Non traditional technologies

BACHELOR OF ENGINEERING

MANUFACTURING TECHNOLOGIES

NON-TRADITIONAL TECHNOLOGIES

by Endika Gandarias

2 by Endika Gandarias

Dr. ENDIKA GANDARIAS MINTEGI Mechanical and Manufacturing department Mondragon Unibertsitatea - www.mondragon.edu (Basque Country) www.linkedin.com/in/endika-gandarias-mintegi-91174653

Further presentations: www.symbaloo.com/mix/manufacturingtechnology

http://www.mondragon.edu/eps

http://www.linkedin.com/in/endika-gandarias-mintegi-91174653







http://www.symbaloo.com/mix/manufacturingtechnology

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CONTENTS

BIBLIOGRAPHY INTRODUCTION NON-TRADITIONAL TECHNOLOGIES:

Ultrasonic Machining (USM) Jet Machining (AJM / WJM / AWJM) Chemical Machining (CM) Electro-Chemical Machining (ECM) Plasma Arc Machining (PAM) Laser Beam Machining (LBM) Electro Discharge Machining (EDM) Ion Beam Machining (IBM) Electron Beam Machining (EBM)

SUMMARY GLOSSARY

by Endika Gandarias

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BIBLIOGRAPHY

BIBLIOGRAPHY

by Endika Gandarias

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The author would like to thank all the bibliographic references and videos that

have contributed to the elaboration of these presentations.

For bibliographic references, please refer to:

• http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)

• http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)

For videos, please refer to:

• www.symbaloo.com/mix/manufacturingtechnology

BIBLIOGRAPHY

by Endika Gandarias

http://www.slideshare.net/endika55/bibliography-71763364

http://www.slideshare.net/endika55/bibliography-71763366

http://www.symbaloo.com/mix/manufacturingtechnology

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INTRODUCTION

INTRODUCTION

by Endika Gandarias

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INTRODUCTION

• Non-traditional technologies refer to a group of processes that remove material NOT using a sharp cutting tool like in conventional machining. In contrast, non-traditional technologies use other type of energies to remove material:

IMPORTANCE OF NON-TRADITIONAL TECHNOLOGIES

• To machine newly developed difficult to cut materials: high strength, high hardness and high toughness.

• When workpiece is too flexible or slender to support conventional cutting/grinding forces.

• To machine complex part geometries which are difficult or impossible to machine by traditional methods.

• To avoid surface damage, such as stresses, created in conventional processes.

MECHANICAL

ELECTRO-CHEMICAL

THERMO-ELECTRICAL

CHEMICAL

by Endika Gandarias

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INTRODUCTION

by Endika Gandarias

Low HAZ

No HAZ

HAZ

HAZ: Heat Affected Zone

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1980, Machining data Handbook

INTRODUCTION

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NON-TRADITIONAL

TECHNOLOGIES

NON-TRADITIONAL TECHNOLOGIES

by Endika Gandarias

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ULTRASONIC MACHINING (USM)

Dimensional tolerance: ± 0,0025mm Surface finish: Ra ~ 0,1-0,8µm

by Endika Gandarias

THERMO-ELECTRICAL MECHANICAL CHEMICAL ELECTRO-CHEMICAL


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A vibrating tool oscillates at ultrasonic frequencies (f=20-30kHz & A=15-50µm).

The tool never contacts the workpiece, and the abrasive slurry flows freely between the tool and the workpiece (20-50 µm gap). Abrasive grains (100-800 grit size) – SiC, Al2O3, CBN, diamond Abrasive slurry – abrasive grains (20-60%) + usually water

PRO:

Low HAZ. Suitable for hard and brittle non-conductive materials: ceramics, glass or carbides

(otherwise EDM or ECM is used). Holes and cavities with various shapes can be produced. Excellent surface finish.

