Syllabus

 Introduction, classification of advanced

machining processes. Principles, Working,
Process Parameters, Estimation of MRR
(simple numerical), Advantages, Limitations
and Application for following processes:
Electric Discharge Machining (EDM),
LASER Beam Machining (LBM), Abrasive
Jet Machining (AJM), Ultra Sonic Machining
(USM) and Electro Chemical Machining
(ECM)
 Comparison of traditional and nontraditional
machining process
Sr.No Traditional machining process Nontraditional machining process

1 Generally macroscopic chip formation Material removal may occur with chip
by shear deformation formation or even no chip formation may
take place.

2 Material removal takes place due to NTM use different energy domains to
application of cutting forces provide machining

3 Cutting tool is harder than work piece In NTM, the tool need not be harder than
at room temperature as well as under the work piece material
machining conditions

4 High tool wear No use of tool or no tool wear

 Classification of Advanced Machining / Material
Removal Processes.

Advanced material removal processes are generally classified

according to the type of energy used to remove material. The
classification of these processes based on the energy is given as
below:
 Abrasive Jet Machining

Principle:-In abrasive jet machining, a focused stream of

abrasive particles, carried by high pressure air or gas is made to
impinge on the work surface through a nozzle and the work
material is made to impinge on the work surface through a
nozzle and work material is removed by erosion by high
velocity abrasive particles.
6
 Abrasive Jet Machining
In Abrasive Jet Machining (AJM), abrasive particles are made to impinge
on the work material at a high velocity. The high velocity abrasive particles
remove the material by micro-cutting action as well as brittle fracture of
the work material.
Process Characteristics
 Medium - CO2,Compressed air, Nitrogen
 Abrasive - Al2O3,SiC(10-25μm)
 W/P -Glass,Ceramics,semiconductor.
 Nozzle -TiC, Sapphire
Process parameters
 Flow rate - 3-10 gm/sec
 S.O.D /NTD - 0.7-1.0 mm
 Velocity - 150-300m/s
 Mixing ratio - mass flow ratio of abrasive to gas
MRR - 16-20 mm3/sec
Surface Finish - 0.15 – 1.5μm
mp unit 4\ABRASIVE JET MACHINING - YouTube.mp4
Abrasive Jet Machining
Process Parameters of AJM
Advantages of Abrasive Jet Machining:
1. Surface of the work piece is cleaned automatically.
2. Ability to cut intricate hole shapes in materials of any hardness &
brittleness.
3. Ability to cut fragile & heat sensitive materials without damage as no
heat is generated due to the passing of gas or air.
4. Smooth surface finish can be obtained.
5. Equipment cost is low./ low capital cost.

Disadvantages of Abrasive Jet Machining:

1. Metal removal rate is low and therefore application is limited.
2. In certain circumstances, abrasive particles might settle over the work
piece.
3. Nozzle life is less. Nozzle should be maintained periodically.
4. additional cleaning of the work surface may occur as there is a
possibility of sticking abrasive grains in softer materials. It cannot be
used to machine soft materials
 Applications of Abrasive Jet machining

 Machining brittle and heat sensitive materials like

glass, quartz,sapphire ,ceramics germanium , silicon
and gallium.
 The process finds application in cutting slots , thin
sections, contouring , drilling, for producing shallow
crevices,deburring,& for producing intricate shapes
in hard & brittle materials .
 It is often used for cleaning & polishing of plastics ,
nylon & teflon components , frosting of interior
surface of the glass tubes , etching of markings on
glass cylinders , etc. 12
 Numericals
Problem 1 : Estimate the MRR in AJM of a brittle material with flow
strength of 4 GPA. The abrasive flow rate is 2 gm/min, velocity
is 200m/s, density of abrasive is 3gm/sec.
 Data Given:
 Flow strength of work material = 4x109 N/m2 4000N /mm2 w σ = =
 Abrasive grain density = 3gm/CC = 3x10-3x10-3 = 3x10-6 kg/mm3
 Mass flow rate of abrasives g ρ = 2gm/min = 2x 10-3/60 kg/sec
 Velocity = V = 200x1000mm/sec

