L24 - Tertiary Manufacturing Processes.ppt

7/21/2019 L24 - Tertiary Manufacturing Processes.ppt

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MECH152-L24-1 (1.0) - 1

Tertiary Manufacturing Processes


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MECH152-L24-1 (1.0) - 2

Tertiary Manufacturing Processes

Grinding and Abrasive ProcessesGrinding

Honing, Lapping, Super-finishing, Poishingand !uffing

"on-traditiona Machining and Ther#a$utting ProcessesMechanica %nergy Processes

%ectroche#ica Machining ProcessesTher#a %nergy Processes

$he#ica Machining


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MECH152-L24-1 (1.0) - 3

Grinding

Grinding #ateria re#ova by an abrasivebonded grinding &hee rotating a high

speed'

Grinding (hee basic para#eters)Abrasive #ateria

Grain si*e

!onding #ateria

(hee grade

(hee structurehttp)++&&&'youtube'co#+&atchv.nT"/Scc(-M0featurePayList0p1A2!345!667A28690inde:;8
http://www.youtube.com/watch?v=RnTNqSccW-M&feature=PlayList&p=3AFB507B668AF162&index=41http://www.youtube.com/watch?v=RnTNqSccW-M&feature=PlayList&p=3AFB507B668AF162&index=41


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MECH152-L24-1 (1.0) - 4

Grinding (hee

Abrasive #ateriasAu#inu# o:ide) grinding ferrous and high-

strength aoys 9844?

Siicon carbide) grinding au#inu#, brass, and

stainess stee, cast irons and certain cera#ics

9344?

$ubic boron nitride) grinding hardened stees

and aerospace aoys 3444?@ia#ond) grinding cera#ics, ce#ented

carbides, and gass 5444?


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MECH152-L24-1 (1.0) - 5

Grain si*e si*e of the abrasive particesTypica grain si*e) 7-934


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MECH152-L24-1 (1.0) - 6

Grinding (hee

!onding #aterias re/uires strength,toughness, hardness, and te#peratureresistance'

itrified bond) baBed cay and cera#ics, #ost

co##onSiicate) o& heat generation, too grinding

.ubber) fe:ibe, cutoff operation

.esin) ther#osets, rough grinding and cuttoffSheac) arnish, strong but not rigid, good finish

Metaic) Csuay bron*e, dia#ond of cubic boronnitride &hees


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MECH152-L24-1 (1.0) - 7

Grinding (hee

(hee structure and (hee grade(hee structure reative spacing of the abrasive

grains in the &heegD bD p 8'4

g - proportion of abrasive grain in the &heeb - proportion of bond #ateria in the &hee

p - proportion of pores in the &hee

(hee grade bond strength bet&een abrasive

grits, argey depending on b' Grade is#easured on a scae bet&een soft


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MECH152-L24-1 (1.0) - 8

Grinding (hee Specification

(hee specification) 14A;6H6FF14 Prefi:


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MECH152-L24-1 (1.0) - 9

Grinding (hee Specification

(hee specification) FF@834PJJMEE8+7FF Prefi:


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MECH152-L24-1 (1.0) - 10

Grinding (hee $onfigurations


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MECH152-L24-1 (1.0) - 11

Grinding Anaysis

Materia re#ova rate, M..

vwwd

vw= &orB speed

w cutting &idth

d depth of cut

Specific energy Fcv + v

wwd

Fc= cutting force

v &hee speed

K#proving surface finish)

Kncreasing &hee speed

and+or &hee surface grit

density


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MECH152-L24-1 (1.0) - 12

Grinding Process

Specific energy is #uch greater thanconventiona #achining

Most of the energy in grinding resuts in

high &orB surface te#perature (orBpiece te#perature can be o&ered by

grinding fuid'

http)++&&&'efunda'co#+processes+#achining+grind'cf#
http://www.efunda.com/processes/machining/grind.cfmhttp://www.efunda.com/processes/machining/grind.cfm