CON:

Low MRR (Material Removal Rate). Small depth of holes and cavities can be produced. Tool wear rate is fast (tool is usually softer than the

workpiece as it needs to be tough: soft steel or stainless steel).

by Endika Gandarias


VIDEO VIDEO VIDEO

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Types of parts made by this process

by Endika Gandarias


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JET MACHINING (AJM / WJM / AWJM)


AJM: Dimensional tolerance: ± 0,05mm Surface finish: Ra ~ 0,15-1,5 µm

WJM / AWJM: Dimensional tolerance: ± 0,025mm Surface finish: Ra ~ 1,6-6.3 µm

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Abrasive Jet Machining (AJM) It is an abrasive blasting machining process that uses abrasives (SiC, Al2O3 or glass bead of

Ø15-40µm) propelled by a high velocity (150-300m/s) gas (air or inert gas) to erode material from the workpiece.

It is mainly used for finishing operations: deburring, cleaning and polishing (cutting thin plates too).

PRO: Low HAZ. It can be easily automated for high production volumes. Ability to machine hard and brittle materials. Good surface finish.

CON:

Low MRR. Tends to round off sharp edges

and it produces tapered cut.

by Endika Gandarias


BLASTING

VIDEO

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Water Jet Machining (WJM)

It uses a fine, high pressure, high velocity (540-1400m/s) stream of water (~ Ø0.1-0.4mm) directed at the work surface to cause cutting of the workpiece.

Cutting of all non-metallic materials (food, composites, plastics, fabrics, rubber, wood, paper,…).

PRO: Low HAZ. It can be easily automated. Ability to machine flexible materials. Burr produced is minimum.

CON:

Limited number of materials can be cut economically. It produces tapered cut. Noisy.

by Endika Gandarias


VIDEO VIDEO

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Abrasive Water Jet Machining (AWJM)

The water jet contains abrasive particles (quartz sand, SiC or Al2O3 at 60-120 grit size, up to 900 m/s) to increase the material removal rate and enable cutting of thick and hard materials.

Cutting of metallic and non-metallic materials (marble, granite, stone, composites, wood, titanium alloys,…).

Same PROs and CONs as WJM.

by Endika Gandarias


VIDEO

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Various non-metallic parts (WJM) 5-axis waterjet cutting head (WJM)

Cutting food (WJM) Marble waterjet cutting (AWJM)

by Endika Gandarias


VIDEO

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CHEMICAL MACHINING (CM)

CHEMICAL

Dimensional tolerance: ± 0,08mm Surface finish: Ra ~ 0,1-6,3 µm

by Endika Gandarias

THERMO-ELECTRICAL MECHANICAL ELECTRO-CHEMICAL


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This process is also called etching.

The metal is removed by the chemical attack of an acidic or alkaline etchant (FeCl3, H2SO4, HNO3). The portion of workpiece where no material is to be removed is masked (maskant: polymer or rubber) before chemical etching. The process is usually carried out at high temperature.

Steps: Cleaning masking etching demasking

PRO: No HAZ and no forces. It is not workpiece hardness dependent. Complicated shapes can be produced. Good surface quality. Simple to implement, low tooling and equipment cost. Suitable for low production runs. No burr formation.

CON:

Very low MRR, limited to thin layers. Difficult to get sharp corners. Low dimensional accuracy.

by Endika Gandarias

CHEMICAL THERMO-ELECTRICAL MECHANICAL ELECTRO-CHEMICAL

VIDEO VIDEO VIDEO

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Missile skin-panel section contoured by chemical milling to improve the stiffness-to-weight ratio of the part.

Weight reduction of space-launch vehicles by the chemical milling of aluminum-alloy plates.

by Endika Gandarias

CHEMICAL THERMO-ELECTRICAL MECHANICAL ELECTRO-CHEMICAL

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ELECTRO-CHEMICAL MACHINING

(ECM)

ELECTRO-CHEMICAL


by Endika Gandarias

THERMO-ELECTRICAL CHEMICAL MECHANICAL

ELECTRO-CHEMICAL MACHINING (ECM)

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Electrochemical machining removes material from an electrically conductive workpiece by anodic dissolution. Workpiece geometry is obtained by a formed electrode tool which is in close proximity but separate.

