM)


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EDMEDM

y TYPICALY USEDFOR VERY HARD MATERIAL

y ONLY ELEVTRIACLY CONDUCTIVE MARERILSCAN BEMACHINES

y MATERIALS: STEEL, TITANIUM, CARBIDE

y COMMONLY USEDFOR TOOLANDDIE INDUSTRY FOR MOLDMAKING

y AIROSPACE AND ELCTRONIC INDUSTRIESWHEREPRODUCTION QUANTITY REMAIN LOW.


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EDMEDM

WIRE EDM SIKER EDM

y ELECTRO THERMAL

PRODUCTION PROCESS INCHISH SINGLE STAND METALWIRE, CUT METAL THROUGHUSE OF ELECTRICSPARK

y INHERENT PROPERTIESOF

PROCESS, IT EASILY CUTCOMLEX PARTSOUT OF HARDCONDUCTIVE MATERILS

y TWO METAL PARTSSUMERGED

IN TO ISULATING LIQUIDARECONNECTED TOSOURCE OFCURRENT WHICH ISSWITCHEDON ANDOFFDEPENDSUPONTHE PARAMERSSET ON THECONTROLLER

y THE ELECTRICAL TENSION ISDISCHARGEDANDSPARKJUMPSACROSS, WHICH INSTRIKES THE METAL IS HEATEDSO MUCH THAT IT MELTS


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ELECTRO CHEMICAL MACHININGELECTRO CHEMICAL MACHININGPROCESSPROCESS

# ELECTRICCURRENTIS PASSEDBETWEENTWOCONDUCTROS INTOLIQUIDSOLUTION


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ECMECM

y PRINCIPLE OFOPERATION

y IT WORKSON FARADAYSLAW

y THE AMOUNT OFANY SUBSTANCE DESOLVED ISDIRECTLYPROPOSNATE TO MOUNT OF ELECTRICITY FLOWED

y USEDFOR INNERALLOY STUCTURE METALCOATING,

LIKE ZINKCOATING, PROTECTION COATING


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ELECTRON BEAM MACHININGELECTRON BEAM MACHINING

HIGH VELOCITY

ELECTRONSAREDIRECTED TOWARDSAWP, CREATING BEAT ANDVAPORISING THE METAL


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APPLICATION

y EBM CAN BE USEDFOR VERYACCURATE CUTTING OFWIDEVARITIESOF MELTS

y SURFACE FINISH ISBETTERTHEN OTHE THERMALCUTTINGPROCESS

y BEST USEDFORSMALL PARTS

y IT PRODUCES HAZARDOUS X-RAYS

y ELECTROMAGNATICLENSESARE USED TODIRECT THELECTRON BEAM, BY MEANSOFDEFLECTION, IN TOA VACCUME


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PLASMA ARC MACHININGPLASMA ARC MACHINING

# HIGH VELOCITY JET OFHIGH TEMPRETURE GAS TOMELT ANDDISPLACE MATERIALON ITS PATH

# USEDFORCUTTING SHEETMETALPOWERFULL TORCHESCANCUT UP TO 150mm THICKPLATE


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LimitationsLimitations

RISKOF ELECTROCUTION

DIFFICALT TORAPAIR

SPARK GAP IS TOBEMAINTAINED

LARGE AMOUNT OFRADIOFREQUENCY


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Explosive formingExplosive formingy The driving forceused isexplosioninstead ofpressure.

y This method isusedfortheparts whichareverylargeinsizeand requirehugepressures.


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Explosive formingExplosive forming


y Cheaperthan buildingapress.

y Surface finishismaintained.

y Nophysicalcontact

y Only batchproductionispossible

y Longsetuptime

y Cancause workhardeningin MildSteel.


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Electro hydraulic formingElectro hydraulic forming

y The driving forceused isexplosioninstead ofpressure.

y

Thisissimilartoexplosive formingexceptthesourceused.

y Instead ofexplosive, electricarcisused.


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Electro hydraulic formingElectro hydraulic forming


y Sequentialoperationispossible

y Precisecontrolcan beachieved.

y Only batchproductionispossible

y Largecapacitor bankrequired.


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Electromagnetic formingElectromagnetic forming

y Lenzslaw.

y Thissystem worksonmagneticrepulsiontoovercomeyieldstrength.

y Used inradialysymmetricconductingobjects.

y Used effectively withCu, Al;also with M.S.


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Electromagnetic formingElectromagnetic forming


y

Deformitiesareavoided.

y Metalscan be formedovernonconductingmaterialslikeglass

and plastic.y Reduced spring backy Surfaceremainsuntouched.

y Notapplicable fornonconducting materials

y Safelyashugecurrentisinvolved.

y Limitationinsize


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High Velocity formingHigh Velocity forming

y ImplementingKineticenergy forcarryingout

forging.y Twotypes:a. Hydro-forgeb. Petro-forge


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High Velocity formingHigh Velocity forming


y Noneed ofhigh

pressure.y Compact

y Fastand effectiveaction

y Surfacequality

reduces duetoimpact

y Fast movingpartsincrease

maintenance.


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Ion implantationIon implantationy Advanced methodofachieving desiredqualitiesintheoutermostlayer.

y Ionsof desiredalloyingelementareimplanted intothesurface.


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Ion ImplantationIon Implantation

y Ionsareimplanted withthehelpoflasersorelectron beams.

y The desired propertiesaregiventothesurface byimplantingionsofsuitableelementonthesurface.

y This method findsapplicationin Nitriding

[increaseinsurfacehardness],carbonizing[increasein wearresistance],etc.


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Ion implantationIon implantation


y Low temperature

process.y NochangeinDimensions

y Impossibleto bind

elementscan bebonded intoalloys

y Low depthof

penetration.y Highcostofprocess.

y Canonly workinadirectionnormalto

surface.


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Electro depositionElectro depositiony Electro-depositionistheprocessofformingalayerofone metalover

another.

y WorksonFaradayslaw.


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Rapid PrototypingRapid Prototyping

y Rapid prototypingisthetechnologydeveloped tocreateathree dimensional

modelofaproductinlesstime.y Prototyped partsareused for fastershapereviews, checkingassemblies, marketingand aesthetics.


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Rapid PrototypingRapid Prototyping


y Reduced prototypingtime

y Easyinspection

y Easyvisualization

y Highcost

y Poorsurface finish

y Modelsgenerated inrapid prototypingmachinescannot be

used for mechanicalanalysis.


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STL file formatSTL file formaty Rapid prototypingmachines workin .stl

formaty The fileisgenerated

by meshingthesmooth 3Dsurfacesbytetrahedraltessellations.

y Thesetessellationswhenputtogethergenerateoverall

geometryoftheshape.

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8unconventional Machining Processes