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Non Conventional M

The document discusses the development of new harder and temperature resistant alloys that find applications in industries like aerospace and nuclear engineering. As new materials were developed, unconventional machining processes had to be developed to machine these materials. Electrochemical machining is one such non-traditional technique that utilizes electrolysis to remove metal by dissolving the workpiece acting as the anode in an electrolytic cell. The process involves passing an electric current between an electrode tool as the cathode and the workpiece as the anode immersed in an electrolyte solution.

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Seshi Reddy
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67 views3 pages

Non Conventional M

The document discusses the development of new harder and temperature resistant alloys that find applications in industries like aerospace and nuclear engineering. As new materials were developed, unconventional machining processes had to be developed to machine these materials. Electrochemical machining is one such non-traditional technique that utilizes electrolysis to remove metal by dissolving the workpiece acting as the anode in an electrolytic cell. The process involves passing an electric current between an electrode tool as the cathode and the workpiece as the anode immersed in an electrolyte solution.

Uploaded by

Seshi Reddy
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Chapter 1.

INTRODUCTION
The development of harder & difficult ton machine metals & alloys such as tungsten, tantalum, beryllium, hast alloy, nitralloy, wasp alloy, nimonics, carbide, stainless steels and many other high strength temperature resistant (HSTR) alloys. These materials find wide application in aerospace, nuclear engineering and other industries going to their high strength to weight ratio, hardness and heat resisting qualities. The rapid developments in the field of materials has given an impetus to the modern manufacturing technology to develop, modify and is cover newer technological processes with a view to achieve results that are far beyond the scope of the existing conventional or traditional manufacturing processes. With the developments in the field of materials it has become essential to develop cutting tool materials and processes which can safely and conveniently machine such new materials for sustained productivity, high accuracy and versatility at automation. Consequently, non traditional techniques of machining are providing effective solutions to the problems imposed by the increasing demand for high strength temperature resistant alloys, the requirement of parts with intricate and compacted shapes and materials so hard as to defy machining by conventional methods. The processes are non traditional or non-conventional in the sense that they dont employ a conventional or traditional tool for material removal, instead, they directly utilize some form of energy for metal machining. Conventional machining methods always produce some stress in the metal being cut. Newer methods have been developed that are essentially stress free. Very thin metals can be cut without distortion or stress. The industries always face problems in manufacturing of components because of several reasons. This may be because of the complexity of the job profile or may be due to surface requirements with higher accuracy and surface finish or due to the strength of the materials. This challenge has been accepted and may new materials and unconventional methods of machining have been developed to suit the requirements of industry. The word unconventional means that the metals are such that they cannot be machined by conventional methods, but require some special techniques.

I. ELECTRO CHEMICAL MACHINING


Electrochemical machining (ECM) is based on a controlled anodic electrochemical dissolution process of the workpiece (anode) with the tool (cathode) in an electrolytic cell, during an electrolysis process (Figure 1.1).

Electrolysis is the name given to the chemical process which occurs, for example, when an electric current is passed between two electrodes dipped into a liquid solution. A typical example is that of two copper wires connected to a source of direct current and immersed in a solution of copper sulfate in water as shown in Figure 1. 2.

Figure 1.2. Electrochemical cell [1]


An ammeter, placed in the circuit, will register the flow of current. From this indication, the electric circuit can be determined to be complete. It is clear that copper sulfate solution obviously has the property that it can conduct electricity. Such a solution is termed as electrolyte. The wires are called electrodes, the one with positive polarity being the anode and the one with negative polarity the cathode. The system of electrodes and electrolyte is referred to as the electrolytic

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