HYDRODYNAMIC MACHINING (HDM)

Hydrodynamic machining is a nontraditional mechanical process. Hydrodynamic machining removes

workpiece material and produces a narrow kerf by the cutting action of a fine, high pressure (usually up to
415 MPa), high velocity stream of water or water-based fluid with additives. In HDM, a hydraulically
powered intensifier pressurizes the water used for cutting. An accumulator is used to eliminate pulsation,
as shown in Fig.1.

The relationship between nozzle and workpiece in HDM is illustrated in Fig.2. View (a) defines the
standoff distance, penetration depth, and rake angle. View (b) shows the configuration of positive rake in
relation to nozzle feed.

Operating Parameters

Many variables affect the results of an HDM operation, including nozzle size, water pressure, flow rate,
standoff distance, rake angle, and cutting fluid additives.

Nozzles: In HDM, jet nozzles are made of synthetic sapphire, hardened steel, stainless steel,
or tungsten carbide, depending upon the severity of the operation. For most applications,
orifice diameter is 0.08-0.38 mm. Smaller diameter orifices generate fine cuts; larger size orifices
are used for cutting thicker materials, but require increased horsepower for effective cutting.
For most thin materials, the kerf is usually about 0.03 mm larger than the diameter of the nozzle
orifice.

Water Pressure: Usually, water pressure in HDM operations is 69-415 MPa, although some
difficult- to-cut materials require water pressure in excess of 690 MPa for effective
cutting. Figure 3 shows the relationship between water pressure and jet velocity in HDM. Figure
4 shows how jet velocity affects nozzle flow when nozzles with different orifice sizes are
used. Figure 5 illustrates the relationship between jet velocity and power requirements for various
nozzles and different sizes. Figure 6 shows how to establish hydraulic horsepower
requirements for various pressures and nozzle flow rates.

Cutting Speeds: Work material, water pressure, size of orifice in the jet nozzle, and material
thickness interact to establish effective cutting rates in HDM. On the other hand, cutting speed
directly influences the overall cost of the operation; however, experience shows that lower
traverse rates improve the quality of the cut. In general, cutting speed decreases with
increases in standoff distance, which impacts penetration depth in HDM operations (standoff
distance can range from 2.5-76.5 mm or more, but 3 mm is typical).

Forces & Temperature: Forces applied to the workpiece during HDM are a function of jet
velocity that is dependent upon the water pressure, nozzle size, etc., as shown in Fig. 7.
Generally, these forces are no greater than about 180 N in a direction normal to the workpiece
surface; side forces are very low, so fixturing requirements are usually minimal. In HDM, the
temperature increase may be large enough to melt certain plastics, but it is usually not
considered a major problem in most applications.

Standoff distance: Standoff distance impacts penetration depth in HDM operations, as shown
in Fig. 8. Depending upon the application, standoff distance can range from 2.5-75 mm or
more, but about 3 mm is typical.

Rake Angle: As shows in Fig. 2, perpendicular to positive rake angles from few degrees to
30 is used in HDM. Generally, high rake angles up to about 15 increase penetration depth,
depending upon materials and other parameters.
 Fluid Formulation: Some of the more common additives include glycerin, polyethylene oxide,
and long-chain polymers. The quality of the jet stream in HDM operations dependent upon
good filtration of the fluid. Nozzle life is also a function of the fluid cleanliness. Usually, fluid
filtration to 0.5 m is recommended.

APPLICATIONS

HDM is effective in slitting and contour cutting many nonmetallic materials such as wood and paper,
asbestos, plastic, gypsum, leather, rubber, nylon, fiberglass. Some very thin workpieces of soft metals
can be cut effectively by the process; steel sheet (0.13 mm) and aluminum sheet (0.50 mm) are
processed, but water pressure in excess of 690 MPa is usually required.

Practical experience has shown that, in some cases, brittle materials such as glass, acrylic, ceramics, and
crystal do not appear suitable for cutting by the HDM process because these materials tend to develop
sever cracks and may break under processing conditions. NC equipment for HDM processing is available
in table sizes up to about 1.2 1.5 m, with cutting speeds of up to about 22 m/min.

