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Test 2 Uitm
Test 2 Uitm
Machining processes that involve chip - Electrical energy is used to generate electrical
formation have a number of limitations: spark
Large amounts of energy - Materials removal occurred due to the thermal
Unwanted distortion energy of spark
Residual stresses - Two different types of EDM exist based on the
Non-traditional machining (NTM) processes shape of the tool electrode
have several advantages 1. Ram EDM/sinker EDM
Complex geometries are possible 2. Wire EDM
Extreme surface finish
Tight tolerances
Delicate components
Four basic groups of material removal using
NTM processes
1. Mechanical
2. Chemical
3. Electrochemical
4. Thermal
ECM Process
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
Working Principle
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
Dielectric Fluids EBM
The functions of the dielectric fluid are to: - The energy source is high-velocity electrons,
1. Act as an insulator until the potential is which strike the workpiece surface and
sufficiently high generate heat
2. Provide a cooling medium - Used for very accurate cutting of a wide
3. Act as a flushing medium and carry away the variety of metals
debris in the gap - Surface finish is better and kerf width is
i.e. kerosene, distilled and deionized water narrower than in other thermal cutting
processes
Electrodes - Requires vacuum condition
- Electrodes are made of graphite, brass, copper
or copper–tungsten 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
Process Capabilities
- It is used for drilling and cutting metals,
nonmetallic materials, ceramics, and composite
Advantages Disadvantages materials
- Applicable to all - Produces a hard - Laser-beam machining is being used
materials that are recast (resolidify) increasingly in the electronics and automotive
fairly good electrical surface industries
conductors - Surface may contain - Also used for welding, small-scale and localized
- Hardness, toughness, fine cracks caused by heat treating of metals and ceramics, and
or brittleness of the thermal stress marking of parts
material imposes no - Fumes can be toxic USM
limitations - ultrasonic machining (USM), also called
- Fragile and delicate ultrasonic grinding, high-frequency
parts vibrations delivered to a tool tip, embedded in
an abrasive slurry, by a booster, create accurate
cavities of virtually any shape; that are,
“negatives” of the tool.
- this method is non-thermal, non-electrical, and
non-chemical, it produces virtually stress-free
shapes even in hard and brittle work-pieces.
- Ultrasonic drilling is most effective for hard
and brittle materials; soft materials absorb too
much sound energy and make the process less Features of CNC system
efficient. Machine control unit (MCU
Axis drive relay
Translation axis screw
Controllable drive motor
Feedback device
Chapter 5
Cnc(Computer Numerical Control)
- a method of automatically operating a
manufacturing machine based on a code of
letters, numbers, and special characters
Using CNC to :
Eliminate operator errors (provided machine &
tool operate correctly)
Lower labor cost
Flexibility in changes of component design
Complex design
Repeatable precision and accuracy
Locating Pins
Clamping
To apply pressure and press it against the
locating components