non -traditional machining...
TRANSCRIPT
Emerging out due to the
Limitations of the Traditional Manufacturing Process
Need of Nontraditional Manufacturing Processes
mech14.weebly.com
Characteristics of Conventional Machining
Contact type
Cutting force by the tool is inevitable
Slender job is not possible
Large heat-affected zone
High residual stress
Poor surface integrity
Complicated shape not possible
mech14.weebly.com
Case 1: Square blind hole with good surface finish & accuracy
Manufacturing of Square blind hole
40mm
50m
m
mech14.weebly.com
Case 2: Circular blind hole with high accuracy
Need: Manufacturing of a circular blind hole with accuracy of (+-) 100 micron, taper less than 0.5 degree
F 10 mm
60 m
m
mech14.weebly.com
Case 3: Drilling of circular hole of very small diameter & high aspect ratio
0.2 mm
5 m
m
mech14.weebly.com
Competition in manufacturing industry today demands
New products
Better performance
More features
Low cost
Energy efficiency
Reduction of residual stresses
Low HAZ
mech14.weebly.com
Super alloys, ceramics and composites• Too hard / brittle / difficult to
machine with traditional process
• Improved mechanical, thermal, & chemical properties
• Materials too flexible / slender to handle
Emergence of new exotic materials
Product from quartz
Solar cellmech14.weebly.com
Case-4: Industrial Marking and Drilling with Highest Accuracy
Efficient Marking and Drilling by Excimer Laser with Highest Accuracy
Branding gogglesInk-jet nozzle drilling
Microreactor channels in teflon
mech14.weebly.com
Case 5: 3D-Features on Gold Foil by Electroforming
The part is made of gold foil with a thickness of 10 microns .
The hole diameter is 100 mm .
The posts between the holes have a height of 22.5 microns and a base diameter of 50 mm.
The slots are 50 mm wide, and the walls that define the slots are 50 mm wide and 22.5 mm high.
Dimensional tolerance of +/- 3 mm.
mech14.weebly.com
Case 6: Miniaturised Components
Micro mold (Overall size 2-5 mm)
Micro gear (diameter 300 micron)
mech14.weebly.com
Thermal NTM Processes- Laser Beam Machining (LBM)- Electron Beam Machining (EBM) - Plasma Arc Machining (PAC)- Electrical Discharge Machining (EDM)
Mechanical NTM Processes (Plastic deformation / Abrasive Erosion)- Abrasive Jet Machining (AJM)- Ultrasonic Machining (USM)- Water Jet Machining (WJM)- Abrasive Water Jet Machining (AWJM)
Classifications of NTM Processes
Laser cutting
Ultrasonic machining
of glass
mech14.weebly.com
Classifications of NTM Processes
Electrochemical NTM Processes- Electrochemical Machining (ECM)- Electrochemical Grinding (ECG)
Chemical NTM Processes- Chemical Machining (CHM)- Thermo chemical Machining (TCM)
Kinetic Energy (Atom by atom knocking) - Ion beam
Electrochemical Machining
of complex surfaces
Electro-discharge Machining
mech14.weebly.com
Material removal with chip formation or evenwithout chip formation
Physical tool may or may not be present.
Tool need not be harder than the work piecematerial.
Mostly NTM processes do not use mechanicalenergy for material removal.
Nontraditional media for energy transfer.
Characteristics of Nontraditional Machining (NTM) Processes
mech14.weebly.com
• Basic theory, working principle, and characteristicsof different NTM processes.
• Critical process variables and their effects on process performance and product quality.
• Simple mathematical model relating MRR with machining parameters in NTM.
• Develop understanding to properly assess thecapabilities, limitations, and potentials of NTM inrelations to various industrial applications.
Objective of this course
mech14.weebly.com
MF30604 Non-Traditional Manufacturing Processes (3-0-0: 3 credits)
Needs of manufacturing industries and the concept of surface integrity.The role of newer & innovative processes for the solutions Impact erosion and the evaluation for impregnation of foreign bodies. Theory and application of Abrasive Jet, Water Jet, Abrasive Flow, Ultrasonic, Total Form Machining and Low stress Grinding. Theory and applications of Chemical Processing: Chemical Machining, etching of semiconductors, coating and Electro less forming and CVD. Theory and applications of Electrochemical machining and grinding including, Electrochemical sharpening, polishing, honing and deburring, surface treatment, coating and Electroforming. Thermal energy methods of material processing (machining, welding, cladding, alloying and heat-treatment): Electro-discharge Machining, Laser, Electron beam, Plasma arc, Plasma spray, Ion beam and PVD. Hybridization of processes for improving process capability and surface integrity. Explanation of some processes like ECDG, ultrasonic and Laser assisted processing, LIGA & SLIGA etc.; Generic manufacturing and introduction to rapid prototyping.
** (Topics marked in black colour will be taught by Prof. P Saha and those in blue will be taught by Prof. A K Nath.)
mech14.weebly.com
Nontraditional Manufacturing Processes by Gary F. Benedict, Marcel Dekker,Inc
Modern Machining Processes by P C Pandey & H S Shan, Tata McGraw-Hill
Nonconventional Machining by P K Mishra, Narosa Publishing House
Manufacturing Science by Amitabha Ghosh & A K Mallik, Affiliated East-West Press
Advanced Machining Processes, by El-Hofy, McGraw Hill
Reference Books
mech14.weebly.com