NON TRADITIONAL MACHINING PROCESSES

Presented By-

Arshad Habib Khan Mechanical Engineering M H Saboo Siddik College

Introduction

Rapid growth in the development of harder materials. These materials find application in aerospace, nuclear industries, etc. Machining harder materials by traditional method is difficult. Non traditional concept was emerged in 1960 This method uses some form of energy for metal machining.

TRADITIONAL V/S NON TRADITIONAL

Traditional Old method Tool & work are in contact Machinability depends on hardness Simple shapes Excessive too wear Large cutting force High material removal Less expensive Non Tradional New method No contact Hardness of the workpiece is immaterial Complex shapes Less tool wear No cutting force Low material removal expensive

CLASSIFICATION

MATERIAL APPLICATION

PROCESS SELECTION

Capital cost Tooling cost Consumed power cost Metal removal rate (efficiency) Wear of tooling

ULTRA SONIC MACHINING (USM)

The term ULTRASONIC is used to describe a vibratory wave of a frequency(above 16 Hz) Ultrasonic Transducer is used. Electrical energy is converted into mechanical vibrations Piezo-electric effect is utilized Tool is vibrating at 20-30 kHz

Construction & working

Pros & Cons

Pros Metal removal cost is low Stress free Good surface finish upto 0.02 to 0.8 microns Good accuracy upto +/0.07mm Extremely hard materials can be machined Cons Initial cost is high Power consumption is high Soft materials are difficult to machine Not suitable for heavy metal removal

ABRASIVE JET MACHINING (AJM)

It is a finishing process Focus high speed stream of abrasive particles Used for machining delicate or very hard materials Produces no heat damage to work piece surface Produces a taper in deep cut.

Construction & working

Consists of a power supply & mixer, ehaust hood a and gas or water supply. The nozzle can be held or mounted in a fixture for automatic operation.

Applications of AJM

Paint removal Cleaning Cutting soft materials Pocket milling Drilling Turning Textile, leather industry

WATER JET MACHINING (WJM)

Uses a high velocity jet of water. Mixture of water and abrasives. It finds the appliocation in industries from mining to aerospace.

ELECTRO CHEMICAL MACHINING

Electro chemical process Used for mass production For extremely hard materials

ELECTRO-DISCHARGE MACHINING(EDM)

Thermo Electric Type Spark erosion Material removal due to thermal energy of the spark Electrically conductive materials

Construction &working of EDM

Spark machining or Spark erosion Material is removed by rapidly recurring current discharges between two electrodes Separated by a die electric fluid

TYPES OF EDM

Sinker EDM

Wire EDM

LASER BEAM MACHINING(LBM)

LIGHT AMPLIFICATION STIMULATED EMISSION OF RADIATION. It is a cutting technology uses laser to cut material