Non-Traditional Machining Processes

presented by

Partha Saha

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Emerging out due to the

Limitations of the Traditional Manufacturing Process

Need of Nontraditional Manufacturing Processes

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Characteristics of Conventional Machining

Contact type

Cutting force by the tool is inevitable

Slender job is not possible

Large heat-affected zone

High residual stress

Poor surface integrity

Complicated shape not possible

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What would be the right Manufacturing Process?

– Case Studies

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Case 1: Square blind hole with good surface finish & accuracy

Manufacturing of Square blind hole

40mm

50m

m

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Case 2: Circular blind hole with high accuracy

Need: Manufacturing of a circular blind hole with accuracy of (+-) 100 micron, taper less than 0.5 degree

F 10 mm

60 m

m

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Case 3: Drilling of circular hole of very small diameter & high aspect ratio

0.2 mm

5 m

m

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Competition in manufacturing industry today demands

New products

Better performance

More features

Low cost

Energy efficiency

Reduction of residual stresses

Low HAZ

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Super alloys, ceramics and composites• Too hard / brittle / difficult to

machine with traditional process

• Improved mechanical, thermal, & chemical properties

• Materials too flexible / slender to handle

Emergence of new exotic materials

Product from quartz

Solar cellmech14.weebly.com

Case-4: Industrial Marking and Drilling with Highest Accuracy

Efficient Marking and Drilling by Excimer Laser with Highest Accuracy

Branding gogglesInk-jet nozzle drilling

Microreactor channels in teflon

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Case 5: 3D-Features on Gold Foil by Electroforming

The part is made of gold foil with a thickness of 10 microns .

The hole diameter is 100 mm .

The posts between the holes have a height of 22.5 microns and a base diameter of 50 mm.

The slots are 50 mm wide, and the walls that define the slots are 50 mm wide and 22.5 mm high.

Dimensional tolerance of +/- 3 mm.

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Case 6: Miniaturised Components

Micro mold (Overall size 2-5 mm)

Micro gear (diameter 300 micron)

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Thermal NTM Processes- Laser Beam Machining (LBM)- Electron Beam Machining (EBM) - Plasma Arc Machining (PAC)- Electrical Discharge Machining (EDM)

Mechanical NTM Processes (Plastic deformation / Abrasive Erosion)- Abrasive Jet Machining (AJM)- Ultrasonic Machining (USM)- Water Jet Machining (WJM)- Abrasive Water Jet Machining (AWJM)

Classifications of NTM Processes

Laser cutting

Ultrasonic machining

of glass

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Classifications of NTM Processes

Electrochemical NTM Processes- Electrochemical Machining (ECM)- Electrochemical Grinding (ECG)

Chemical NTM Processes- Chemical Machining (CHM)- Thermo chemical Machining (TCM)

Kinetic Energy (Atom by atom knocking) - Ion beam

Electrochemical Machining

of complex surfaces

Electro-discharge Machining

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Material removal with chip formation or evenwithout chip formation

Physical tool may or may not be present.

Tool need not be harder than the work piecematerial.

Mostly NTM processes do not use mechanicalenergy for material removal.

Nontraditional media for energy transfer.

Characteristics of Nontraditional Machining (NTM) Processes

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• Basic theory, working principle, and characteristicsof different NTM processes.

• Critical process variables and their effects on process performance and product quality.

• Simple mathematical model relating MRR with machining parameters in NTM.

• Develop understanding to properly assess thecapabilities, limitations, and potentials of NTM inrelations to various industrial applications.

Objective of this course

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MF30604 Non-Traditional Manufacturing Processes (3-0-0: 3 credits)

Needs of manufacturing industries and the concept of surface integrity.The role of newer & innovative processes for the solutions Impact erosion and the evaluation for impregnation of foreign bodies. Theory and application of Abrasive Jet, Water Jet, Abrasive Flow, Ultrasonic, Total Form Machining and Low stress Grinding. Theory and applications of Chemical Processing: Chemical Machining, etching of semiconductors, coating and Electro less forming and CVD. Theory and applications of Electrochemical machining and grinding including, Electrochemical sharpening, polishing, honing and deburring, surface treatment, coating and Electroforming. Thermal energy methods of material processing (machining, welding, cladding, alloying and heat-treatment): Electro-discharge Machining, Laser, Electron beam, Plasma arc, Plasma spray, Ion beam and PVD. Hybridization of processes for improving process capability and surface integrity. Explanation of some processes like ECDG, ultrasonic and Laser assisted processing, LIGA & SLIGA etc.; Generic manufacturing and introduction to rapid prototyping.

** (Topics marked in black colour will be taught by Prof. P Saha and those in blue will be taught by Prof. A K Nath.)

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Nontraditional Manufacturing Processes by Gary F. Benedict, Marcel Dekker,Inc

Modern Machining Processes by P C Pandey & H S Shan, Tata McGraw-Hill

Nonconventional Machining by P K Mishra, Narosa Publishing House

Manufacturing Science by Amitabha Ghosh & A K Mallik, Affiliated East-West Press

Advanced Machining Processes, by El-Hofy, McGraw Hill

Reference Books

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