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Ultrasonic Machining (USM), 3

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Ultrasonic Machining (USM), 3 KNOWLEDGE INSTITUTE OF TECHNOLOGY DEPARTMENT OF MECHANICAL ENGINEERING UNCONVENTIONAL MACHINING PROCESS UNIT I - INTRODUCTION Unconventional Machining Process – Need – Classification & Brief overview. MECH-KIOT Machining Processes Machining Processes Conventional Abrasive Nontraditional Turning Drilling Milling Other Grinding Lapping Mechanical Energy Polishing Other Electrochemical Thermal Energy Chemical Machining MECH-KIOT To reduce machining costs • Avoid excess machining allowances during primary processing • Achieve rough shape as “near net” as possible eg. Die casting a piston instead of sand casting reduces machining • Optimize initial shaping and final machining regarding the aspects like machine tools, cutting tools and cutting parameters MECH-KIOT Single – Point Tools Surface of revolution Plane (Job Surfaces rotating) Tool Feed parallel to axis Feed not parallel Job reciprocates reciprocates of rotation to axis of rotation shaping slotting (Cylindrical planing surfaces) External Internal turning, boring screw internal cutting screw cutting At any angle Simultaneous (Conical two axes motion surfaces) contouring, copy turning External taper Internal turning, Taper facing boring MECH-KIOT Multi – Point Tools Cylindrical Surface Plane Surfaces Two edge Multi edge Sizeable Chips Small Chips (Grinding) Surface Cutting cutting (Milling) Plane milling Broaching grinding Lapping drilling Gear shaping Sizeable Chips (Milling, Gear Small Chips cutting) Spiral milling (Grinding) Gear hobbing Cylindrical grinding Centre less grinding MECH-KIOT PEMP EMM2512 MECH-KIOT MECH-KIOT PEMP EMM2512 MECH-KIOT PEMP EMM2512 MECH-KIOT BASIC RULES OF METAL CUTTING • Strong cutting tools with good support • Strong m/c to avoid bending / twisting • Strong dovetail slide ways to give good support • Non excessive depth of cut • Secured work piece holding • Cutting force application to avoid work piece deformation MECH-KIOT WORK PIECE HOLDING CONSIDERATIONS • Chip removal • Access for cutting tool • Design the components to facilitate holding during machining • Avoid / reduce frequency of work removal and re-setting • Use correct Fixtures and Jigs (if need be) MECH-KIOT INTRODUCTION Mechanical Engineering Design Manufacturing Thermal Primary Manufacturing Secondary Manufacturing MECH-KIOT INTRODUCTION • What is Manufacturing? MECH-KIOT INTRODUCTION Material removal processes can be further divided into mainly two groups 1. Conventional Machining Processes 2. Un Conventional Manufacturing Processes Examples of conventional machining processes are turning, boring, milling, shaping, broaching, slotting, grinding etc. Examples of non conventional ( or also called non traditional or unconventional) are 1. Abrasive Jet Machining (AJM), 2. Ultrasonic Machining (USM), 3. Water Jet and Abrasive Water Jet Machining (WJM and AWJM), 4. Electro-discharge Machining (EDM) , 5. Electro Chemical Machining (ECM). MECH-KIOT CONVENTIONAL MACHINING PROCESS MECH-KIOT Basic Process MECH-KIOT Turning Fig-2 Basic scheme of Turning • To produce rotational, axis-symmetric parts. • Feed motion • Feed relative to work piece. MECH-KIOT Turning Operations • Facing • Parting • Grooving • Drilling • Screw cutting Workpiece Materials • Aluminum • Brass • Plastics • Cast Iron • Mild Steel MECH-KIOT Drilling • Drilling Operations • Reaming • Tapping • Counterboring • Countersinking Fig-3 Basic scheme of Drilling • Centering • Spot facing MECH-KIOT Workpiece Materials • Aluminum alloys • Magnesium alloys • Copper alloys • Stainless steels • Cast iron • Plastics MECH-KIOT Milling Fig-4 Basic scheme of Milling MECH-KIOT Milling Operations • Slab Milling • Face Milling • End Milling Fig-5 Slab Milling Fig-6 Face Milling MECH-KIOT Workpiece Materials • Aluminum • Brass • Magnesium • Nickel • Steel • Thermostat plastics • Titanium • Zinc MECH-KIOT Boring Fig-7 Boring operation MECH-KIOT Boring Operations • Single-Edge Boring • Multi-Edge Boring • Step Boring • Reaming Workpiece Materials • Aluminum • Brass • Plastics • Cast Iron • Mild Steel MECH-KIOT Broaching Fig-8 Broaching Tool Broaching Operations • Surface Broaching • Pull down Broaching • Push Broaching • Pot Broaching MECH-KIOT Workpiece Materials • Aluminum • Brass • Bronze • Plastic • Malleable Iron MECH-KIOT Ref: Tool and Manufacturing Engineers Handbook– Tom Drozda, Charles Wick, John T. Benedict, Raymond F. Veilleux Shaping Fig-9 Basic scheme of Shaping MECH-KIOT Planing Fig-11 Basic scheme of Planing MECH-KIOT INTRODUCTION Types of Manufacturing Processes: • Manufacturing processes can be broadly divided into two groups 1. Primary manufacturing processes 2. Secondary manufacturing processes. • The Primary manufacturing process provides basic shape and