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MECH152-L24-1 (1.0) - 13

Surface Grindinghttp)++&&&'&itherstoo'co#+surfacegrinding'ht#

MECH152L241(10)14
http://www.witherstool.com/surfacegrinding.htmlhttp://www.witherstool.com/surfacegrinding.html


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MECH152-L24-1 (1.0) - 14

$yindrica Grinding

http)++&&&'youtube'co#+&atchvbhuM73f:7c

MECH152L241(10)15
http://www.youtube.com/watch?v=bhjuM85fx8chttp://www.youtube.com/watch?v=bhjuM85fx8c


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MECH152-L24-1 (1.0) - 15

$enteress Grinding

http)++&&&'youtube'co#+&atchvB335Eoeu17s0".8

http)++&&&'youtube'co#+&atchv=%5EMBu&;0featurereated

MECH152L241(10)16
http://www.youtube.com/watch?v=k557Zoeu38s&NR=1http://www.youtube.com/watch?v=K_E7lZMkuw4&feature=relatedhttp://www.youtube.com/watch?v=K_E7lZMkuw4&feature=relatedhttp://www.youtube.com/watch?v=k557Zoeu38s&NR=1


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MECH152-L24-1 (1.0) - 16

.eated Abrasive Processes

Honing round hoe Lapping fat or sighty spherica surface

Superfinishing fat surface, e:terna

cyinder Poishing Misceaneous shapes

!uffing - Misceaneous shapes

MECH152L241(10)17


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MECH152-L24-1 (1.0) - 17

Surface .oughness aues

MECH152L241(10)18


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MECH152-L24-1 (1.0) - 18

Honing

Honing speed typicay 4'1 1 #+s

Grit si*e typicay 14 644http)++&&&'youtube'co#+&atchv1N4FnAf&yC

MECH152L241(10)19
http://www.youtube.com/watch?v=3O0XnA_fwyUhttp://www.youtube.com/watch?v=3O0XnA_fwyU


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MECH152-L24-1 (1.0) - 19

Lapping

2or production of surface of e:tre#e accuracy and

s#oothness

2uid suspended abrasive partices bet&een &orBpieceand apping too having the shape of the &orBpiece

Grit si*e 144 - 644 http)++&&&'youtube'co#+&atchvGEJ1CC7a9C7http)++&&&'youtube'co#+&atchvAoOs;$2aNc

MECH152L241(10)20
http://www.youtube.com/watch?v=GZY3UU8a2U8http://www.youtube.com/watch?v=Ao9s4VCFaOchttp://www.youtube.com/watch?v=Ao9s4VCFaOchttp://www.youtube.com/watch?v=GZY3UU8a2U8


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MECH152-L24-1 (1.0) - 20

Superfinishing

Si#iar to honing

Shorter stroBe > ;'3 ## up to 8344 stroBes + #inute

Lo&er pressure bet&een too and &orBpieceLo&er &orB speed > 4'93 #+s

S#aer grit si*e > up to 8444

http)++&&&'youtube'co#+&atchv.i"#LH!.5dB

MECH152-L24-1(10)-21
http://www.youtube.com/watch?v=RiNmLHBR7dkhttp://www.youtube.com/watch?v=RiNmLHBR7dk


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MECH152-L24-1 (1.0) - 21

Poishing

Poishing.e#oving scratches and burrs by #eans of

abrasive grains attached to a poishing &hee

rotating at high speed of around 17 #+s'

Abrasive grains are gued to the outside

periphery of fe:ibe &hee'

Grit si*e ranges fro# 94 to 894'

http)++&&&'youtube'co#+&atchv&cJ2NH4O&;

http)++&&&'youtube'co#+&atchvFB#;=.Q9s0featurereated

MECH152-L24-1(10)-22
http://www.youtube.com/watch?v=wcYFOH09_w4http://www.youtube.com/watch?v=Xkm4KRJQV2s&feature=relatedhttp://www.youtube.com/watch?v=Xkm4KRJQV2s&feature=relatedhttp://www.youtube.com/watch?v=wcYFOH09_w4


