nontraditional machining presentation

7/18/2019 NonTraditional Machining Presentation

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Non-traditionalMachining Processes

ME 355, Introduction to

Manufacturing Processes


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Outline

Abrasive Grinding

Non-traditional Machining Processes

ltrasonic Machining Abrasive !ater "et Machining

#he$ical Machining

Electro-che$ical Machining

Electro-che$ical Grinding

Electrodischarge Machining %aser &ea$ Machining

#ase 'tudies

(verall Process co$)arisons


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Grinding


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Abrasive Grinding

#an be vie*ed as

$ulti)le ver+ s$all

cutting edges esults in a ver+ fine

finish

#an leave residualstresses

'lo*, s$all $aterial

re$oval rates

')aring out


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Standard Grinding Wheel

Designation

!hile this is s)ecific to grinding, reali.e that there aresi$ilar standard designations in $ost industries

/ae the ti$e to learn the standard designations earl+ sothat +ou can s)ea intelligibl+ *ith those *ithin the

industr+0


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Ultrasonic

Machining

ltrasonic vibration 12, 4.of ver+ s$all a$)litudes 106-07 $$ drive the for$ tool1sonotrode of ductile $aterial1usuall+ soft steel

An abrasive slurr+ is flo*edthrough the *or area

/he *or)iece is brittle in nature1i0e0 glass

/he *or)iece is graduall+eroded a*a+0


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Waterjet and Abrasive Waterjet

(AWJ !utting


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Abrasive

Waterjet and

Waterjete"a#$les


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Abrasive

Water Jet 4igh )ressure *ater 12,-

8, )si

Educt abrasive into strea$

#an cut e9tre$el+ thic )arts 15-:inches )ossible /hicness achievable is a function of

s)eed

/*ice as thic *ill tae $ore thant*ice as long

/ight tolerances achievable #urrent $achines 02; 1older

$achines $uch less ca)able < 0:;

"et *ill lag $achine )osition, so

controls $ust )lan for it


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!he#ical Machining (!he#illing A))lications=

Aeros)ace industr+

Engraving

#ircuit boards

A $asant is a))lied over

areas +ou don>t *ant to$achine Photoche$ical $ethods

A))l+ $asant to entire surfaceand use laser to cut

Place the entire )art in ache$ical bath 1acid or alalide)ending u)on the $etal

#ontrol te$)erature and ti$eof e9)osure to control

$aterial re$oval


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%lectro-!he#ical

Machining (%!M !ors on the )rinci)le of

electrol+sis acceleratedche$illing

?ie is )rogressivel+

lo*ered into *or)iece as*or)iece is dissociatedinto ions b+ electrol+sis

Electrol+tic fluid flo*saround *or)iece tore$ove ions and $aintainelectrical current )ath

%o* ?# voltage, ver+4igh current 1@ a$)s


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%lectroche#ical grinding

#o$bines electroche$ical $achining *ith

conventional grinding

Grinding *heel is the cathode

Metal bonded *heel *ith dia$ond or Al2(3

abrasive

Maorit+ of $aterial re$oval fro$ electrol+ticaction 1B5C therefore ver+ lo* *heel *ear

Much faster than conventional grinding


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%lectrode Discharge

Machining (%DM

?irect #o$)etitor of E#M $uch $oreco$$on than E#M

/he tool acts as a cathode 1t+)icall+gra)hite is i$$ersed in a ?ielectric fluid*ith conductive *or)iece

?# voltage 1


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Die Sin&er

vs' Wire

%DM ?ie siner E?M

/he die sins into the )art

as it s)ars a*a+ the*or)iece

Most co$$on Inection

$olding die )rocess

!ire E?M /he electrode is a *ire that

traverses through the )art

#o$$on for E9trusion

?ies


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aser )ea# Machining

%asers are high intensit+ focused light sources #(2

Most *idel+ used

Generall+ $ore )o*erful that FAG lasers

#utting o)erations co$$onl+Nd=FAG 1Neod+$iu$ ions in an Fttriu$ Alu$inu$

Garnet %ess )o*erful

Etching$aring t+)e o)erations $ore co$$onl+

%i$ited in de)th of cut 1focus of light

!ould li$it *or)iece to less than : inch 1H ;t+)icall+


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!ase Stud*

#N# Mill

#N# !ire E?M

#N# E?M


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Wire %DM (not sho+n, Die Sin&er

%DM, Anodied

Di.. t P t Wi %DM


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Di..erent Part - Wire %DM /

$ro.iling and drilling


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!ase Stud* 0hree

:0 #N# Milling 20 'etu) on *ire E?M

30 JA After *ire E?M 60 Grinding a face on the )art


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Setu$ o. Die Sin&er %DM

:0 %ocating )arts relative to

$achine20 %ocating the electrode

relative to )arts setu)


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Die Sin&er in action and .inished

$roduct


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Overall Machining 0olerances and Sur.ace 1oughness

nontraditional machining presentation

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