NAME : SAMUEL KIRUBI NGURE

REG NO: E023-01-2115/2023

DEPARTMENT: MECHANICAL DEPARTMENT
COURSE: BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING
ASSINMENT NO. 1
UNIT CODE:EMG 1205

ULTRASONIC MACHINING

1. Process of Ultrasonic Machining (USM)

USM is a non-traditional machining process that employs high-frequency vibrations

and abrasive particles to erode material from a workpiece. It excels in machining
hard, brittle, and geometrically complex components that pose challenges for
conventional methods.

Components:

Vibrator: Transforms electrical energy into high-frequency (20–50 kHz) mechanical

vibrations.
Tool (Sonotrode): Made of ductile material (e.g., titanium, brass, steel) to withstand
vibrations; transmits vibrations to the abrasive slurry.
Abrasive Slurry: Suspends hard abrasive particles (e.g., silicon carbide, boron carbide,
diamond) in a liquid carrier (e.g., water, oil); erosion agent.
Workpiece: Material to be machined.
Feed Mechanism: Controls tool/workpiece relative motion.
Working Principle:

Vibration Creation: The electrical signal excites the vibrator, generating high-
frequency oscillations.
Vibration Amplification: The amplitude transformer (booster) amplifies and focuses
the vibrations towards the tool tip.
Slurry Delivery: The pump circulates the abrasive slurry across the machining zone.
Material Removal: Vibrations cause the tool to oscillate at high speed, impacting the
abrasive particles against the workpiece, resulting in micro-chipping and material
erosion.
Debris Removal: Used slurry and eroded material are flushed away by the carrier
liquid.

2. Types of USM Processes:

a) Rotary USM: Employs a rotating tool for higher material removal rates and
cylindrical/conical geometries.

b) Vibration-Assisted Machining (VAM): Combines conventional machining

(turning, milling) with superimposed ultrasonic vibrations for improved surface
finish and reduced tool wear.

c) Abrasive Flow Machining (AFM): Uses a pressurized abrasive jet directed by

vibrations for intricate shaping and deburring.

d) Ultrasonic Wire Erosion (UWE): Similar to wire EDM but with ultrasonic
vibrations on the wire for faster cutting and reduced thermal damage.

3. Applications of Ultrasonic Machining:

Aerospace: Turbine blades, fuel injectors, micro-nozzles, heat exchangers.

Electronics: Semiconductor packaging, MEMS devices, piezoelectric components.
Medical: Bone screws, dental implants, surgical instruments, microfluidic devices.
Jewelry: Intricate patterns, engravings, gemstone shaping.
Other: Watches, lenses, filters, micro-optics, fuel cells:

4. Merits and Demerits of Ultrasonic Machining:

Machinability: Processes hard, brittle,
Merits: and heat-sensitive materials.
Precision: Achieves tight tolerances and
intricate geometries. Slow Material Removal Rate: Generally
Non-thermal: Minimizes thermal slower than conventional methods.
distortion and stress. Tool Wear: Abrasives cause tool wear,
Clean Cutting: Generates minimal burrs requiring frequent tool changes.
and recast layer. Complexity: Setup and process control
Environmentally Friendly: Less noise require skill and expertise.
and dust compared to conventional Cost: Equipment and abrasives can be
methods. expensive.
Limitations: Unsuitable for large
Demerits: workpieces or soft materials.

ELECTRODISCHARGE MACHINING

1. Process of Electrodischarge Machining (EDM)

Electrodischarge Machining (EDM), also known as spark machining, spark eroding,

or die sinking, is a non-traditional machining process used to create complex shapes
and features in electrically conductive materials. Unlike traditional machining
methods that rely on physical tool contact, EDM employs controlled electrical
discharges to erode material from the workpiece.

Key Components:

Power Supply: Generates high-voltage DC pulses ranging from 60V to 300V.

Electrode: Tool made of conductive material (e.g., copper, brass, tungsten) with the
desired final shape.
Dielectric Fluid: Non-conductive liquid (e.g., deionized water, hydrocarbon oil) that
acts as an insulator and coolant.
Workpiece: Conductive material to be machined.
Servo System: Precisely controls the electrode movement based on process
parameters.

Working Principle:

Gap Establishment: The electrode and workpiece are positioned close to each other
with a small gap filled with dielectric fluid.
Ionization: The power supply applies a high voltage, creating an electric field across
the gap.
Spark Generation: When the voltage exceeds the dielectric breakdown strength, a
spark ionizes the dielectric, forming a conductive plasma channel.
Material Removal: Heat generated by the spark melts and vaporizes material from
both the electrode and workpiece at the point of contact.
Debris Removal: The dielectric fluid flushes away molten material and eroded
particles.
Servo Movement: The servo system adjusts the electrode position based on
feedbackto maintain the gap and desired machining path.

