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    Conventional Machining Process

    Uploaded by

    Rajadurai Baskaran
    The document discusses conventional and unconventional machining processes. Conventional processes use physical contact between a tool and workpiece to remove material, while unconventional processes do not require contact and instead use various forms of focused energy like thermal, electrical, electrochemical, or mechanical energy. Unconventional machining processes (UCM) were developed to overcome limitations of conventional processes like inability to machine hard materials, poor accuracy and surface finish. UCM processes are classified based on the type of energy used, the mechanism of material removal, and the medium that transfers the energy. Examples of various UCM processes and factors for selecting a suitable process are provided.

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    Conventional Machining Process

    Uploaded by

    Rajadurai Baskaran
    115 views6 pages
    The document discusses conventional and unconventional machining processes. Conventional processes use physical contact between a tool and workpiece to remove material, while unconventional processes do not require contact and instead use various forms of focused energy like thermal, electrical, electrochemical, or mechanical energy. Unconventional machining processes (UCM) were developed to overcome limitations of conventional processes like inability to machine hard materials, poor accuracy and surface finish. UCM processes are classified based on the type of energy used, the mechanism of material removal, and the medium that transfers the energy. Examples of various UCM processes and factors for selecting a suitable process are provided.

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    The document discusses conventional and unconventional machining processes. Conventional processes use physical contact between a tool and workpiece to remove material, while unconventional processes do not require contact and instead use various forms of focused energy like thermal, electrical, electrochemical, or mechanical energy. Unconventional machining processes (UCM) were developed to overcome limitations of conventional processes like inability to machine hard materials, poor accuracy and surface finish. UCM processes are classified based on the type of energy used, the mechanism of material removal, and the medium that transfers the energy. Examples of various UCM processes and factors for selecting a suitable process are provided.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    115 views6 pages

    Conventional Machining Process

    Uploaded by

    Rajadurai Baskaran
    The document discusses conventional and unconventional machining processes. Conventional processes use physical contact between a tool and workpiece to remove material, while unconventional processes do not require contact and instead use various forms of focused energy like thermal, electrical, electrochemical, or mechanical energy. Unconventional machining processes (UCM) were developed to overcome limitations of conventional processes like inability to machine hard materials, poor accuracy and surface finish. UCM processes are classified based on the type of energy used, the mechanism of material removal, and the medium that transfers the energy. Examples of various UCM processes and factors for selecting a suitable process are provided.

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    ME-6004- UNCONVENTIONAL MACHINING PROCESS

    UNIT-1

    CONVENTIONAL MACHINING PROCESS:

    METAL IS REMOVED BY USING SOME SHARP TOOLS WHICH IS HARDER THAN THE WORKPIECE AND
    IS SUBJECTED TO WEAR.IN THIS PROCESS TOOL AND WORK PIECE ARE IN DIRECT CONTACT WITH EACH
    OTHER.

    DEMERITS OF CONVENTIONAL:

     Metal is removed by chip formation which is expensive and difficult process

     Chips produced are unwanted by-products.

     Disposal and recycling of chips is a tedious process.

     Large cutting forces are involved, so proper work holding devices are required.

     Large amt of heat are generated between tool & work piece

    UNCONVENTIONAL MACHINING PROCESS:

    This process do not employ conventional tool for metal removal instead, they directly utilize
    some form of energy for metal machining. In this process there is no physical contact between tool
    and workpiece.

    NEED FOR UCM:

     very high hardness and strength of the material ( above 400 HB) can be processed.

     The degree of accuracy and surface finish are poor in conventional type.

     Played a considerable role in aerospace , automobile, tool and die making industries.

     So the unconventional methods are developed to overcome these difficulties

     Ceramics and composites can be machined using UCM


    ME-6004- UNCONVENTIONAL MACHINING PROCESS
    CLASSIFICATION OF UCM

     I) BASED ON TYPE OF ENERGY

    a) Thermal energy

    b) Electrical Energy

    c) Electro- chemical energy

    d) chemical energy

    e)mechanical energy

     II)Based on mechanism involved:

     A) erosion

     B) ionic dissolution

     C) vaporisation

     Based on source of energy required

     HYDROSTATIC PRESSURE

     HIGH CURRENT DENSITY

     IONISED MATERIAL

     ) Based on medium of transfer of energy:

     High voltage particles

     Electrolyte

     Electron

     Hot gases

    MECHANICAL ENERGY: Material is removed by mechanical erosion of the work piece

     Ultrasonic Machining (USM)

     Abrasive Jet Machining (AJM)

     Water Jet Machining (WJM)

    ELECTRICAL ENERGY: Electrical energy is used to cut the material

     Electro Discharge Machining (EDM)

     Wire Cut Electrical Discharge Machining (WCEDM)


    ME-6004- UNCONVENTIONAL MACHINING PROCESS

    ELECTRO-CHEMICAL ENERGY METHODS: Metal is removed by ion displacement of


    workpiece in contact with chemical solution

     Electro Chemical Machining (ECM)

     Electro Chemical Grinding (ECG)

     Electro Chemical Honing (ECH)

     Electro Chemical Deburring (ECD)

    THERMAL ENERGY: Heat energy is concentrated on a small area of the work piece to melt and
    vaporize the tiny bits of work material.

     Laser beam Machining (LBM)

     Plasma Arc Machining (PAM)

     Electronic Beam Machining (EBM)

     Ion Beam Machining (IBM)

    SELECTION OF PROCESS:

    SL.NO MATERIAL METHOD

    1 Non metals like ceramic, plastics, glass USM, AJM,EBM,LBM

    2 Regractories USM, AJM,EDM,EBM

    3 Titanium EDM

    4 Super Alloy AJM, ECM, EDM, PAM

    5 Steel ECM, CHM, EDM,PAM


    ME-6004- UNCONVENTIONAL MACHINING PROCESS

    FACTORS CONSIDERED FOR THE PROCESS SELECTION:

     PHYSICAL PARAMETERS:

    Parameter ECM EDM EBM LBM PAM USM AJM

    VOLT 5-30 50-500 2X10^5 4.5X10^3 250 220 220

    CURRENT(A) 40000 15-500 0.001 2 600 12 1

    Kw 100 2.7 0.15 20 220 2.4 .22

    Gap (mm) 0.5 0.05 100 150 7.5 .25 .75

    Work material difficult Tungsten All All All Tungsten Hard &

    hard mtrl Carbide brittle

    Shapes to be machined:

     Micro holes- LBM

     Small holes- EBM

     Honing- ECM

     Grinding-AJM, EDM

     Threading-EDM

    PROCESS CAPABILITY

     Can be analysed w.r.t

     Metal removal rate

     Tolerance maintained

     Surface finish

     Depth of surface

     Power required
    ME-6004- UNCONVENTIONAL MACHINING PROCESS
    Process Economy:

     Capital cost
     Tooling cost
     Power requirement
     Metal removal rate efficiency
     Tool consumption

    LIMITATION:

     More expensive process


     Mtrl removal rate is slow
     AJM,CHM,PAM & EBM are not commercially economical

    ADVANTAGES:

     increase productivity

     reduction of rejected components

     close tolerance is possible

     tool mtrl not be harder than work piece

     harder mtrl can be machined by this method

     do not have any scrab mtrl


    ME-6004- UNCONVENTIONAL MACHINING PROCESS

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