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MECH152L241 (1.0) 22

!uffing

!uffingSi#iar to poishing but used to for# high

uster surface

(hees are softer

ery fine grit si*e #i:ed in buffing co#pound

Speed ;4 to 73 #+s

Perfor# #anuay

http)++&&&'youtube'co#+&atchvKsc8n@*LaB

MECH152-L24-1(10)-23

" t diti M hi i d
http://www.youtube.com/watch?v=lIsc1nDzLakhttp://www.youtube.com/watch?v=lIsc1nDzLak


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MECH152L241 (1.0) 23

"on-traditiona Machining and

Ther#a $utting Processes

Mechanica %nergy Processes %ectroche#ica Machining Processes

Ther#a %nergy Processes

$he#ica Machining

MECH152-L24-1(1.0)-24


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MECH152L241 (1.0) 24

Mechanica %nergy Processes

Ctrasonic Machining (ater et $utting

Abrasive et Machining

MECH152-L24-1(1.0)-25


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MECH152L241 (1.0) 25

Ctrasonic Machining

Ctrasonic #achiningAbrasive surry driven over the &orBpiece by an

utrasonic vibration too at about 94BH*

A#pitude vibration of 4'456##

Too #aterias soft stee and stainess stee

Abrasive #aterias boron nitride, boron carbide,

au#inu# o:ide, siicon carbide, dia#ond

Grit si*e 844 to 9444

Gap si*e about 9 ti#es grit si*e

Adobe Acrobat

Document

MECH152-L24-1 (1.0) - 26


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C 5 (.0) 6

Ctrasonic Machining

The grit si*e deter#ines the surface finish

The concentration of abrasive in the &ater-based surry

is bet&een 94R to 64R'

MECH152-L24-1 (1.0) - 27


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( )

(ater et $utting

Cses a fine, high-pressure &ater et

to cut the &orBpiece

@ia#eter of no**e 4'8>4'; ##

(ater et pressure ;44 MPa

"o**e #ateria sapphire, ruby or

dia#ond2itration syste# to separate s&arf

Process para#eters standoff distance


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Abrasive et Machining

Abrasive &ater et cutting

Abrasive partices, au#inu# o:ide, siicon o:ide,

added to the et strea# to faciitate cutting

Grit si*e) 64 -894

"o**e dia#eter) 4'93 4'61 ##Abrasive et #achining

High veocity gas et &ith abrasive #aterias

@ry gas


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%ectroche#ica Machining Processes

%ectroche#ica #achining

%ectroche#ica deburring and grinding

MECH152-L24-1 (1.0) - 30


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.e#oves #eta fro# an eectricayconductive &orBpiece by anodic dissoution

(orBpiece


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%ectroche#ica Machining


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Typica eectrode gap distance 4'453 to 4'53 ##

%ectroyte &ater pus sat


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%ectroche#ica

@eburring and Grinding%ectroche#ica deburring


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%ectroche#ica

@eburring and Grinding%ectroche#ica grinding


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Ther#a %nergy Processes

%ectric @ischarge Machining

%ectron !ea# Machining

Laser !ea# Machining

Arc $utting Processes N:yfue $utting Processes

MECH152-L24-1 (1.0) - 36



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Too &ear occurs &ith high sparB te#perature'

The &orB #ateria re#ova versus too &ear ratio isbet&een 8 to 844

%ectrode #ateria - graphite, copper, brass, copper

tungsten, etc'Hardness and strength of the &orB #ateria do notaffect the process, &hie the #eting point is agoverning factor'

@ieectric fuids incude hydrocarbon ois, Berosene,and distied or deioni*ed &ater'

Csed for too fabrication and parts production'



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%ectric @ischarge (ire $utting

Specia for# of %@M using a s#a-dia#eter&ire as the eectrode to cut a narro& Berf in

the &orB'

