non traditional machining processes by arshad habib khan

NON TRADITIONAL MACHINING PROCESSES

Presented By-

Arshad Habib Khan

Mechanical EngineeringM H Saboo Siddik College Of Engineering

Introduction

• Rapid growth in the development of harder materials.

• These materials find application in aerospace, nuclear industries, etc.

• Machining harder materials by traditional method is difficult.

• Non traditional concept was emerged in 1960

• This method uses some form of energy for metal machining.

TRADITIONAL V/S NON TRADITIONAL

Traditional

• Old method• Tool & work are in contact• Machinability depends on

hardness• Simple shapes• Excessive too wear• Large cutting force• High material removal• Less expensive

Non Tradional

• New method• No contact• Hardness of the workpiece is

immaterial• Complex shapes• Less tool wear• No cutting force• Low material removal• expensive

CLASSIFICATION

MATERIAL APPLICATION

PROCESS SELECTION

• Capital cost• Tooling cost• Consumed power cost• Metal removal rate

(efficiency)• Wear of tooling

ULTRA SONIC MACHINING (USM)

• The term ULTRASONIC is used to describe a vibratory wave of a frequency(above 16 Hz)

• Ultrasonic Transducer is used.• Electrical energy is converted into

mechanical vibrations• Piezo-electric effect is utilized• Tool is vibrating at 20-30 kHz

Construction & working

Pros & Cons

Pros

• Metal removal cost is low

• Stress free

• Good surface finish upto 0.02 to 0.8 microns

• Good accuracy upto +/-0.07mm

• Extremely hard materials can be machined

Cons

• Initial cost is high• Power consumption is high• Soft materials are difficult to

machine• Not suitable for heavy metal

removal

ABRASIVE JET MACHINING (AJM)

• It is a finishing process• Focus high speed stream of

abrasive particles• Used for machining delicate

or very hard materials• Produces no heat damage to

work piece surface• Produces a taper in deep cut.

Construction & working

• Consists of a power supply & mixer, ehaust hood a and gas or water supply.

• The nozzle can be held or mounted in a fixture for automatic operation.

Applications of AJM

• Paint removal• Cleaning• Cutting soft materials• Pocket milling• Drilling• Turning• Textile, leather industry

WATER JET MACHINING (WJM)

• Uses a high velocity jet of water.

• Mixture of water and abrasives.

• It finds the appliocation in industries from mining to aerospace.

ELECTRO CHEMICAL MACHINING

• Electro chemical process

• Used for mass production

• For extremely hard materials

ELECTRO-DISCHARGE MACHINING(EDM)

• Thermo Electric Type• Spark erosion• Material removal due to

thermal energy of the spark

• Electrically conductive materials

Construction &working of EDM

• Spark machining or Spark erosion

• Material is removed by rapidly recurring current discharges between two electrodes

• Separated by a die electric fluid

TYPES OF EDM

• Sinker EDM

• Wire EDM

LASER BEAM MACHINING(LBM)

• LIGHT AMPLIFICATION STIMULATED EMISSION OF RADIATION.

• It is a cutting technology uses laser to cut material