Nontraditional Manufacturing Process

NONTRADITIONAL MANUFACTURING PROCESSES
BY
RAKESH CHANDER SAINI ASST. PROF. MAIT, DELHI, INDIA
RCSAINI.BLOGSPOT.COM
CLASSIFICATION OF UNCONVENTIONAL MACHINING PROCESSES
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Need of Unconventional Machining

New materials & alloys with very low mach inability. Producing complicated geometries. Machining a complicated turbine blade made of super alloys.
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Unconventional machining processes

Energy Type
Mechanical
Electrochemical
Mechanical & Electrochemical rcsaini.blogspot.com
Chemical
Thermal
Mechanical
Mechanics of material removal: Erosion Energy source: Mechanical / fluid motion Process: Abrasive jet machining(AJM) and Ultrasonic machining(USM)
Electrochemical
Mechanics of material removal: Ion displacement Energy source: Electric Current Process: Electrochemical machining (ECM)
Mechanical & Electrochemical

Mechanics of material removal: Ion displacement & Plastic Shear Energy source: Electric Current and mechanical motion Process: Electrochemical grinding (EGM)
Chemical
1. Mechanics of material removal: Corrosive action Energy source: Corrosive agent Process: Chemical Machining 2. Mechanics of material removal :Fusion and vaporization Energy source: Electric spark & High speed electrons Process: Electric discharge machining and Electron beam machining
Thermal

Energy source:-Powerful radiation Process:- Laser beam machining Energy source:-Ionized substance Process:- Ion beam machining & Plasma arc machining
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Electrical Discharge Machining
Electrical Discharge Machining (EDM)
Thermal erosion process in which an electrically generated spark burns or vaporizes electrically conductive material. The spark is generated due to a gap between the work piece and a tool. The smaller the gap the better the accuracy and the slower the MRR. The spark generates a temperature of 14000-21000 oF. Introduced in the 1940s
EDM
Machining action forms a gap between the part and the electrode (tool) which causes a spark that removes the material Electrode is (-) and the part is (+) Electrodes can be made from
Brass Copper Graphite
EDM
Cutting action takes place in a dielectric fluid which helps to contain the spark and flush away chips Metal removal rates (MRR) are low compared to other process like milling
EDM, MRR= 1 cu. in to 15 cu. in per hr.
EDM
Applications Finish geometry for molds ( die sinking) Ram Most common die material include: Hardened Steel Heat-treated Steel Carbides Punch & dies for blanking, shearing, and progressive die tooling Wire
Materials That can be EDMed

Titanium Hot rolled Steel Cold Rolled Steel Copper Brass High Temperature Alloys
MECHANICS OF EDM
EDM CIRCUITS
Resistance-capacitance relaxation circuit with a constant DC. Rotary impulse generator Controlled pulse circuit
EDM CIRCUITS
R-C relaxation circuit
EDM CIRCUITS
Rotary impulse generator
EDM CIRCUITS
Controlled pulse circuit
CHARACTERISTICS OF MRR
Benefits
No cutting force generated Intricate details Superior surface finish Accuracy/Repeatability Smaller/Deeper Holes Well suited for automation Allows heat treatment before EDMing eliminating the risk of distortions.
Limitations
Low MRR Electrodes require lead-time and are consumable work piece must be electrically conductive
EDM Surface Layers

Resulting surface has three distinct layers Top layer: Expelled molten material and electrode material Recast (white) layer: Metallurgical altered. May be reduced using the right controls, or removed using polishing Heat affected layer: Affected by the process heat, but not melted.
EDM Cycle
Cycle consists of 2 parts: On-time: Spark is on Off-time: Spark is off All work takes place during the on-time Spark length is determined by: Work Material Electrode material Rough or finish cutting Desired surface finish Flushing conditions
EDM Cycle
Long On-time High MRR Rough surface Larger recast layer Deeper heat-affected layer Short On-time Avoids problems above, but Metal may not be removed fast enough; disturbing the spark.
EDM- Types
RAM EDM (Die sinker or vertical EDM)

Uses a tool with the negative of the desired shape as an electrode. Wire EDM Uses a wire as an electrode, mainly for cutting or contouring.
RAM EDM Subsystems

