ME2026 Unconventional Machining Processes

Assignment I
Compiled by: Prof.B.Ramesh, (Ph.D.), Associate Professor in Mechanical Engineering,
St.Josephs College of Engineering, Chennai-119
Part B
1. Explain the reasons for the development of Unconventional Machining Process. Discuss
about the criteria recommended in selection of these processes.

(8+8)

There has been a rapid growth in development of harder and difficult to-machine metals
and alloys
Conventional machining is uneconomical for such materials and the degree of accuracy and
surface finish attainable is poor.
Advance strength level of work piece has a catastrophic effect on machining bill .
There need to be an improvement in machining technology
Merchant ( 1960) emphasized the need for development of newer concepts.
The newer machining processes developed are often called modern machining processes
or unconventional machining process
These are unconventional in the sense that conventional tools are not employed for metal
cutting instead energy in its direct form is utilized

2. (i) Explain the factors that should be considered during the selection of an appropriate
unconventional machining process for a given job.
(8)
A particular machining method found suitable under given conditions may not be equally
efficient under other conditions.
A careful selection of process is essential for the machining problem
Before selection the process the following aspects must be studied
Physical parameters
Properties of work material
Shape to be obtained
Process capability
Economic considerations

EDM and USM require approximately same power

ECM consumes roughly 40% more
ECM is an excellent method for drilling long slender holes (Length /diameter >20)

(ii) Compare and contrast the various unconventional machining process on the basis of the
type of energy employed, material removal rate, transfer media and economical aspects.
(8)
Modern machining methods are classified according to the type of fundamental
machining energy employed
Following table gives classification based on type of energy , mechanism of metal
removal, the source of energy requirements

3. (i) Classify the unconventional machining processes on the basis of mechanism of material

removal and energy sources used.

(8)

(ii) What exactly are the items that can be considered with respect to the analysis of economics of
various non traditional machining processes? Briefly explain.

4. Make a comparison between traditional and unconventional machining processing in terms of

cost, application, scope, machining time, advantages and limitations.

5. For different nonconventional processes, present in the form of a table, various process
parameters recommended.

6. Explain the basis upon which modern machining are classified. Why the unconventional

machining process not completely taking over the conventional machining process?

7. Analyze and compare the various nontraditional machining processes with respect to their
capability for the following operations:

Cavity sinking

Micro drilling

Contouring a surface

Pocketing Operation
(4x4=16)

Unit II

Part B
1. (i) Enumerate the salient features of AJM. (8)
This process of removal of material by impact erosion through the action of a
concentrated, high velocity stream of grit abrasives
It is used to cut hard and brittle materials and the process is free from vibration
AJM uses a stream of fine grained abrasive mixed with carrier gases at high
pressure
Stream is directed by means of a suitably designed nozzle onto the work surface
to be machined.
Material removal occurs due to erosion caused by abrasive particles

(ii) Discuss in detail about the AJM process variables that influences the rate of material removal
and accuracy in the machining. (8)

Carrier Gas
Gases used are air, carbondioxide and nitrogen
Air is widely used ( low cost and easily available)
Gas should be non toxic , cheap easily available
Capable of being dried and cleaned easily
Abrasives
Aluminum oxide , Silicon carbide are used for cutting
Sodium bicarbonate, Dolomite and glass beads are used for cleaning , etching ,
de-burring and polishing
The abrasive should have a sharp and irregular shape and be fine enough to
remain suspended in the carrier gas
Should have excellent flow characteristics
Grain size
Most favorable grain size 10 to 50 microns
Course grains are recommended for cutting
Finer grains are useful in polishing, deburring etc.
Jet Velocity
Kinetic Energy of the abrasive jet is utilized for metal removal by erosion.
Erosion to occur the jet must impinge the work surface with a certain minimum
velocity
Jet velocity is a function of nozzle pressure, nozzle design, abrasive size, mean
number of abrasives per unit volume of carrier gas. (M)
Vol. Flow rate of abrasives / unit time
M=
------------------------------------------Vol. flow rate of the carrier gas/ unit time

2. What is the fundamental principle of abrasive jet machining? Briefly explain, with a neat
diagram, the abrasive jet machining process. In abrasive water jet machining, how is material
removal rate increased? Also state how nozzle life is improved in such a machining process.

