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Lecture 1 Non-Conventional Machining

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7 views

Lecture 1 Non-Conventional Machining

Uploaded by

nassermuhammad46
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Non-Conventional Machining

MTE545

Dr Tarek mohamed
Course Contents
Introduction to non-conventional machining.

Electrical discharge machining (EDM) .

Electrochemical Machining.

Chemical Machining.

Ultrasonic Machining.

Laser processing.

Water jet machining.


1-1 What is production
• It comprises:
1. the design of the product.
2. the selection of raw materials.
3. the sequence of processes through which the product will be
manufactured.
• Production is a complex activity involving a wide variety of
resources and activities, such as:

• Product design • Purchasing • Marketing


• Machinery and tooling • Manufacturing • Sales
• Process planning • Production control • Shipping
• Materials • Support services • Customer service
Introduction to non-traditional machining
• In traditional methods of machining, gradual metal removal from
the surface of the product due to failure of cohesion of material
grains in the form of chips due to cutting forces, and superior
hardness of tool.
Some examples of traditional Machining:

Turning Milling

Grinding
Drilling
• Concepts of material removal is used by adapting different means of
energies to perform the required cutting:
• Forms of Energy for different nontraditional processing techniques
1. Thermal energy
2. Mechanical energy
3. Chemical or electrochemical energy.
• The reasons for using non-traditional machining methods:
1- The development of very hard workpiece materials and a high
strength and brittle material (such as graphite and glass), which are
not economically machined by the conventional methods.
It will be difficult to find a tool material harder than the workpiece.
2- produce complex shapes and dies which are costly, difficult or even
impossible to be produced by traditional methods.
3- Very small size features like (Holes with diameter < 1mm)
4- Workpiece is too flexible to resist cutting forces or too difficult
to clamp.
5- Requirements for surface finish and tolerances are very high.
6- Temperature rise or residual stresses are undesirable or
unacceptable.
The non-traditional machining methods can be classified
according to the concept of metal removal into:
(a) Thermal effect
1- Electric discharge machining (EDM)
2- Electron beam machining (EBM)
3- Laser beam machining (LBM)
4- Plasma arc machining (PAM)
(b) Mechanical effect
1- Ultrasonic machining (USM)
2- Abrasive water jet machining (AWJM)
(c) Chemical or electrochemical effect.
1- Chemical machining (CHM)
2- Electrochemical machining (ECM)
5-2 Electrical discharge machining (EDM)
5-2-1 Basic concepts of EDM
• EDM is a process for producing holes, external shapes,
profiles or cavities in an electrical conductive workpiece by
means of the controlled application of high-frequency
electrical discharges to vaporize or melt the workpiece
material in a particular area.
• A voltage exceeding the breakdown voltage of the gap
(depending on the size of gap and the insulating resistance of
the dielectric) is applied to initiate a discharge.
• The dielectric in the gap is ionized at the two closest points
between the electrode and workpiece and a massive current
flow results causing erosion of a particle of metal.
Advantages of EDM The main advantages of EDM are:
1- By this process, materials of any hardness can be machined.
2-No burrs are left in machined surface.
3- One of the main advantages of this process is that thin and brittle components
can be machined without distortion.
4- Complex internal shapes can be machined.

Limitations of EDM The main limitations of this process are:


1- This process can only be employed in electrically conductive materials.
2- Material removal rate is low and the process overall is slow compared to
conventional machining processes.
3- Unwanted erosion and over cutting of material can occur.
4- Rough surface finish when at high rates of material removal.
• The rate of material removal from the tool and workpiece is
asymmetric, it depends on:
1. Polarity.
2. Thermal conductivity
3. Melting point of the materials.
4. Duration time.
5. Intensity of the discharge (Aplied Power V & I).

• By suitable selection of parameters, the rate of erosion of the


workpiece can be increased whilst that of the tool is decreased.
Wire EDM cutting process
EDM process parameters
• The tool electrode:
The tool electrode material should have rigidity, low electrical resistivity and a high melting point such
as Graphite and tungsten.
• The dielectric fluid:
The fluid must be of low cost and has the following properties:
(i) Low viscosity to ensure efficient flushing (ii) Non-toxic (iii) Non-corrosive
(iv) Rapid ionization followed by rapid de-ionization
• The main functions of the dielectric fluid are to
1. Flush the eroded particles from the machining gap
2. Provide insulation between the electrode and the workpiece
3. Cool the section that was heated by the discharging effect
• The dielectric fluid mostly used in EDM are white spirit, Kerosine, Paraffin and light oil and
de-ionized water which is used for wire EDM.
Common dielectric flushing modes.

Rotary EDM.
ED sawing schematic.
Process characteristics
• Accuracy of EDM, easily achieved (± 0.005 to ± 0.01 mm).
• Surface finish: Ra = 1 to 2 µ m can be achieved easily and 0.25 to 1 µ m in special case.
Main disadvantages of EDM
1. A drop in the fatigue strength of the workpiece due to the formation of micro cracks on the machined
surface.
2- A rapid tool wear due to the very high temperature in the cutting gap.
3- The workpiece material must be electrically conductive which restrict the use of EDM for non-
conductive one
4- High initial cost.
Some applications of EDM
1. Production of dies of complex shape and very hard
materials.
2. Producing complex slots, square holes and holes with very
small diameter up to 0.1 mm.

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