An electrolyte acts as a current carrier, and high electrolyte movement in the tool-workpiece gap washes metal ions away from the workpiece (anode) before they are deposited on the tool (cathode).

Tool – generally made of bronze, copper, brass or stainless steel. Electrolyte – salt solutions in water. Power – DC supply 5-25V & 1000A.

PRO:

High MRR No HAZ & no mechanical distortion. There is almost no tool wear. It is not workpiece hardness dependent. Complex shapes with deep cavities. Burr free surface.

CON:

Workpiece electrically conductive. Expensive tooling and equipment. High power consumption.

by Endika Gandarias

ELECTRO-CHEMICAL THERMO-ELECTRICAL CHEMICAL MECHANICAL

VIDEO VIDEO VIDEO

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by Endika Gandarias

ELECTRO-CHEMICAL THERMO-ELECTRICAL CHEMICAL MECHANICAL

Its industrial application has been extended to: • ECM machining • ECM drilling • ECM deburring • ECM grinding • ECM polishing

VIDEO

VIDEO

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PLASMA ARC MACHINING (PAM)

Dimensional tolerance: ± 1.3mm Surface finish: Ra ~ 0,8-6,3 µm

by Endika Gandarias

THERMO-ELECTRICAL MECHANICAL ELECTRO-CHEMICAL CHEMICAL


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A plasma is a ionized gas typically formed when heating the gas at high temperatures (>5000ºC). Plasma state: Molecules are separated into atoms, and atoms are disaggregated into free electrons and positive atom nucleus.

It uses a high velocity jet of high temperature gas (Ar, N, H, He or mixtures of them) called plasma that melts the metal and then removes the molten material to form a kerf.

The electrode (W) and nozzle of the gun create a strong electric arc gases collide the arc and become into plasma.

It is used to cut flat metal sheets and plates and it can be used manually or by CNC.

PRO: Highest MRR among non-traditional processes. Very hard and brittle metals can be machined.

CON:

Relatively large HAZ. Generally used for conductive materials (Plasma is

highly conductive). High cost equipment. Safety precautions are needed. Rough surface finish.


by Endika Gandarias


VIDEO

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by Endika Gandarias


VIDEO

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LASER BEAM MACHINING (LBM)


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LASER stands for Light Amplification by Stimulated Emission of Radiation.

It uses the light energy from a laser to remove material by vaporization and ablation. Laser beam melts the material by focusing a coherent beam of monochromatic light on the workpiece.

Energy of the coherent light is concentrated not only optically, but also in terms of time. The type of laser used in LBM is typically the CO2 gas laser.

It is used to perform cutting, drilling, slotting or scribing.

PRO: Unlimited range of materials: high hardness metals,

ceramics, glass, rubber, wood, cloth, food,… Does not require a vacuum. No tool wear. Easy to be automatized.

CON:

Low MRR. HAZ exists. High reflectivity materials (mirror) may be a problem. Expensive equipment. High energy consumption. It produces tapered cut.

by Endika Gandarias


VIDEO VIDEO

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Sheet metal cutting

by Endika Gandarias

PHB stent

Coronary Stent


Tube cutting

VIDEO

VIDEO

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ELECTRICAL DISCHARGE MACHINING

(EDM) Dimensional tolerance: ± 0.025mm Surface finish: Ra ~ 0,05-12,5 µm

by Endika Gandarias


ELECTRICAL DISCHARGE MACHINING (EDM)

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The workpiece is removed by a series of sparks that cause localized melting and evaporation of the material in the presence of a dielectric fluid.

The workpiece is typically submerged in a dielectric bath of deionized water or oil.


by Endika Gandarias


VIDEO

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A formed electrode tool produces the shape of the workpiece. Electrode – copper, tungsten, graphite or brass.

PRO:

It is one of the most widely used non-traditional processes. It is not workpiece hardness dependent. Complex geometries can be produced.

CON:

Low MRR. HAZ exists. Workpiece needs to be electrically conductive. Not capable to produce sharp corners. Tool wear affects dimensional accuracy.