Electrochemical machining (ECM)

is a method of removing metal by an electrochemical process. It is normally used for mass
production and is used for working extremely hard materials or materials that are difficult to machine
using conventional methods.[1] Its use is limited to electrically conductive materials. ECM can cut
small or odd-shaped angles, intricate contours or cavities in hard and exotic metals, such as titanium
aluminides, Inconel, Waspaloy, and high nickel, cobalt, and rhenium alloys.[2] Both external and
internal geometries can be machined.
ECM is often characterized as "reverse electroplating", in that it removes material instead of adding
it.[2] It is similar in concept to electrical discharge machining (EDM) in that a high current is passed
between an electrode and the part, through an electrolytic material removal process having a
negatively charged electrode (cathode), a conductive fluid (electrolyte), and a conductive workpiece
(anode); however, in ECM there is no tool wear.[1] The ECM cutting tool is guided along the desired
path close to the work but without touching the piece. Unlike EDM, however, no sparks are created.
High metal removal rates are possible with ECM, with no thermal or mechanical stresses being
transferred to the part, and mirror surface finishes can be achieved.
In the ECM process, a cathode (tool) is advanced into an anode (workpiece). The pressurized
electrolyte is injected at a set temperature to the area being cut. The feed rate is the same as the
rate of "liquefication" of the material. The gap between the tool and the workpiece varies within 80
800 micrometers (0.0030.030 in.)[1] As electrons cross the gap, material from the workpiece is
dissolved, as the tool forms the desired shape in the workpiece. The electrolytic fluid carries away
the metal hydroxide formed in the process.[2]
As far back as 1929, an experimental ECM process was developed by W.Gussef, although it was
1959 before a commercial process was established by the Anocut Engineering Company. B.R. and
J.I. Lazarenko are also credited with proposing the use of electrolysis for metal removal.[2]
Much research was done in the 1960s and 1970s, particularly in the gas turbine industry. The rise of
EDM in the same period slowed ECM research in the west, although work continued behind the Iron
 Curtain. The original problems of poor dimensional accuracy and environmentally polluting waste
have largely been overcome, although the process remains a niche technique.
The ECM process is most widely used to produce complicated shapes such as turbine blades with
good surface finish in difficult to machine materials. It is also widely and effectively used as
a deburring process.[2]
In deburring, ECM removes metal projections left from the machining process, and so dulls sharp
edges. This process is fast and often more convenient than the conventional methods of deburring
by hand or nontraditional machining processes.[1]

Contents
[hide]

1Advantages
2Disadvantages
3Currents involved
4Setup and equipment
5Applications
6Similarities between EDM and ECM
7Difference between ECM and ECG
8See also
9Notes
10External links

Advantages[edit]
1. Complex, concave curvature components can be produced easily by using convex and
concave tools.
2. Tool wear is zero, same tool can be used for producing infinite number of components.
3. No direct contact between tool and work material so there are no forces and residual
stresses.
4. The surface finish produced is excellent.
5. Less amount of heat is generated.

Disadvantages[edit]
The saline (or acidic) electrolyte poses the risk of corrosion to tool, workpiece and equipment.[2]
Only electrically conductive materials can be machined. High Specific Energy consumption.

Currents involved[edit]
The needed current is proportional to the desired rate of material removal, and the removal rate in
mm/minute is proportional to the amps per square mm.
Typical currents range from 0.1 amp per square mm to 5 amps per square mm. Thus, for a small
plunge cut of a 1 by 1 mm tool with a slow cut, only 0.1 amps would be needed.
However, for a higher feed rate over a larger area, more current would be used, just like any
machining processremoving more material faster takes more power.
Thus, if a current density of 4 amps per square millimeter was desired over a 100100 mm area, it
would take 40,000 amps (and lots of coolant/electrolyte).

Setup and equipment[edit]

An ET 3000 ECM machine by INDEC of Russia

ECM machines come in both vertical and horizontal types. Depending on the work requirements,
these machines are built in many different sizes as well. The vertical machine consists of a base,
column, table, and spindle head. The spindle head has a servo-mechanism that automatically
advances the tool and controls the gap between the cathode (tool) and the workpiece.[1]
CNC machines of up to six axes are available.[2]
Copper is often used as the electrode material. Brass, graphite, and copper-tungsten are also often
used because they are easily machined, they are conductive materials, and they will not corrode.[1]

Applications[edit]
Some of the very basic applications of ECM include:

Die-sinking operations
Drilling jet engine turbine blades
Multiple hole drilling
Machining steam turbine blades within close limits
Similarities between EDM and ECM[edit]
The tool and workpiece are separated by a very small gap, i.e. no contact in between them is
made.
The tool and material must both be conductors of electricity.
Needs high capital investment.
Systems consume lots of power.
A fluid is used as a medium between the tool and the work piece (conductive for ECM and
dielectric for EDM).
The tool is fed continuously towards the workpiece to maintain a constant gap between them
(ECM may incorporate intermittent or cyclic, typically partial, tool withdrawal).

Difference between ECM and ECG[edit]

Electrochemical grinding (ECG) is similar to electrochemical machining (ECM) but uses a
contoured conductive grinding wheel instead of a tool shaped like the contour of the workpiece.