2. Types of EDM Processes:

Ram EDM (Die Sinking): Most common type, uses a ram-mounted electrode to create
cavities and molds.
Wire EDM: Employs a continuously fed wire as the electrode for intricate shapes and
thin profiles.
Sinker-Lesso EDM: Combines ram and wire EDM capabilities for complex
geometries.
Micro EDM: Utilizes specialized tools for micro-machining applications.
Drilling EDM: Creates precise holes with small diameters.

3. Applications of EDM:

Aerospace: Turbine blades, fuel injectors, honeycomb structures.

Automotive: Dies, molds, engine components, gears.
Electronics: Microcircuits, medical implants, sensors.
Medical Industry: Surgical tools, prosthetics, dental implants.
Tool and Die Making: Molds, punches, dies, complex shapes.
Aerospace Components: Turbine blades, rocket engine nozzles, fuel injectors.
Other: Jewelry, watches, filters, heat exchangers, microfluidics.

4. Merits and Demerits of EDM:

Merits: Slow Material Removal Rate: Generally

slower than conventional methods.
High Precision: Achieves tight Tool Wear: Electrodes experience wear,
tolerances and complex geometries. requiring regular changes.
Machinability: Processes hard, brittle, Complexity: Requires skilled operators
and heat-sensitive materials. and careful process control.
Non-thermal: Minimizes thermal High Energy Consumption: Can be
distortion and stress. energy-intensive compared to other
Burr-free Machining: Creates clean cuts methods.
with minimal burrs. Surface Finish: May require additional
Flexible Tooling: Various electrode finishing for specific surface
shapes and sizes are possible. requirements.
Environmental Concerns: Used
Demerits: dielectric fluid needs proper disposal.

ELECTROCHEMICAL MACHINING

It is a non-traditional machining process that utilizes electrolysis to remove material

from a conductive workpiece. Instead of physically cutting metal, it dissolves it
through controlled, electrically driven chemical reactions.
Two electrodes are immersed in an electrolyte solution (a conductive liquid). When a
high voltage is applied, the negatively charged tool (cathode) attracts positively
charged metal ions from the positively charged workpiece (anode). These ions
dissolve into the electrolyte, effectively "dissolving" the workpiece where the tool
touches it.
Key Steps

Tool and Workpiece Preparation: The tool, typically made of copper, brass, or
graphite, is designed to match the desired final shape. The workpiece, made of a
conductive material like metal or some alloys, is secured in place.
Electrolyte Flow: A pressurized flow of electrolyte (saltwater, sodium nitrate solution,
etc.) is directed between the tool and workpiece.
Electrolysis Initiation: Applying a high-voltage DC current creates an electric field,
ionizing the electrolyte.
Material Removal: Metal ions from the workpiece dissolve into the electrolyte as
positively charged ions attracted to the cathode. Simultaneously, hydrogen gas forms
at the cathode due to the electrolysis process.
Debris Removal: The flowing electrolyte carries away dissolved metal and hydrogen
gas, ensuring continuous machining.
Tool Feed: The tool is precisely moved towards the workpiece by a servo system,
maintaining a small gap and replicating the desired shape.

2. Types of Electrochemical Machining (ECM) Processes:

Different ECM variations cater to specific needs:

Ram ECM (Die Sinking): The most common type, utilizes a ram-mounted tool for
creating complex cavities and molds.
Flow ECM: Employs a flowing electrolyte stream for machining intricate shapes and
internal channels.
Rotary ECM: Rotates the tool for faster material removal and machining cylindrical
or conical geometries.
Micro ECM: Uses specialized tools and techniques for micromachining applications
with high precision.
Reverse Polarity ECM: Employs alternating polarity to improve surface finish and
reduce tool wear.

3. Applications of Electrochemical Machining (ECM):

ECM's unique capabilities make it valuable in various industries:

Aerospace: Turbine blades, fuel injectors, honeycomb structures.

Automotive: Dies, molds, engine components, gears.
Electronics: Microcircuits, medical implants, sensors.
Medical Industry: Surgical tools, prosthetics, dental implants.
Tool and Die Making: Molds, punches, dies, complex shapes.
Aerospace Components: Turbine blades, rocket engine nozzles, fuel injectors.
Other: Jewelry, watches, filters, heat exchangers, microfluidics.

4. Merits and Demerits of Electrochemical Machining (ECM):

Merits:
Slow Material Removal Rate: Generally
High Precision: Achieves tight slower than conventional methods,
tolerances and complex geometries, impacting productivity.
ideal for intricate shapes. Tool Wear: Electrodes experience wear,
Machinability: Processes hard, brittle, requiring regular changes and adding
and heat-sensitive materials that are cost.
difficult for conventional machining. Complexity: Requires skilled operators
Non-thermal: Minimal thermal and careful process control due to its
distortion and stress, crucial for electrochemical nature.
maintaining material properties. High Energy Consumption: Can be
Burr-free Machining: Creates clean cuts energy-intensive compared to other
with minimal burrs, reducing finishing methods.
steps. Surface Finish: May require additional
Flexible Tooling: Various electrode finishing for specific surface
shapes and sizes are possible for diverse requirements.
applications. Environmental Concerns: Used
electrolyte fluid needs proper disposal
Demerits: and handling.