(orBpiece is fed continuousy and so&y past the

&ire to achieve the cutting path

(ire dia#eter 4'456 to 4'1 ##

(ire #ateria brass, copper, tungsten, and

#oybdenu#'

http)++&&&'youtube'co#+&atchvSr4B$1e.K$70featurePayList0p1A2!345!667A28690inde:16

MECH152-L24-1 (1.0) - 41


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%ectric @ischarge (ire $utting

MECH152-L24-1 (1.0) - 42


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%ectron !ea# Machining

High veocity strea# of

eectrons focused on the

&orBpiece surface to

&ed, cut or heat-treat it

$onducted in vacuu#!ea# dia#eter do&n to

4'493 ##

Hoe depth-to-dia#eter

844)8ThicBnees) 4'93 to 6'1 ##

"o too &ear

http)++&&&'youtube'co#+&atchvf@JuSeApiQ

http)++&&&'youtube'co#+&atchv/!NoyfuN3rM0featurereated

MECH152-L24-1 (1.0) - 43


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Laser !ea# Machining

Laser to re#ove #ateria

by vapori*ation and

abation

Types of asers carbon

dio:ide gas asers and

JAG asers

@riing, sitting, sotting,

scribing, and #arBing

Hoe si*e do&n to 4'493

##

Cni#ited &orBpiece

#ateria

MECH152-L24-1 (1.0) - 44


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Arc $utting Processes

%ectric arcing bet&een an eectrode and the&orBpiece to generate intense heat for&eding or cutting #eta

Pas#a arc cutting

Pas#a is a superheated, eectricay ioni*ed gas


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Arc $utting Processes

Pas#a arc cutting

Ma:i#u# &orBpiece

thicBness 834 ##

Ma:i#u# feed rate 4'879

#+s

.ough cutting surface and

#etaurgica da#age

http)++&&&'youtube'co#+&atchvn9F#2"c5L;0featurereated

http)++&&&'youtube'co#+&atchv#ydN:H&EC0featurereated

http)++&&&'youtube'co#+&atchvc%T=/@9o!;0featurereated

MECH152-L24-1 (1.0) - 46


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N:yfue $utting Processes

2a#e cutting using energy fro# e:other#ic

reaction of the #eta &ith o:ygen

2ues incude acetyene, propyene, and

propane'

http)++&&&'youtube'co#+&atchvBsM3="Q:BC

http)++&&&'youtube'co#+&atchv8F@H$4=5sK

MECH152-L24-1 (1.0) - 47


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$he#ica Machining

$he#ica Miing

$he#ica !anBing

$he#ica %ngraving

Photoche#ica MachiningToerance as cose as 4'4493 ##

MECH152-L24-1 (1.0) - 48


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$he#ica Miing

Se/uence of processing steps in che#ica #iing


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$he#ica !anBing

Se/uence of processing steps in che#ica banBing


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$he#ica banBing

MECH152-L24-1 (1.0) - 51

$h i i


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$he#ica %ngraving

Process si#iar to the other che#ica

processes e:cept)

2iing to appy paint or other coating into the

recessed area

Pane i##ersed in a soution to dissoves the

resist but not the coating #ateria

.esist is re#oved highighting the coating

pattern

MECH152-L24-1 (1.0) - 52

Ph h i M hi i


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Photoche#ica Machining


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Appication $onsiderations

ery s#a hoes beo& 4'893 ## dia#eter'


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Appication $onsiderations

Specia shapes for &hich the non traditiona processes are appropriate


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Materias $onsideration

MECH152-L24-1 (1.0) - 56

M hi i $h i i


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Machining $haracteristics

MECH152-L24-1 (1.0) - 57

@ i f M f t i


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@esign for Manufacturing

Part @ra&ing

Seect stocB

Process Pan $hecB toerances and datu#

Seect process Set up

2i:ture

Process conditions

Measure#ent

PacBaging

Maintenance

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L24 - Tertiary Manufacturing Processes.ppt

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