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Applications of Ultrasonic Machining:: Chemical Machining (CHM) Electro-Chemical Machining (ECM)

Ultrasonic machining can be used to machine precise and intricate shapes, drill round holes of any shape, grind brittle materials, profile holes, engrave, trepan, coin, and thread hard materials. Chemical machining uses controlled chemical dissolution to remove material, while electrochemical machining uses controlled electrochemical dissolution between a tool electrode and workpiece electrode in an electrolytic cell, allowing the area of material removal to be controlled. Overcut refers to the gap between the electrode and machined area in electrodischarge machining. Laser beam machining allows for high precision cutting of complex shapes without tool contact due to the focusable and rapidly movable laser beam.

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130 views2 pages

Applications of Ultrasonic Machining:: Chemical Machining (CHM) Electro-Chemical Machining (ECM)

Ultrasonic machining can be used to machine precise and intricate shapes, drill round holes of any shape, grind brittle materials, profile holes, engrave, trepan, coin, and thread hard materials. Chemical machining uses controlled chemical dissolution to remove material, while electrochemical machining uses controlled electrochemical dissolution between a tool electrode and workpiece electrode in an electrolytic cell, allowing the area of material removal to be controlled. Overcut refers to the gap between the electrode and machined area in electrodischarge machining. Laser beam machining allows for high precision cutting of complex shapes without tool contact due to the focusable and rapidly movable laser beam.

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rk
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Applications of ultrasonic Machining:

 Machining very precise and intricate shaped articles.


 Drilling the round holes of any shape.
 Grinding the brittle materials.
 Profiling the holes.
 Engraving.
 Trepaning and coining.
 Threading.
 Slicing and broaching hard materials.

Chemical Machining (CHM) Electro-Chemical Machining (ECM)

As the name suggests, CHM is one It is one electrical energy based NTM
chemical energy based NTM process. process.

Here material is removed in ionic form due


Here also material is removed in ionic
to controlled dissolution by chemical
form but due to controlled electro-
etchant. Etchant slowly dissolves metal to
chemical dissolution of work metal.
realize machining.

It is independent of electrical conductivity


The workpiece must be electrically
of workpiece metal. So it can be applied
conductive as it is used as anode of the
for conductive and non-conductive
electrolytic cell.
materials.

No additional electrode is necessary as An electrode having curvature according


the chemical reaction takes place between to intended shape is absolutely required to
etchant and workpiece. complete the electrical circuit.

One DC power supply is required to


No power supply is necessary as the maintain desired potential difference
process is not related to electrical energy. between cathode (tool electrode) and
anode (workpiece).

Here suitable etchant (based on workpiece Instead of etchant, appropriate electrolyte


material) is employed. Typical etchant is applied in ECM. Typical electrolyte
include FeCl3, CuCl3, FeNO3, HNO3 and HF. include NaCl and NaNO3.

The rate of chemical dissolution is very Rate of electro-chemical dissolution can


hard to control. Once the process is be controlled during machining simply by
initiated, the rate cannot be controlled adjusting inter-electrode gap and current.
accurately anymore.

It cannot inherently control the area from


where material should be dissolved. This process can inherently control the
Material is removed wherever the area from where material should be
worksurface is exposed to etchant. Thus removed (dissolution occurs only from the
mask can be separately applied to control areas where tool is in close proximity).
exposure.

Chemical etchants are highly corrosive The etchant is not such corrosive and thus
and thus the process possesses a risk to the process is somewhat risk-free towards
the operator. operator

Overcut refers to the gap between the electrode (tool) in EDM on each side of the
tool and the machined hole, cavity, or kerf (in wire EDM).

Characteristics of Laser Beam and Laser Beam MachiningSpecial Characteristics of


LaserCutting processes characteristics1.Can be focussed to maximum intensityHigh cutting
speedor to lower intensity as needed Narrow kerf, Straight sides, Little heat effect2.Can
be moved rapidly on the workCutting of complex shapes No tool/work contact
Precision location3.When projected some distancefrom the lensRemote cutting over long
stand-off distances4.Dedicated to an on-line processNo re-routing necessary5.Time
shared between stations Cut and weld using same beam. Use in additional cutting
stations.6.Power shared on a job or between station Two or more cuts simultaneously

roundness, lays, and large bumps, cannot be removed by AFM process because material is removed
almostuniformly.16

flow gap between the external surface and the tooling issufficiently tight for adequate abrasive action.7
Large

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