Power Supply Dielectric System Electrode Servo System
RAM EDM Subsystems

Power Supply Provides a series of DC current discharges between the electrode and the work piece. Controls the servo system to maintain the gap. Power is automatically cutoff if a short circuit occurs.
RAM EDM Subsystems

Dielectric System (dielectric = electrically nonconducting) Introduces clean dielectric fluid into the cutting zone. Flushes away cutting debris Fluid is pumped through nozzles or holes in the electrode and/or work piece. Low pressure holes are preferable. Low Viscosity Absence of toxic vapours Chemically neutrality Absence of inflaming tendency Low Cost
RAM EDM Subsystems

Electrode Shape is the negative of the cavity to be generated. Has a -ve polarity. Made of high strength material with high melting point, easy to machine (Brass, Copper, Graphite) Orbiting could be used to contour complex shapes instead of straight sinking
RAM EDM Subsystems

Servo System It feeds the electrode into the work piece maintaining a constant gap. Continuous check for a short circuit.
Wire EDM
A wire (reel) is used as an electrode and fresh wire is introduced all the time through the wire subsystem. Uses deionized water which removes heat and reduces the recast layer. Wire diameter is usually 0.002-0.013 speed is about 20-25 sq. in/hr.
Wire EDM
Cut plates as thick as 300mm Could produce holes with different top/bottom profiles. This is important for extrusion applications Could be used for cutting stacked parts, but flushing is problematic May be used for deep hole drilling L:D > 30:1
Modern Wire EDM Components

Computer controls of cutter path Automatic self-threading features Multiheads for cutting more than one part at the same time Wire breakage prevention controls Programmed machine cycles (similar to CNC)
Laser Beam Machining
Introduction
Laser stands for light amplification by stimulated emission of radiation. The underline working principle of laser was first put forward by Albert Einstein in 1917 though the first industrial laser for experimentation was developed around 1960s. Laser beam can very easily be focused using optical lenses as their wavelength ranges from half micron to around 70 microns. Focused laser beam as indicated earlier can have power density in excess of 1 MW/mm2. As laser interacts with the material, the energy of the photon is absorbed by the work material leading to rapid substantial rise in local temperature. This in turn results in melting and vaporization of the work material and finally material removal.
Laser Fundamentals
Acronym of Light Amplification Stimulated Emission of Radiation
Basics of Laser
Atoms are present initially at the Ground State. The atoms go to Excited State when a high energy is applied (called pumping). When atoms moves back to the ground state, photons (particle of light) are released. Two mirrors reflect the photons back and forth and excite more electrons. One mirror is partially reflective to allow some light to pass through which creates a narrow laser beam.
Stimulated Emission
1. Laser in OFF state
2. Flash Tube excite
3. Some Atoms emit Photons
atoms in the Ruby Rod
Stimulated Emission Contd.

4. Photons run parallel to the rod direction & reflect back and forth and thus stimulate emission on more atoms
5. Laser light passes through partially-reflective mirror
Laser Beam Characteristics

Monochromaticity: The rays of laser beam are monochromatic ie it has one wavelength. Coherence: All waves are in phase with wavelength varying from 0.1- 70 m. Collimated: The rays of laser beam are perfectly parallel . Polarized: Electric field oscillates in one plane. Extremely Bright: The rays of laser beam produce power density as high as 107 W/mm2
Mechanics of Material Removal

Machining by laser beam is achieved through the following phases:
Interaction of laser beam with work material: The absorbed light propogates into the medium and energy is transferred to lattice atoms in form of heat. The absorption is described by Lamberts law. Heat conduction and temperature rise Melting , vapourisation.

Equipment Setup
A coiled Xenon flash tube is placed around the ruby rod . Internal surface of the container is made highly reflecting. Capacitor is charged and very high voltage is applied to triggering electrode for flash initiation.
Working Principle
The emitted laser beam is focussed by a lens system and the focussed beam meets the work surface removing small portion of the material by vapourisation. A very small fraction of the molten metal is vapourised so quickly that substantial mechanical impulse is generated throwing out large portion of liquid metal.
Lasing Medium
Many materials can be used as the heart of the laser. Depending on the lasing medium lasers are classified as solid state and gas laser. Solid-state lasers are commonly of the following type

