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ME 388 Assignment - NTM

This document provides instructions for an assignment on non-traditional machining processes. It includes 8 problems analyzing various non-traditional machining techniques like electrochemical machining (ECM), abrasive jet machining (AJM), ultrasonic machining (USM), and electric discharge machining (EDM). It also includes 10 true/false statements about various non-traditional machining processes to be marked as true or false.

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Ganesh Chelluboyina
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375 views3 pages

ME 388 Assignment - NTM

This document provides instructions for an assignment on non-traditional machining processes. It includes 8 problems analyzing various non-traditional machining techniques like electrochemical machining (ECM), abrasive jet machining (AJM), ultrasonic machining (USM), and electric discharge machining (EDM). It also includes 10 true/false statements about various non-traditional machining processes to be marked as true or false.

Uploaded by

Ganesh Chelluboyina
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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ME 388- Manufacturing processes II

Assignment 1 Non-traditional machining processes

Note:

 If you are not clear about any parameters, use suitable assumptions
 Please refer either lecture slides or text book (Ghosh/Mallick)

1) The composition (%by weight) of the Nimonic 75 alloy is as given here:

Ni Cr Fe Ti Si Mn Cu

73 19.5 4.5 0.4 1.2 0.8 0.6

Calculate the removal rate (in mm3/sec) when a current of 500 A is passed. Use the
lowest valency of dissolution for each element. Use both methods to calculate the
gram equivalent weight.

Gram atomic Valency of


Metal Density (g/cm3)
weight dissolution

Ni 58.71 2/3 8.90

Cr 51.99 2/3/6 7.19

Fe 55.85 2/3 7.86

Ti 47.9 3/4 4.51

Si 28.09 4 2.33

Mn 54.94 2/4/6/7 7.43

Cu 63.57 1/2 8.96

2) Find out approximate time required to machine a square hole (10 mm × 10 mm) in a
tungsten carbide plate of thickness 4 mm. The abrasive grains are 0.01 mm diameter.
The feeding is done with a constant force of 3.5 N. The amplitude of tool oscillation is
about 25 µm, the frequency being 25 kHz. The fracture hardness of WC can be
approximately taken as 6900 N/mm2. The slurry contains 1 part of abrasive to about 1
part of water.

3) During an ECM operation on an iron workpiece with a square-face copper tool (using
brine as the electrolyte), both having a flat surface, a feed rate of 2.5 mm/min is used.
The dc voltage used is 12 V and the total overvoltage is 1.5 V. The dimension of the
tool face is 25.4 mm × 25.4 mm. The boiling temperature of the electrolyte is 95C.
Find out the total force acting on the tool. Use the data
Viscosity of electrolyte = 0.876 × 10-3 kg/m-sec,
Density of electrolyte = 1.088 g/cm3,
Specific heat of electrolyte = 0.997,
Conductivity of electrolyte = 0.2 -1 cm-1,
Ambient temperature (initial temperature of electrolyte) = 35 C.

4) During AJM at a mixing ratio of 0.3, calculate the mass ratio if the ratio of the density
of abrasives and density of carrier gas is 20.

5) During an electric discharge drilling of a 12 mm square hole in a low carbon steel


plate of 4 mm thickness, brass tool and kerosene are used. The resistance and the
capacitance in the relaxation circuit are 50  and 10 µF respectively. The supply
voltage is 210 volts and the gap is maintained at such a value that the discharge
(sparking) takes place at 150 volts. Estimate the time required to complete the drilling
operation.

6) A cylindrical impression of diameter 10 mm and 3 mm depth is to be machined by


USM in tungsten carbide. If the feed force is 6 N, the average diameter of the grains
in the abrasive slurry is 10 μm, the tool oscillation amplitude is 30 μm, and the
frequency is 20 kHz. The slurry contains one part of abrasives to about one part of
water. The fracture hardness of tungsten carbide workpiece is 7000 N/mm.2 and that
of the copper tool is 1500 N/mm2. Calculate the machining time. Assume k1 = 0.3, k2
= 1.8 mm2, and k3 = 0.6. Use suitable assumptions if any parameter is not given.

7) In an ECM operation with the flat surfaces, a 12 V dc supply is used. The


conductivity of the electrolyte is 0.3 ohm-1 cm-1, a feed rate of 1 mm/min is used. The
workpiece is pure iron. Calculate the equilibrium gap. Consider the total overvoltage
to be 2 V. (Mallik)

8) Calculate USM time required for a hole of diameter 7 mm in tungsten carbide plate
(fracture hardness = 6900 N/mm2) if the thickness of the plate is 1.5 hole diameter.
The mean abrasive grain size is 15 µm diameter. The feed force equal to 4 N. The
amplitude of tool oscillation is 25 µm and the frequency is equal to 25 kHz. The tool
material used is copper having fracture hardness equal to 1.5 × 103 N/mm2. The slurry
contains one part abrasive to one part water. Take the values different constants as k1
= 0.3, k2 = 1.8 mm2, k3 = 0.6, and abrasive density = 3.8 g/cm3. Calculate the ratio of
the volume removed by throwing to that removed by hammering.

9) A 100 µm wide slot is to be cut in a 1.5 mm thick tungsten sheet, using an electron
beam with a power of 7 kW. What will be the speed of cutting?
10) A circular hole of 12.5 mm diameter is to be machined in titanium alloy block by
using the current density of 6 A/mm2, estimate the time required for a hole depth of
20 mm if the theoretical specific removal rate is 1.6 mm3/min A and the current
efficiency is 90%. Compare this time with the time required for conventional drilling
at 300 rpm and a feed rate of 0.15 mm/rev.

Mark true (T) or false (F):


a) The current used in EDM is an alternating current.
b) The volume of material removal in USM is directly related to the frequency.
c) AJM can be used to reduce the diameter of a mild steel rod from 14 to 12 mm.
d) Graphite electrodes are more favorable to ECM than EDM.
e) Tool life in EDM is infinite.
f) AWJM can be used to cut composite materials.
g) Air plasma is less expensive than gas-shielded plasma.
h) Material removal rate in AJM is greater than that in AWJM.
i) A heat-affected layer of 0.5 mm is left after AJM.
j) In USM, for the same static load, the larger the tool diameter, the greater will be the
penetration rate.
k) Complex shapes are produced in glass using EDM.
l) Plasma jet machining (PJM) produces more accurate parts than EDM.

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