Sinking EDM

by Endika Gandarias


VIDEO

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Wire EDM

It uses a small diameter wire (Ø0,08-0,3mm) to cut a narrow kerf in the work. Wire – brass, copper, tungsten or molybdenum

PRO:

It is one of the most widely used non-traditional processes. It is not workpiece hardness dependent. It is well-suited to produce: gears, dies, cams,…

CON:

HAZ exists. Workpiece needs to be electrically

conductive. Expensive equipment.

by Endika Gandarias


VIDEO VIDEO

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by Endika Gandarias

Sinking EDM die Wire EDM parts

Sinking EDM: screw thread

Sinking EDM: cavities produced by shaped electrodes

Sinking EDM: fuel injection nozzle


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ELECTRON BEAM MACHINING

(EBM) Dimensional tolerance: ± 0,08mm Surface finish: Ra ~ 0,2-6,3µm

by Endika Gandarias


ELECTRON BEAM MACHINING (EBM)

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It is a metal removal process that uses a high velocity focused stream of electrons (Ø~25µm).

Electrons are created when high voltage is applied to a Wolframium filament Accelerated by a strong electric field (200.000km/s) Focused by magnetic fields Kinetic energy of the electrons is transformed into thermal energy which melts and vaporizes the material.

Vacuum chamber is necessary to avoid electron-air molecules collisions.

It is used for drilling small holes, cutting, engraving, heat treatments, and improving surface roughness.

PRO: Works on any material. It is not workpiece hardness dependent. Very small holes and slots can be machined No tool wear.

CON:

Low MRR. HAZ exists. Vacuum requirements limit part size. Expensive equipment.

by Endika Gandarias


VIDEO

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EBM in a vacuum

EBM in ambient air

by Endika Gandarias

Surface roughness improvement

Material: 316L SS Hole: Ø~0,1mm Thickness: ~1,5mm


VIDEO

VIDEO

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ION BEAM MACHINING (IBM)

THERMO-ELECTRICAL

Dimensional tolerance: ± ??mm Surface finish: Ra ~ <0.0001 µm

by Endika Gandarias

MECHANICAL ELECTRO-CHEMICAL CHEMICAL


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This process is also called Focused Ion Beam (FIB).

A stream of charged atoms (ions) of an inert gas (Ar, He, Ga) is accelerated in a vacuum chamber by electrical means and directed toward the workpiece to remove (or add) atoms. When an atom strikes a cluster of atoms on the workpiece, it dislodges between 0.1 and 10 atoms from the workpiece material. Spot size Ø~2-20nm

Electrons are created when high voltage is applied to a Wolframium filament (high temperature) Accelerated by a strong electric field those interact with inert gas atoms to produce ions: Ar + e− → Ar+ + 2e-

It is used in micro/nanofabrication for smoothing of laser mirrors, polishing optical & shaping

surfaces,…

PRO: Capable of modifying any material at

micro/nano scale.

CON: Low MRR. HAZ exists (< 1 μm). Vacuum chamber is required. High cost equipment.

by Endika Gandarias


VIDEO

VIDEO

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Photonics

by Endika Gandarias


VIDEO

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SUMMARY

SUMMARY

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SUMMARY

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SUMMARY

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SUMMARY

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GLOSSARY

GLOSSARY

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GLOSSARY

by Endika Gandarias

ENGLISH SPANISH BASQUE

Ablation Ablación Ablazio Bead Abalorio Beira ale Beam Haz Sorta Blasting Chorreado Jariaketa Brass Latón Letoia Breakdown Ruptura Haustura Brittle Frágil Hauskor Bubble Burbuja Burbuila Burr Rebaba Bizar Cam Leva Espeka Cardboard Cartón Kartoi Chamber Cámara Ganbera Cladding Aporte Aportazio Close Cerca Gertu Cloth Tela Oihal Cluster Grupo Multzo Coating Recubrimiento Estaldura Coil Bobina Bobina Collide Chocar Talka egin Conductive Conductor Eroale Copper Cobre Kobre Debri Desecho Hondakin Deburring Desbarbado Bizar kentze Die Molde Molde Dielectric Dieléctrico / No conductor Dielektriko / Ez eroale Disaggregated Disgregado Sakabanatuta Dislodge Dislocar Dislokatu Drain Desagüe Hustubide