 Solution:-
Water jet and Abrasive Water jet (AWJ)
Cutting
 Abrasive
Waterjet and
Waterjet
examples
Abrasive Water Jet
 Ultrasonic machining Process

Principle:-Ultrasonic Machining is a non-traditional process, in

which abrasives contained in a slurry are driven against the work by a
tool oscillating at low amplitude (25-100microns) and high frequency
(15-30 kHz).
Ultrasonic Machining consists of :
1. High Power sine wave generator
2. Magneto-strictive Transducer
3. Tool Holder
4. Tool

18
 High power sine wave generator
 This unit converts low frequency (60 Hz) electrical power to high
frequency (20kHz) electrical power.
 Transducer
 The high frequency electrical signal is transmitted to traducer which
converts it into high frequency low amplitude vibration. Essentially
transducer converts electrical energy to mechanical vibration. There are
two types of transducer used
 1. Piezo electric transducer 2. Magneto- strictive transducer.
 Piezo electric transducer: These transducer generate a small electric
current when they are compressed. Also when the electric current is passed
though crystal it expands. When the current is removed , crystal attains its
original size and shape. Such transducers are available up to 900 Watts.
Piezo electric crystals have high conversion efficiency of 95%.
 Magneto - strictive transducer: These also changes its length when
subjected to strong magnetic field. These transducer are made of nickel ,
nickel alloy sheets. Their conversion efficiency is about 20-30%. Such
transducers are available up to 2000 Watts. The maximum change in
length can be achieved is about 25 microns. 19
 Tool holder. OR Horn.
 The tool holder holds and connects the tool to the transducer. It virtually
transmits the energy and in some cases, amplifies the amplitude of
vibration. Material of tool should have good acoustic properties, high
resistance to fatigue cracking. Due measures should be taken to avoid
ultrasonic welding between transducer and tool holder. Commonly used
tool holders are Monel, titanium, stainless steel. Tool holders are more
expensive, demand higher operating cost.
 Tool
 Tools are made of relatively ductile materials like Brass, Stainless steel or
Mild steel so that Tool wear rate (TWR) can be minimized. The value of
ratio of TWR and MRR depends on kind of abrasive, work material and
tool materials.

20
 OPERATIONS OF
 ULTRASONIC CUTTING
As the tool vibrates with a
specific frequency, an abrasive
slurry usually a mixture of
abrasive grains and water of
definite proportion) is made to
flow through the tool work
interface. The impact force
arising out of vibration of the
tool end and the flow of slurry
through the work tool
interface actually causes
thousands of microscopic
abrasive grains to remove the
work material by abrasion.
Material removal from the hard
and brittle materials will be the
form of sinking, engraving or
any other precision shape 21
 Ultrasonic Machining
Main uses of USM:
- Welding plastics (package sealing)
- Wire-bonding (IC chips)
- Machining brittle materials
power
supply ~
Transducer

Up-down vibration of tool

hammers the abrasive particles
against workpiece, causing cutting

Nozzle Abrasive
slurry
Process Characteristics
Tool material:- - Brass, Mild steel
Abrasive:- - Al2O3,SiC(10-25um) ,boron carbide
Abrasive size -15 μm – 150 μm
W/P - Hard and Brittle material · Glass,
Sapphire, Alumina. Ferrite

Process parameters
Voltage - 200 V
Current - 12 amp
Feed rate - 0.1 mm/sec
Gap - 0.2 -0.5 mm
Vibration frequency - 19 - 25 kHz
Amplitude -10 – 50 μm
MRR -15 mm3/min
Surface Finish -0.2 - 2.5μm
Process Parameters of USM
 Advantages:-
 It can be used machine hard, brittle, fragile and non conductive
material
 No heat is generated in work. Metal removal cost is low.
 Non-metal (because of the poor electrical conductivity) that
cannot be machined by EDM and ECM can very well be machined
by USM.
 It is burr less and distortion less processes.
 The machined component is stress free.
 Physical properties of materials remains unchanged.