Ruby which is a chromium alumina alloy having a wavelength of 0.7 m Nd-glass lasers having a wavelength of 1.64 m Nd-YAG laser having a wavelength of 1.06 m
These solid-state lasers are generally used in material processing. The generally used gas lasers are
Helium ,Neon , Argon , CO2 etc.
Lasers can be operated in continuous mode or pulsed mode. Typically CO2 gas laser is operated in continuous mode and Nd YAG laser is operated in pulsed mode. Nd:YAG (neodymium-doped yttrium aluminium garnet; Nd:Y3Al5O12) is a crystal that is used as a lasing medium for solid-state lasers. rcsaini.blogspot.com
Expression for Surface temperature

(0,t)=2H/k( t/)0.5 where K- thermal conductivity - thermal diffusivity H- heat flux (0,t)- surface temperature t-time
Time required to reach Melting Temperature

tm=/ ( mk/2H)2 where - thermal diffusivity k- thermal conductivity m melting temperature of material H- heat flux tm- time required for surface to reach this temperature
Critical Parameters of Laser Beam Machining

Mechanics of Material removal : Melting & vaporization Medium : Normal Atmosphere Tool :High power laser beam Maximum material removal rate : 5mm3/min Specific power consumption:1000 W/mm3/min Critical Parameters: Beam power intensity , beam diameter , melting temperature.
Advantages of Laser beam Machining

Laser machining is a thermal process: it depends on thermal and optical properties rather than the mechanical properties Laser machining is a non-contact process: No cutting forces generated Laser machining is a flexible process Laser machining produces a higher precision and smaller kerb* widths results (as small as 0.005mm dia hole)
*Kerf is the gap created after melting away the material.
Advantages of Laser beam Machining

For most industrial materials up to 10mm thick, laser cutting has a significantly higher MRR. Laser Cutting has ability to cut from curved work-pieces. For cutting fibrous material (wood, paper, etc.) laser cutting eliminates residue and debris. In laser machining there is no physical tool. Thus no machining force or wear of the tool takes place. Large aspect ratio in laser drilling can be achieved along with acceptable accuracy or dimension, form or location Micro-holes can be drilled in difficult to machine materials Though laser processing is a thermal processing but heat affected zone specially in pulse laser processing is not very significant due to shorter pulse duration.
Disadvantages of Laser beam Machining

It has very large power consumption. It cannot cut materials with high heat conductivity and high reflectivity. Efficiency of LBM process is very low ie about 0.3 to 0.5 %. Laser cutting effectiveness reduces as the workpiece thickness increases.
Applications
Manufacturing of metal sheets for truck bed hitch plates. Splicing of aluminium sheets in the aircraft industry Cutting of Multi Layered Insulation for spacecraft Laser beam is used for drilling micro holes(up to 250 m diameter) and cutting very narrow slots.
Applications
Examples of laser cutting using pulsed CO2 Laser
Height following Laser nozzle
Applications
Razor blades are welded using laser spot Models created by prototyping rapid

Nontraditional Manufacturing Process

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Nontraditional Manufacturing Process

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NONTRADITIONAL MANUFACTURING PROCESSES

CLASSIFICATION OF UNCONVENTIONAL MACHINING PROCESSES

Need of Unconventional Machining

Unconventional machining processes

Mechanical & Electrochemical rcsaini.blogspot.com

Mechanical & Electrochemical

Electrical Discharge Machining

Electrical Discharge Machining (EDM)

Materials That can be EDMed

EDM Surface Layers

RAM EDM Subsystems

RAM EDM Subsystems

RAM EDM Subsystems

RAM EDM Subsystems

RAM EDM Subsystems

Modern Wire EDM Components

Laser Beam Machining

Acronym of Light Amplification Stimulated Emission of Radiation

2. Flash Tube excite

3. Some Atoms emit Photons

atoms in the Ruby Rod

Stimulated Emission Contd.

5. Laser light passes through partially-reflective mirror

Laser Beam Characteristics

Mechanics of Material Removal

Helium ,Neon , Argon , CO2 etc.

Expression for Surface temperature

Time required to reach Melting Temperature

Critical Parameters of Laser Beam Machining

Advantages of Laser beam Machining

Advantages of Laser beam Machining

Disadvantages of Laser beam Machining

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