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GLOSSARY

by Endika Gandarias


Drilling Taladrado Zulaketa Electro discharge machining Mecanizado por electroerosión Elektrohigadura bidezko mekanizazio Electron Beam Machining Mecanizado por haz de electrones Elektroi sorta bidezko mekanizazio Engraving Grabado Grabazio Etchant Atacante Erasotzaile Etching Ataque químico Eraso kimiko Exhaust Campana de humos Kanpai Fabric Tela Ohial Fair Justo Justu FeCl3 Cloruro de hierro Burdin kloruro Focal length Longitud / Distancia focal Foku distantzia Focus Enfocar Enfokatu Gap Hueco Hutsune Gear Engrane Engranai Glass Vidrio Beira Glazing Vidriado Beiratze Grain Grano Ale Grid Rejilla Bursin sare / Sareta Grit Grano abrasivo Ale urratzaile Gun Pistola Pistola H2SO4 Ácido sulfúrico Azido sulfuriko Hardening Temple Tenple Hardness Dureza Gogortasuna Heat Calor Bero Heating Calentador Berogailu HNO3 Ácido nítrico Azido nitriko Insulating Aislante Isolatzaile Ion beam machining Mecanizado por haz de iones Ioi sorta bidezko mekanizazio

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GLOSSARY

by Endika Gandarias


Jet machining Mecanizado por chorro Zurrusta bidezko mekanizazio Kerf Canal de corte Mozte bide Leek Puerro Porru Len Lente Lente Machining Mecanizado Mekanizazio Marble Mármol Marmol Maskant Enmascarante Estalki / Maskaratzaile Melt Derretir Urtze Mirror Espejo Ispilu Molten Derretido Urturiko Non traditional technologies Tecnologías no tradicionales Teknologia ez ohikoak Nozzle Boquilla Aho / Pita Plasma arc machining Mecanizado por plasma Plasma bidezko mekanizazio Plate Placa Plaka / Xafla Polishing Pulido Leunketa Powder Polvo Hauts Propel Impulsar Bultzatu Pump Bomba Bonba Reel Carrete / Bobina Bobina Removal rate Tasa de eliminación Ezabapen tasa Rough Basto Trauskil Rubber Goma / Caucho Goma / Kautxu Scribing Trazado a mano Eskuz idatzia Shaping Dar forma Forma eman Sharp Afilado Zorrotz Shear Cizallado Zizailaketa Sheet Chapa Xafla Sinking EDM Electroerosión por penetración Sartze elektrohigadura

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GLOSSARY

by Endika Gandarias


Skin Piel Azal Slender Esbelto Lerden Slot Ranura Arteka Slurry Pasta / Lodo Ore / Lokatz Spark Chispa Txinpart Spot Punto Puntu Sputter Escupir Jaurti Stainless steel Acero inoxidable Altzairu erdoilgaitz Standoff distance Distancia de alejamiento Urruntze tarte Stands for Significa Adierazi / Esan nahi Stiffness Rigidez Zurruntasun Stone Piedra Harri Stream Chorro Zurrusta Strength Resistencia Erresistentzia Surface roughness Rugosidad superficial Gainazal zimurtasuna Tapered cut Corte inclinado Mozte inklinatu Tough Resistente Iraunkor Toughness Tenacidad Zailtasun Transducer Transductor Transduktore Ultrasonic machining Mecanizado ultrasónico Ultrasoinu bidezko mekanizazio Vacuum Vacío Huts Wash Limpiar Garbitu Wear Desgaste Higadura Welding Soldadura Soldadura Wire EDM Electroerosión por hilo Harizko elektrohigadura Workpiece Pieza Pieza

Engineering

Non traditional technologies