Disadvantages:-
 Low MRR i.e. upto 13 mm3/sec , hence not suitable for heavy
metal removal.
 Rather high tool wear
 Low depth of hole
 Initial equipment cost & tooling cost is high.
 Power consumption for machine is also high.
 Application:-
•simplicity of the process makes it economical for a wide range of
applications such as
1. Introducing round holes & holes of any shape for which a tool can be
made . The range of obtainable shapes can be increased by moving the
workpiece during cutting.
2. In performing / machining operations likes drilling , grinding, profiling
& milling operations on all materials both conducting & non conducting.
3. In machining glass , ceramic , tungsten & other hard carbides , gem ,
stones such as synthetic ruby.
4. In cutting threads in components made of hard metals & alloys by
approximately rotating & translating either the workpiece or the tool.
5. In making tungsten carbide & diamond wire drawing dies & dies for
forging & extrusion processes.
6. Enabling a dentist to drill a hole of any shape on teeth without creating
any pain.

26
Metal removal rate

27
 Numericals
Problem:-
Glass is being machined at a MRR of 6 mm3/min by Al2O3
abrasive grits having a grit size of 150 μm. If 100 μm grits were
used, what would be the MRR?

Solution:-

Amplitude of vibration (ao) μm, Frequency of vibration (f) kHz,Feed force (F)
mm/min,,Abrasive size (dg) μm , Contact area of the tool (A),mm2, Volume concentration of
abrasive in water slurry – C , indentation on w/p(σw)
 Electric Discharge Machining Process

Principle: EDM is the thermal erosion process in which metal is removed

by a series of recurring electrical discharges between a cutting tool acting as
an electrode and a conductive work piece, in the presence of a dielectric
fluid ,the discharge occurs in a voltage gap between the electrode and work
piece. Heat from the discharge vaporizes minute particles of work piece
material, which are then washed from the gap by the continuously flushing
dielectric fluid -
 EDM Process
 EDM spark erosion is the same as having an electrical short
that burns a small hole in a piece of metal it contacts. With
the EDM process both the workpiece material and the
electrode material must be conductors of electricity. The
EDM process can be used in two different ways:
 1. A preshaped or formed electrode (tool),usually made from
graphite or copper, is shaped to the form of the cavity it is to
reproduce. The formed electrode is fed vertically down and
the reverse shape of the electrode is eroded (burned) into the
solid workpiece.
 2. A continuous-travelling vertical-wire electrode, the
diameter of a small needle or less, is controlled by the
computer to follow a programmed path to erode or cut a
narrow slot through the workpiece to produce the required
30
shape.
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
 Electro-Discharge Machining Electrode EDM
(EDM)

- Sparks between electrode-workpiece

- Dielectric flushes the metal powder

- Inexpensive, precise, complex shapes

- Workpiece must be a conductor
[source: iprod.auc.dk]
Wire-cut EDM

[source: www.magnix.co.kr]
Process Characteristics
 Tool material:-Cu,Brass,graphite
 Dielectric:- Kerosene,Parafin oil, Transformer oil
 W/P:-Conducting metals and Alloys
Process parameters
 Voltage - 100V -300V
 Current - 50 amps
 Feed rate - 0.1 mm/sec
 Spark gap - 0.01- 0.1 mm
 Melting point - 10000o C
MRR - 10-20mm3/min
Surface Finish - 0.2 2.5 μm mp unit 4\Electrical Discharge
Machining EDM - YouTube.mp4
Process Parameters of EDM
 Advantages of EDM
• Complex shapes that would otherwise be difficult to produce
with conventional cutting tools.
• Extremely hard material to very close tolerances..
• There is no direct contact between tool and work piece
• A good surface finish can be obtained.
• Disadvantages of EDM
• The slow rate of material removal.
• Potential fire hazard associated with use of combustible oil
based dielectrics.
• Power consumption is high.
• Excessive tool wear occurs during machining. /low tool life.
• Materials which are only good conductor of electricity can
be machined.
Application:-
• Hardened steel dies, stamping tools, wire drawing and
extrusion dies, header dies,
• forging dies, intricate mould cavities and such parts are
made by the EDM process.
• Micro-EDM process can successfully produce micro-pins,
micro-nozzles and micro-cavities.
• EDM is used in automobile industry for drilling very small
diameters holes in fuel injection nozzle.
• It is also useful for re-sharpening of cutting tools &
broaches.
• Internal gears & internal threads can be cut in harden
materials by using suitable attachment. 36
 Numerical/Formula

Problem:-
A certain alloy whose melting point = 2,000 0F is to be
machined in EDM. If a discharge current = 25A, what is the
expected metal removal rate?