This process of removal of material by impact erosion through the action of a

concentrated, high velocity stream of grit abrasives
It is used to cut hard and brittle materials and the process is free from vibration
AJM uses a stream of fine grained abrasive mixed with carrier gases at high
pressure
Stream is directed by means of a suitably designed nozzle onto the work surface
to be machined.
Material removal occurs due to erosion caused by abrasive particles

Mechanism of material removal in AWJ machining

The general domain of parameters in entrained type AWJ machining system is given below:
Orifice Sapphires 0.1 to 0.3 mm
Focussing Tube WC 0.8 to 2.4 mm
Pressure 2500 to 4000 bar
Abrasive garnet and olivine - #125 to #60
Abrasive flow - 0.1 to 1.0 Kg/min
Stand off distance 1 to 2 mm
Machine Impact Angle 60o to 900
Traverse Speed 100 mm/min to 5 m/min
Depth of Cut 1 mm to 250 mm
Mechanism of material removal in machining with water jet and abrasive water jet is rather
complex. In AWJM of ductile materials, material is mainly removed by low angle impact by
abrasive particles leading to ploughing and micro cutting. Such process has been studied in detail
initially by Finnie[1] as available in the edited volume by Engels[1]. Further at higher angle of
impact, the material removal involves plastic failure of the material at the sight of impact, which
was studied initially by Bitter[2,3]. Hashish[4] unified such models as applicable under AWJM at a
later stage. In case of AWJM of brittle materials, other than the above two models, material would
be removed due to crack initiation and propagation because of brittle failure of the material. Kim et
al [5] have studied this in detail in the context of AWJM.

3. (i) Describe with the help of sketches , the effect of stand off distance on material removal rate
and machining accuracy in AJM. (8)
(ii) Enumerate with neat schematic diagram various elements of abrasive water jet machining
process. (8)
Stand Off Distance ( SOD)
Stand off is defined as the distance between face of the nozzle and the work

surface
A large SOD results in the flaring up of jet which leads to poor accuracy
Small MRR at low SOD is due to reduction in nozzle pressure with decrease in
distance
Small MRR at large SOD is due to reduction in jet velocity with increase in
distance.

4. With a neat sketch explain the principle of working of water jet machining process. List the
advantages and disadvantages of WJM process.

Water Jet Machining

Employs a fine jet of water with a high pressure ( 1500-4000MN/sq.m) and high
velocity ( upto twice the speed of sound)
When fine jet bombarded on the work piece erodes the material.
High velocity flow is virtually stopped, then the KE is converted to pressure
energy ( called stagnation pressure)
Mechanism of Metal removal
Mechanism of water jet machining is erosion caused by localized compressive failure
which occurs when the local fluid pressure exceeds the strength of the material
Jet cutting equipment
Pump : to pressurize the liquid to 1500 4000 MN/sq m
Tubing : High pressure to transport fluid
Ratio Outside to inside diameter is 5 to 10
Tubing made of solid stainless steel
Valves: most high pressure valves are of needle type
Nozzle : made of sintered diamond and sapphire
Exit diamter of nozzle 0.05 to 0.35mm

Advantages
Water is cheap, non toxic
Any contour can be cut
Does not generate heat
Best suited for explosive environments

5. (i) Explain the principle of USM with neat diagram. (10)

(ii) List the commonly used abrasive powder for the tooling of USM and their properties. (6)

Ultrasonic Machining

Ultrasonic frequency above the upper frequency of human ear

There are two types of waves , namely longitudinal waves and shear waves.
Longitudinal waves are mostly used in ultrasonic applications since they can be
easily propagated.
Device used to any type of energy into ultrasonic waves is called transducer.

Introduction

Material is removed by the action of abrasive grains

Abrasive particles are driven into the work surface by the tool oscillating normal
to the work surface at high frequency
The tool is shaped as approximate mirror image of the configuration of the cavity
desired in the work .

Some abrasives used are

o Alumium oxide ( Alumina)
o Boron Carbide
o Silicon carbide
o Diamond dust
Boron is the most expensive abrasive material but is best suited for tungsten
carbide , tool steel and precious stones
Silicon finds the maximum application
Diamond dust ensures good accuracy, surface finish and cutting rates
The size of abrasive vary from 200 and 2000 grit
Course grades are good for roughing, whereas finer grades (1200 to 2000) are
used for finishing
In actual practice the surface roughness of the machined face is governed by work
material, roughness on toll surface, vibration amplitude, fineness of abrasive grit,
efficient slurry circulation

6. Briefly discuss about the mechanisms involved in material removal by USM.

The abrasive grains are thrown onto the work surface and then the surface is
chipped
The abrasive grains are hammered on to the work surface
Erosion or cavitation occurs under the tool and causes material removal
7. Compare the USM, WJM and AJM in terms of process capabilities and limitations.
X18. (i) Write a note on advantages and limitations of USM. (8)
(ii) Give the operational summary of USM. (8)