Assignment Non Conventional Machining

Bishwash Neupane
32105; Design and Manufacturing

Electrochemical Machining
1. In an ECM operation the frontal working area of the electrode is 1555 mm2. Applied
current = 1200 amps and voltage = 12 volts. The material being cut is nickel (valence
= 2). Consult Table 22.1 for the specific removal rate of nickel. (a) If the process is
90% efficient, determine the rate of metal removal in mm3/min. (b) If the resistivity
of the electrolyte = 150 ohm-mm, determine the working gap.
Answer:
Here,
Frontal working area of electrode = 1555 mm2
Applied Current = 1200 amps
Voltage = 12 volts
Material being cut is Nickel
a) If the process is 90% efficient, rate of metal removal in mm3/min:
We have,
𝑉 = 𝐶∗𝐼∗𝑡
V= volume of metal removed, mm3
C=a constant called the specific removal rate that depends on atomic weight,
valence, and density of the work material, mm3/amp-s
I = current (amps)
T=time (min)
So;
𝑉/𝑡 = 𝐶 ∗ 𝐼
For Nickel, C=3.42*10-2 mm3/sec=3.42*10-2 *60 mm3/min
𝑉/𝑡 = 3.42 ∗ 10 − 2 ∗ 60 ∗ 1200 ∗ 0.9
= 2216.16 𝑚𝑚3/𝑚𝑖𝑛
b) If the resistivity of the electrolyte = 150 ohm-mm, the working gap:
𝑅 = 𝑉/𝐼 = 12/1200 = 0.01 𝑜ℎ𝑚;
We have,
𝑅 = (𝑔 ∗ 𝑟)/𝐴
𝑔 = (𝑅 ∗ 𝐴)/𝑟
𝑔 = 0.10 𝑚𝑚
2. A square hole is to be cut using ECM through a plate of low alloy steel that is 12 mm
thick. The specific removal rate for this steel is 3.7 x 10-2 mm3/A-s. The hole is 35 mm
on each side, but the electrode used to cut the hole is slightly less than 35 mm on its
sides to allow for overcut, and its shape includes a hole in its center to permit the flow
of electrolyte and to reduce the area of the cut. This tool design results in a frontal
area of 245 mm2. The applied current = 1200 amps. (a) Using an efficiency of 95%,
how long will it take to cut the hole? (b) If the tool were designed with a frontal area
equal to the hole size, how long will it take to cut the hole?
Answer:
Here,
Thickness of alloy steel = 12 mm
Specific removal rate= 3.7 * 10-2 mm3/A-s
Dimension of Hole = 35 mm*35 mm
Frontal area of electrode = 245 mm2
Applied current = 1200 amps
a) Using an efficiency of 95% time to cut the hole:
We have;
𝑉 = 𝐶∗𝐼∗ 𝜂
But,
𝑉 = 𝐴 ∗ 𝑡 = 245 ∗ 12 = 2940 𝑚𝑚3
So,
𝑡 = 𝑉/(𝐶 ∗ 𝐼 ∗ 𝜂)
𝑡 = 69.7 𝑠 = 1.16 𝑚𝑖𝑛
b) If the tool were designed with a frontal area equal to the hole size, time required to
cut the hole:
Using an efficiency of 95% time to cut the hole:
We have;
𝑉 = 𝐶∗𝐼∗ 𝜂
But,
𝑉 = 𝐴 ∗ 𝑡 = 35 ∗ 35 ∗ 12 = 14700 𝑚𝑚3
So,
𝑡 = 𝑉/(𝐶 ∗ 𝐼 ∗ 𝜂)
𝑡 = 348.050 𝑠𝑒𝑐 =5.81 min
Electric Discharge Machining

3. An electric discharge machining operation is performed on tungsten. Determine the
amount of metal removed in the operation after one hour at a discharge current of 20
amps for this metal. Use metric units and express the answers in mm3/hr. Refer to
Table 4.1 for the melting temperature of tungsten.
Answer
Here;
Time = 1 hrs
Current (I) = 20 amps
Melting point for tungsten Tw = 3410 degree Celsius
𝑀𝑅𝑅 = 𝐾𝐼/𝑇𝑚 1.23
𝑀𝑅𝑅 = 2159 𝑚𝑚3 /ℎ𝑟𝑠
4. In a wire EDM operation performed on 12-mm-thick C1080 steel using a tungsten