MRR = (C I)/(Tm1.23) = (5.08 x 25)/(2,0001.23)

= 0.011 mm3/min.
 Laser Beam Machining (LBM),

Principle:-
LBM uses the light energy of a laser beam to remove material by
vaporization. In this process the energy of coherent light beam is focused
optically ,so that the released energy results in an impulse against the work
surface that does melting and evaporation.
mp unit 4\laser.mp4
 Laser cutting

Light Amplification by Stimulated Emission of Radiation

- High energy density (small focus area)

- Uses: Cutting, welding, precision holes
- Common lasers: CO2, Nd:YAG
- Continuous power or Pulsed (more precise)

Nd:YAG laser cut:

larger dia and
heat-affected zone

Femtosecond laser cut:

smaller diameter,
lower thermal damage
Microscope image of laser cut hole
Construction of LBM
 It consists of a stimulating light source
(xenon flash lamp ) & a laser rod.
 Laser rod or laser tube consists of a pair of
mirrors , which are placed at each end of a
tube.
 Setup also consists of a flash tube / lamp
(energy source) ,laser , power source ,
focusing source(lens) & cooling system.
 The whole setup is fitted inside an enclosure
40
which has highly reflective surface inside it.
Working of LBM
 In operation , the optical energy (light ) radiated from the
flash lamp is focused on the laser rod (tube) , from where it
is reflected with the help of mirrors & accelerated in its
path.
 The reflected light is emitted in the form of a slightly
divergent beam.
 A lens is placed in the path of this beam of light which
converges & focuses the light beam on the component to
be machined.
 This impact of laser beam on the component melts the
work material & due to this it vapourizes . Hence it is also
called as thermal cutting process. 41
 Process Characteristics of LBM
 Type of laser- Nd-YAG,Argon, CO2
 Material - conductive and Nonconductive metals,
plastics, rubbers, ceramics and composites.

 Laser Power = 5KW(CO2) -40 KW(Nd-YAG)

 Cutting Speed -200-600 mm/min
 Type and pressure of assist gas -Air (1-3 bar)
 Mode of Operation - Pulsed
MRR -0.001-0.001
Surface Finish - 0.5- 1.5 μm
Advantages:-
• The ability to cut almost all materials
• In LBM process there is no direct contact between the tool &
workpiece , hence tool wear does not exist.
• Extremely small holes can be drilled easily.
• Refractory materials can be easily worked, also used for dissimilar
metals.
• No limit to cutting paths as the laser point can move in any paths.
• No cutting lubricants are required
• The fragile materials are easy to cut on a laser without any support.
Disadvantages
• Laser processes involve high capital investments and high
operating costs. Highly skilled operators required.
• Laser holes are tapered to some extent (approximately 1% of the
drill depth)
• It cannot drill blind holes to precise depths.
• Safety precautions & procedures are to be followed.
• Limited life of flash lamp leads high operational cost.
Application:-
Material removal – drilling, cutting and tre-panning
• Welding ,Cladding ,Alloying
• Drilling micro-sized holes
• LBM is mainly used for trimming of sheet metal ,
carbon resistors & plastic parts.
• LBM is also suitable for dynamic balancing of
precise rotating components like watches.
• Cutting complicated profiles on thin films for
making ICs engraving patterns on thin films LBM
is used. 44
Metal removal rate in LBM

45
 Numericals
Problem:-The CO2 laser of 5 KW is used to cut, 5mm thick
carbon steel cut at 1m/min.
Solution:-
WL= Power(KW), RL=Rate of Cutting, Q= MRR mm3/min
 Electro Chemical Machining

