Chapter 4:

Advanced machining
Ref: Manufacturing Engineering &
Technology,
S. Kalpakjian, Pearson

Chapter Outline
1.
2.
3.
4.
5.

Introduction
Electrochemical Machining
Electrical-discharge Machining
Electron-beam Machining
Ultrasonic Machining

4.1 Introduction

Machining processes that involve chip

formation have a number of limitations:

Large amounts of energy

Unwanted distortion
Residual stresses
Burrs
Delicate or complex geometries may be difficult or
impossible

4.1 Introduction

Non-traditional machining (NTM) processes have

several advantages

Complex geometries are possible

Extreme surface finish
Tight tolerances
Delicate components
Little or no burring or residual stresses
Brittle materials with high hardness can be machined
Microelectronic or integrated circuits are possible to mass
produce

NTM Processes

Four basic groups of material removal using

NTM processes

Mechanical
Chemical
Electrochemical
Thermal

Conventional End Milling vs. NTM

Typical machining parameters

Feed rate
Surface finish
Dimensional accuracy
Workpiece/feature size

NTM processes typically have lower feed

rates and require more power consumption
The feed rate in NTM is independent of the
material being processed

4.1 Electrochemical Machining Process

Electrochemical
machining (ECM)
removes material by an
electrochemical
process
The tool is the cathode
and the workpiece is
the anode
Shape of workpiece is
the mirror image of tool
Figure Schematic diagram of
electrochemical machining process
(ECM).

4.1 Electrochemical Machining Process

p - density

4.1 Electrochemical Machining Process

As potential difference applied (2 to 30 V)
-At cathode (tool): electrolyte & water molecules ionize:
H2O H+ + OHNAClNa+ + Clpositive ions move towards the tool & negative ions move
towards the workpiece:
2H+ + 2e H2

-At anode (workpiece): metal molecules ionize break free

from the workpiece & travel to the tool
Fe Fe 2+ + 2e
- FeCl2 and Fe(OH)2 precipated in the form of sludge

Electrochemical Processing

Used to machine complex cavities and

shapes in high-strength materials
ECM process leaves a burr-free, bright
surface and used as deburring process
Electrolyte sweeps away any heat and waste
product during the reaction
Penetration rate is a function of inter
electrode gap

Electrochemical Machining
Application

Electrochemical Machining
Application

Burr free edges & smooth finishes

in medical devices

Advantages and Disadvantages of

Electrochemical Machining

Advantages

ECM is well suited for the

machining of complex
two-dimensional shapes
Poorly machinable
materials may be
processed
Little or no tool wear
No burr & no distortion of
the holes

Disadvantages

Initial tooling can be

timely and costly
Environmentally harmful
by-products

Electrochemical Machining

4.2 Electrical Discharge Machining

Process is based on the erosion of metals by spark

discharges
Two different types of EDM exist based on the shape of
the tool electrode
Ram EDM/sinker EDM
Wire EDM

EDM Processes

Examples of EDM workpieces

Graphite electrode & product

Electrical-discharge Machining
Principle of Operation

Figure 4.2 EDM or spark erosion machining of metal, using pulse

DC. The table can make X-Y movements.

Electrical-discharge Machining
Principle of Operation

EDM system consists of a electrode and the workpiece,

connected to a power supply (pulse DC) and placed in
a dielectric fluid.

The gap is filled by a die-electric fluid, which ionized at

the narrowest inter electrode gap.

The ionization of die electric fluid creates a conduction

path and produced spark.

The spark produces tiny crater in the workpiece by

melting & vaporization

High temperature also melt & vaporize the tool (wear)

Die electric flushes the chips

Electrical-discharge Machining
Principle of Operation

Fig. Formation of conduction path

& spark at inter electrode gap

Fig. Conduction path collapse &

die electric fluid flushes the chips

Electrical-discharge Machining
Principle of Operation

Electrical energy is dissipated as the thermal energy of

the spark.
Heat flux leads to extreme rise in temp. (>10,000deg C)
Material removal occurs due to instant vaporization of
the material & melting
The material-removal rate can be estimated from
MRR 4 104 ITw1.23

I = current in amperes
Tw = melting temp of work piece

Electrical-discharge Machining
Dielectric Fluids

The functions of the dielectric fluid are to:

1. Act as an insulator until the potential is sufficiently high
2. Provide a cooling medium
3. Act as a flushing medium and carry away the debris in
the gap
i.e. kerosene, distilled and deionized water

Electrical-discharge Machining
Electrodes

Electrodes are made of graphite, brass, copper or

coppertungsten alloys

Can be shaped by forming, casting, powder metallurgy,

or CNC machining techniques

Tool wear is related to the melting points of the

materials involved

Lower the melting point of the electrode, the higher is

the wear rate

Electrical-discharge Machining:
Wire EDM

Similar to contour cutting with a band saw

A slowly moving wire travels along a prescribed path
will cut the workpiece
Wire is made of brass, copper, tungsten, molybdenum,
zinc- or brass-coated or multicoated

Advantages and Disadvantages of EDM

Advantages
Applicable to all
materials that are fairly
good electrical
conductors
Hardness, toughness,
or brittleness of the
material imposes no
limitations
Fragile and delicate
parts

Disadvantages
Produces a hard recast
(resolidify) surface
Surface may contain
fine cracks caused by
thermal stress
Fumes can be toxic

Electrical-discharge Machining

Electron-beam Machining

The energy source is high-velocity electrons, which strike the

workpiece surface and generate heat
Used for very accurate cutting of a wide variety of metals
Surface finish is better and kerf width is narrower than in other
thermal cutting processes
Requires vacuum condition

4.5 Laser-beam Machining

The source of energy is a laser which focuses optical

energy on the surface of the workpiece
The highly focused, high-density energy source melts
and evaporates portions of the workpiece in a
controlled manner

Laser-beam Machining
Process Capabilities

It is used for drilling and cutting metals, nonmetallic

materials, ceramics, and composite materials

Laser-beam machining is being used increasingly in

the electronics and automotive industries

Also used for welding, small-scale and localized heat

treating of metals and ceramics, and marking of parts