wire electrode whose diameter = 0.125 mm, past experience suggests that the overcut
will be 0.02 mm, so that the kerf width will be 0.165 mm. Using a discharge current =
15 amps, what is the feed rate that can be used in the operation? Estimate the melting
temperature of 0.80% carbon steel from the phase diagram of Figure 6.4.
Answer:
𝑇𝑚 = 1500° 𝐶 For 1080 steel
Discharge Current = 15 amps
We have;
𝑀𝑅𝑅 = (664 ∗ 15)/(15001.23 )
𝑀𝑅𝑅 = 73.92 𝑚𝑚3/𝑚𝑖𝑛
Now frontal area of kerf;
𝐴 = 0.165 ∗ 12 = 1.98 𝑚𝑚2
Now, feed rate is found as;
𝐹𝑟 = 𝑀𝑅𝑅/𝐴
73.92
𝐹𝑟 = = 37.33𝑚𝑚/𝑚𝑖𝑛
1.98
The required feed rate that can be used in the operation is 37.33 mm/min.
5. A wire EDM operation is used to cut out punch-and-die components from 25-mm-thick
tool steel plates. However, in preliminary cuts, the surface finish on the cut edge is poor.
What changes in discharge current and frequency of discharges should be made to improve
the finish?
Answer:
In order to improve the surface finish in EDM , the discharge current could be reduced,
and frequency of discharge could be increased.
Chemical Machining
6. Chemical milling is used in an aircraft plant to create pockets in wing sections made
of an aluminum alloy. The starting thickness of a work part of interest is 25 mm. A
series of rectangular-shaped pockets 15 mm deep are to be etched with dimensions
200 mm by 400 mm. The corners of each rectangle have a radius = 15 mm. The etchant
is NaOH. Consult Table 22.2 for the penetration rate and etch factor. Determine (a)
metal removal rate in mm3/min, (b) time required to etch to the specified depth, and
(c) required dimensions of the opening in the cut and peel maskant to achieve the
desired pocket size on the part.
Answer:
Here,
Starting thickness = 25 mm
Rectangular pockets dimension = 200*400*15 all in mm
Corners of each rectangle has radius = 15 mm
Penetration rate for this combination = 0.025 mm/min
Etch factor Fe = 1.75
a. Metal Removal Rate (MRR);
𝐴𝑟𝑒𝑎; 𝐴 = (200 ∗ 400) − (30 ∗ 30) − (𝜋 ∗ 152 ) = 79807 𝑚𝑚2
𝑀𝑅𝑅 = 0.025 ∗ 79807 = 1995.2 𝑚𝑚3 /𝑚𝑖𝑛
b. 𝑇𝑖𝑚𝑒 𝑡𝑜 𝑚𝑎𝑐ℎ𝑖𝑛𝑒; (𝑒𝑡𝑐ℎ) 𝑇𝑚 = 15/0.025 = 600 𝑚𝑖𝑛 = 10 ℎ𝑟𝑠
c. Undercut = d/Fe = 15/1.75 = 8.57 mm
𝑀𝑎𝑠𝑘𝑎𝑛𝑡 𝑜𝑝𝑒𝑛𝑖𝑛𝑔 𝑙𝑒𝑛𝑔𝑡ℎ = 𝐿 − 2𝑢 = 400 − 2(8.57) = 382.86 𝑚𝑚
𝑀𝑎𝑠𝑘𝑎𝑛𝑡 𝑜𝑝𝑒𝑛𝑖𝑛𝑔 𝑤𝑖𝑑𝑡ℎ = 𝑊 − 2𝑢 = 200 − 2(8.57) = 182.86 𝑚𝑚
𝑅𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑐𝑜𝑟𝑛𝑒𝑟 = 𝑅 − 𝑢 = 15 − 8.57 = 6.43 𝑚𝑚
7. In a certain chemical blanking operation, a sulfuric acid etchant is used to remove
material from a sheet of magnesium alloy. The sheet is 0.25 mm thick. The screen
resist method of masking was used to permit high production rates to be achieved. As
it turns out, the process is producing a large proportion of scrap. Specified tolerances
of ±0.025 mm are not being achieved. The foreman in the CHM department
complains that there must be something wrong with the sulfuric acid. "Perhaps the
concentration is incorrect," he suggests. Analyze the problem and recommend a
solution.
Answer
The problem in this chemical blanking operation is that the screen resist method of
masking cannot achieve the tolerances perfect. The photoresist method should have been
used and the process should be changed over to adopt this method.

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Bishwash Neupane

32105; Design and Manufacturing

Electric Discharge Machining

4. In a wire EDM operation performed on 12-mm-thick C1080 steel using a tungsten

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