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Non-traditionalMachining Processes
ME 355, Introduction to
Manufacturing Processes
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Outline
Abrasive Grinding
Non-traditional Machining Processes
ltrasonic Machining Abrasive !ater "et Machining
#he$ical Machining
Electro-che$ical Machining
Electro-che$ical Grinding
Electrodischarge Machining %aser &ea$ Machining
#ase 'tudies
(verall Process co$)arisons
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Grinding
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Abrasive Grinding
#an be vie*ed as
$ulti)le ver+ s$all
cutting edges esults in a ver+ fine
finish
#an leave residualstresses
'lo*, s$all $aterial
re$oval rates
')aring out
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Standard Grinding Wheel
Designation
!hile this is s)ecific to grinding, reali.e that there aresi$ilar standard designations in $ost industries
/ae the ti$e to learn the standard designations earl+ sothat +ou can s)ea intelligibl+ *ith those *ithin the
industr+0
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Ultrasonic
Machining
ltrasonic vibration 12, 4.of ver+ s$all a$)litudes 106-07 $$ drive the for$ tool1sonotrode of ductile $aterial1usuall+ soft steel
An abrasive slurr+ is flo*edthrough the *or area
/he *or)iece is brittle in nature1i0e0 glass
/he *or)iece is graduall+eroded a*a+0
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Waterjet and Abrasive Waterjet
(AWJ !utting
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Abrasive
Waterjet and
Waterjete"a#$les
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Abrasive
Water Jet 4igh )ressure *ater 12,-
8, )si
Educt abrasive into strea$
#an cut e9tre$el+ thic )arts 15-:inches )ossible /hicness achievable is a function of
s)eed
/*ice as thic *ill tae $ore thant*ice as long
/ight tolerances achievable #urrent $achines 02; 1older
$achines $uch less ca)able < 0:;
"et *ill lag $achine )osition, so
controls $ust )lan for it
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!he#ical Machining (!he#illing A))lications=
Aeros)ace industr+
Engraving
#ircuit boards
A $asant is a))lied over
areas +ou don>t *ant to$achine Photoche$ical $ethods
A))l+ $asant to entire surfaceand use laser to cut
Place the entire )art in ache$ical bath 1acid or alalide)ending u)on the $etal
#ontrol te$)erature and ti$eof e9)osure to control
$aterial re$oval
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%lectro-!he#ical
Machining (%!M !ors on the )rinci)le of
electrol+sis acceleratedche$illing
?ie is )rogressivel+
lo*ered into *or)iece as*or)iece is dissociatedinto ions b+ electrol+sis
Electrol+tic fluid flo*saround *or)iece tore$ove ions and $aintainelectrical current )ath
%o* ?# voltage, ver+4igh current 1@ a$)s
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%lectroche#ical grinding
#o$bines electroche$ical $achining *ith
conventional grinding
Grinding *heel is the cathode
Metal bonded *heel *ith dia$ond or Al2(3
abrasive
Maorit+ of $aterial re$oval fro$ electrol+ticaction 1B5C therefore ver+ lo* *heel *ear
Much faster than conventional grinding
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%lectrode Discharge
Machining (%DM
?irect #o$)etitor of E#M $uch $oreco$$on than E#M
/he tool acts as a cathode 1t+)icall+gra)hite is i$$ersed in a ?ielectric fluid*ith conductive *or)iece
?# voltage 1
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Die Sin&er
vs' Wire
%DM ?ie siner E?M
/he die sins into the )art
as it s)ars a*a+ the*or)iece
Most co$$on Inection
$olding die )rocess
!ire E?M /he electrode is a *ire that
traverses through the )art
#o$$on for E9trusion
?ies
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aser )ea# Machining
%asers are high intensit+ focused light sources #(2
Most *idel+ used
Generall+ $ore )o*erful that FAG lasers
#utting o)erations co$$onl+Nd=FAG 1Neod+$iu$ ions in an Fttriu$ Alu$inu$
Garnet %ess )o*erful
Etching$aring t+)e o)erations $ore co$$onl+
%i$ited in de)th of cut 1focus of light
!ould li$it *or)iece to less than : inch 1H ;t+)icall+
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!ase Stud*
#N# Mill
#N# !ire E?M
#N# E?M
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Wire %DM (not sho+n, Die Sin&er
%DM, Anodied
Di.. t P t Wi %DM
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Di..erent Part - Wire %DM /
$ro.iling and drilling
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!ase Stud* 0hree
:0 #N# Milling 20 'etu) on *ire E?M
30 JA After *ire E?M 60 Grinding a face on the )art
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Setu$ o. Die Sin&er %DM
:0 %ocating )arts relative to
$achine20 %ocating the electrode
relative to )arts setu)
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Die Sin&er in action and .inished
$roduct
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Overall Machining 0olerances and Sur.ace 1oughness