Principle:-
Electrochemical machining (ECM) removes material by anodic
dissolution with a rapidly flowing electrolyte. The tool is the
cathode and the work piece acts as anode.C:\MP2\UNIT-
IV\REFERENCE BOOKS\ECM.pdf
 ECM construction
 It consists of a tank in which the workpiece to be machined is
placed.
 The positive terminal of D.C supply is connected to the
workpiece hence acts as anode & negative terminal is
connected to tool hence acts as cathode.
 Also set up consists of a servomotor which is used to control
the tool feed.
 Electrolyte used in the process is reused ; hence to remove
the machined particles from electrolyte , filter is placed into
the path.
 To lift the electrolyte from electrolyte reservoir , pump is
used & a filter is connected to the pump. 48
 ECM working
 The tool & workpiece are held close to each other with a
small gap ( upto 0.5mm) between them.
 A d.c voltage of about 3-30 V is applied between the tool
& workpiece , & electrolyte is pumped into the gap.
 Due to applied voltage current starts flowing via
electrolyte with positively charged ions being attracted
towards the tool & negatively charged ions being attracted
towards workpiece.
 Due to this flow of ions , electrochemical reaction takes
place & hence thee is removal of metal from the workpiece
in the form of sludge.
 This sludge is taken away from the gap by the electrolyte49
which is flowing continuously.
 Electrochemical Machining (ECM)

Reverse of electro-plating (workpiece is anode)

Main uses:
- Dies and glass-making molds, turbine and compressor blades, Holes, Deburring

Due to low forces on tool,

ECM can be used to make
holes at very large angle to
a surface – an example is
shown in the turbine nozzle
holes in the figure here.
[source: www.barber-nichols.com]
Process Characteristics
 Tool material - Cu,Brass,Stainless steel
 Electrolyte - Nacl,sodium Nitrate
 W/P - Conducting metals and Alloy
Process parameters
 Voltage - 5V -30V
 Current - 10,000 amp
 Gap - 0.125 – 0.250 mm
MRR - 200-300 mm3/min
Surface Finish - 0.1 -2.5 μm
 Process Parameters of ECM
 Feed Rate: A high feed rate results in higher metal removal
rate.
 Voltage: Low voltage decreases the MRR and results in
better surface finish and tolerance control.
Advantages:-
ECM is well suited for the machining of complex two-dimensional shapes
Delicate parts may be made
Difficult-to machine geometries
Poorly machinable materials may be processed
Little or no tool wear
Disadvantages:-
Initial tooling can be timely and costly
Environmentally harmful by pollution.
Application:-
• Die sinking
• Profiling and contouring
• Trepanning
• Grinding
• Drilling
• Micro-machining mp unit 4\ElectroChemical Machining (ECM) -
YouTube.mp4
Metal removal rate in ECM

54
 Numerical
Problem:-
In electrochemical machining of pure iron a material removal rate of 600
mm3/min is required. Estimate current requirement.

Data:-
MRR=600mm3/min =10mm3/minMC=3.67x10-2 mm3/amp-sec,

Solution:-
10mm3/min=3.67x10-2mm3/amp-secx0.1x I(Current)
I(Current)=272.47 amp
Comparison of Non-Traditional Machining
Process
Applicability to materials
Comparison of Machining characteristics
Comparison of economy of the processes
Effect of metal removal rate on power consumption.
 References
Text Books:
1. S. K Hajra Choudhury , Elements of workshop technology – Vol. II,,
Media Promoters AndPublishers, Mumbai
2.Amitabh Ghosh and Asok kumar Mallik, Manufacturing science, Ellis
Horwood Ltd
3.Mikell. P. Grover, Fundamentals of Modern Manufacturing, Pearson
Publications
4. P. C. Sharma, Production Engineering, S. Chand Publication.
Reference Books:
1. Production technology –HMT, Tata McGraw Hill publication
2. V. K Jain, Advanced machining processes , Allied Publisher, New Delhi
3. Gary F. Benedict, Non – traditional manufacturing processes, Marcel
Dekker Inc.
4. P. H. Joshi, Jigs and fixtures, Tata McGraw Hill
5. P. N. Rao, CAD/CAM Principles and Applications,
Website:-
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