LASER BEAM MACHINING

It is a non-traditional machining process that utilizes the focused intensity of a laser

beam to remove material from a workpiece. Unlike traditional methods relying on
physical contact, LBM offers high precision, minimal heat-affected zones, and the
ability to work with diverse materials, making it a valuable tool in various industries.

1. Process of Laser Beam Machining:

Key components:
Laser Source: Generates a highly focused beam of light with high energy
density. Common types include CO2 lasers, Nd:YAG lasers, and fiber lasers.
Focusing Optics: Lenses and mirrors direct and concentrate the laser beam onto the
workpiece.
Workpiece: The material to be machined, made of metal, plastic, ceramic, or other
laser-compatible materials.
Gas Assist (optional): Inert gas flow assists in material removal and debris flushing.

Working principle:

Laser Energy Delivery: The laser source emits a concentrated beam of light.
Beam Focusing: Optics direct and focus the beam onto a tiny spot on the workpiece.
Material Interaction: The intense heat at the point of focus melts, vaporizes, or ablates
the material, depending on the laser parameters and material properties.
Debris Removal: Melted or vaporized material is ejected by the laser's pressure or
blown away by an optional gas assist.
Controlled Movement: The laser beam or workpiece is precisely moved using
computer-controlled axes to create the desired shape or pattern.

2. Types of Laser Beam Machining Processes:

Laser Cutting: Creates clean, precise cuts through various materials, ideal for sheet
metal, plastics, and textiles.
Laser Drilling: Produces accurate, high-aspect-ratio holes in diverse
materials, including metals, ceramics, and composites.
Laser Engraving: Marks, etches, or ablates surfaces for customization, decoration, and
identification purposes.
Laser Ablation: Rapidly removes thin layers of material for micromachining
applications, surface cleaning, and thin-film processing.
Laser Welding: Offers precise and localized welding of metals and some
plastics, often used in micro-manufacturing and repair.

3. Applications of Laser Beam Machining:

LBM's versatility finds applications in numerous sectors:
Aerospace: Turbine blades, fuel injectors, honeycomb structures, lightweight
components.
Automotive: Body panels, engine components, welding, marking, and engraving.
Electronics: Printed circuit boards, microchips, connectors, medical devices.
Medical Industry: Surgical instruments, prosthetics, dental implants, microfluidic
devices.
Jewelry and Watches: Intricate designs, engravings, customization, and component
shaping.
Telecommunications: Fiber optic components, waveguides, micro-optics.
Tool and Die Making: Molds, punches, dies, complex shapes, and delicate features.
Other: Consumer electronics, packaging, textiles, furniture, and even artistic
creations.

4. Merits and Demerits of Laser Beam Machining:

Merits:
High Precision: Achieves tight
tolerances and intricate Demerits:
geometries, exceeding most traditional High Initial Cost: Lasers and associated
methods. equipment can be expensive compared
Versatile Material Processing: Works to traditional tools.
with diverse materials, including Limited Material Thickness: Primarily
metals, plastics, ceramics, and even suitable for thin to medium-thickness
some organic materials. materials due to energy absorption
Non-contact Process: Minimizes limitations.
mechanical stress and distortion, crucial Reflectivity Issues: Reflective materials
for delicate components. may require special techniques or pre-
Heat-affected Zone (HAZ) treatment.
Minimization: Offers localized Safety Precautions: Requires proper
heating, reducing thermal damage and training and safety protocols due to high
maintaining material properties. laser power and potential hazards.
Clean and Burr-free Cuts: Requires Slower Processing Speed: Can be slower
minimal post-processing due to precise than some conventional methods for
material removal. specific applications.
Automation and Flexibility: Adapts to Environmental Considerations: May
various applications through computer- generate fumes and require proper
controlled programing and different ventilation or filtration systems.
laser types.

References
 Benardos, P. D., & Vosniakos, G. C. (2014). Manufacturing of micro- and
nano-components by ultrasonic machining. CIRP Journal of Manufacturing
Science and Technology, 7(4), 300-316.
 Davim, J. P. (2019). Non-conventional machining (2nd ed.). Springer.
 Januš, W., Młocek, K., & Kacprzyk, S. (2019). A review of ultrasonic
machining—Process capabilities, limitations, and current trends. Archives of
Civil and Mechanical Engineering, 19(4), 1228-124
 https://youtu.be/qA5LYWOvK2U?si=SgiJnHJ7Il79Afe-