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Non Conventional machining processes
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Machining… with a difference!!
That’s what Non-conventional Machining is all about…!!!!
Objective of Presentation
At the end of this presentation, audience will be aware of merits of Non conventional machining processes over their traditional counter-parts.
Need
Why NCM?
• In-House machining of complex and less machinable jobs.
• Economical and Faster than purchasing readymade job.
• Processes are computer-controlled, so negligible human intervention during machining,
Outline
– Ultrasonic Machining– Water Jet Machining– Electro-chemical Machining– Electro-chemical Grinding– Electrodischarge Machining– Conclusion
Ultrasonic Machining
• Ultrasonic vibration (20,000 Hz) of very small amplitudes (0.04-0.08 mm) drive the form tool of ductile material (usually soft steel)
• An abrasive slurry is flowed through the work area
• Used for brittle materials like glass.
Water Jet Machining
• High pressure water (20,000-60,000 psi)
• Induct abrasive into stream• Tight tolerances achievable• Can cut extremely thick parts (5-10
inches possible)
Water Jet Machining Products
Electro-Chemical Machining (ECM)
• Works on the principle of electrolysis
• Die is progressively lowered into workpiece as workpiece is dissociated into ions by electrolysis
• Low DC voltage, very High current (700 amps)
• Used to machine Dies, easily deformable and bittle materials.
Electrochemical grinding
• Combines electrochemical machining with conventional grinding
• Grinding wheel is the cathode
• Metal bonded wheel with diamond or Al2O3 abrasive
• Majority of material removal from electrolytic action (95%) therefore very low wheel wear
• Much faster than conventional grinding
• Used to grind brittle and thin jobs.
Electrical Discharge Machining (EDM)
• The tool acts as a cathode (typically copper and graphite) is immersed in a Dielectric fluid with conductive workpiece
• DC voltage 40-400V is applied. • Sparking at around 12,000 deg F.• Cycle repeated at 200,000-500,000 Hz• Dielectric:
– Acts as an insulator – Cools tool and workpiece– Flushes out debris from work area
Die Sinker vs. Wire EDM
• Die sinker EDM– The die sinks into the part as
it sparks away the workpiece
– Most common Injection molding die process
• Wire EDM– The electrode is a wire that
traverses through the part
– Common for Extrusion Dies
EDM Products
Conclusion
Non Conventional machining processes are used when required attributes are impossible to achieve with traditional machining processes.
Any Queries???
Thank You!!!