size to the material as per designer’s requirement. For example: Casting, forming, powder metallurgy processes provide the basic shape and size. • The Secondary manufacturing processes provide the final shape and size with tighter control on dimension, surface characteristics etc. Most of Material removal processes are mainly the secondary manufacturing processes. MECH-KIOT COMPARISON Conventional Non Conventional Generally macroscopic chip Material removal may occur with chip formation or even no chip formation by shear deformation. formation may take place. For example in AJM, chips are of microscopic size and in case of Electrochemical machining material removal occurs due to electrochemical dissolution at Chip atomic level Formation Tool There may be a physical tool There may not be a physical tool present. For example in laser jet present. for example a cutting tool machining, machining is carried out by laser beam. However in in a Lathe Machine, Electrochemical Machining there is a physical tool that is very much required for machining. MECH-KIOT Conventional Non Conventional Cutting tool is harder than work piece at room There may not be a physical tool temperature as well as under machining conditions present. For example in laser jet machining, machining is carried out by laser beam. However in Characteristic of Electrochemical Machining there is Tool a physical tool that is very much required for machining. Material removal takes place due to application of Mostly NTM processes do not cutting forces – energy domain can be classified as necessarily use mechanical energy mechanical to provide material removal. They Material Removal use different energy domains to Process provide machining. For example, in USM, AJM, WJM mechanical energy is used to machine material, whereas in ECM electrochemical dissolution constitutes material removal. MECH-KIOT Conventional Non Conventional Conventional machining involves the direct contact of tool and work Whereas unconventional machining does not Tool Contact –piece require the direct contact of tool and work piece. Surface Finish Lower accuracy and surface finish. Higher accuracy and surface finish. MECH-KIOT Conventional Non Conventional Suitable for every type of material Not Suitable for every type of Material Economy economically. material economically Tool life is less due to high surface Tool life is more Tool Life contact and wear. Material Wastage Higher waste of material due to Lower waste of material due to low high wear. or no wear. Noise Level Noisy operation mostly cause sound Quieter operation mostly no sound pollutions pollutions are produced. Cost Lower capital cost Higher Capital Cost MECH-KIOT Conventional Non Conventional Equipment Setup Easy set-up of equipment. Complex set-up equipment. Operator level Skilled or un-skilled operator may Skilled operator required. required Process Generally they are manual to Generally they are fully automated operate. process. Efficiency They cannot be used to produce Can be used to produce prototype prototype parts very efficiently and parts very efficiently And economically. economically. Spare Parts Easily Available Not so easily available MECH-KIOT Conventional Vs Unconventional 1) Conventional machining process involved tool wearing as there is a physical contact between the tool and the work piece. In non-conventional process, this is not the case. 2) Non-conventional tools are more accurate and precise than the conventional tool. 3) No noise pollution is created as a result of non-conventional methods as these tools are much quieter. 4) Tool life is long for non-conventional processing. 5) Non-conventional tools are very expensive than the conventional tools. 6) Non-conventional tools have complex setup and hence requires a skilful operation by expert workers, whereas conventional tools do not require any special expert for its operation and are quite simple in set-up. Conventional Vs Unconventional 7) Spare parts of conventional machines are easily available but not for non-conventional machines. 8) Extremely hard material can be cut easily with the help of non conventional machining but for conventional machining raw material should be less hard than cutting tool. 9) In conventional machining: Material removal takes place due to application of cutting forces – energy domain can be classified as mechanical. In Non Conventional Machining :Mostly NTM processes do not necessarily use mechanical energy to provide material removal. They use different energy domains to provide machining. For example, in USM, AJM, WJM mechanical energy is used to machine material, whereas in ECM electrochemical dissolution constitutes material removal. Conventional Vs Unconventional 10) Non Conventional machines can handle very complex jobs as compare to Conventional machining. 11) In
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