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Introduction To Unconventional Machining Processes

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30 views12 pages

Introduction To Unconventional Machining Processes

Uploaded by

ashishjang82
Copyright
© © All Rights Reserved
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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Presentation on

Unconventional Machining
Processes

Submitted To :- Submitted By :-
Mr.Dean Sir ROHIT
RPSCET,Balana (L22ME27)
B.TECH (ME)
RPSCET,Balana
Introduction to
Unconventional
Machining Processes

Explore the fascinating world of unconventional machining techniques that go beyond


traditional methods. Discover innovative approaches to shaping materials with precision
and efficiency.
Electrical Discharge Machining
(EDM)

1. Principle: EDM uses electrical discharges to remove material from a


conductive workpiece, allowing complex shapes to be formed without
physical contact.

2. Process: The workpiece and an electrode tool are submerged in a


in a dielectric fluid and a voltage is applied, creating electrical sparks
sparks that erode the material.

3. Advantages: EDM can machine hard, brittle, and heat-resistant


materials, and produce intricate geometries that are difficult or
impossible with conventional machining methods.
Electrochemical Machining
(ECM)

ECM is a non-traditional machining process that uses an electrochemical


electrochemical reaction to remove material from a workpiece. An electrolyte
electrolyte solution is pumped between the tool electrode and the workpiece,
workpiece, and an electric current flows between them, dissolving the
workpiece material.
This process allows for the creation of intricate shapes and features, making it
suitable for machining hard-to-machine materials. ECM is a contactless process,
resulting in no tool wear and producing a smooth surface finish.
Ultrasonic Machining (USM)

1 Principle
USM uses high-frequency vibrations to remove material from a workpiece through abrasive
action. A tool vibrates at 20-40 kHz, generating microchipping and erosion of the surface.

2 Process
The workpiece and tool are submerged in a slurry of abrasive particles. The vibrating tool creates
a cavitation effect, causing the abrasive particles to impact the workpiece surface.

3 Advantages
USM can shape hard, brittle materials like ceramics, glass, and carbides with high precision. It
creates smooth finishes and is well-suited for complex geometries.
Abrasive Jet Machining (AJM)

High-Precision Cutting Versatile Applications Controlled Material


Removal
Abrasive jet machining uses a This non-contact process can be
high-velocity stream of abrasive used to machine a wide range of The abrasive jet can be precisely
particles to precisely cut and materials, including ceramics, controlled to remove material in a
shape materials with minimal composites, and difficult-to- targeted manner, making it ideal
thermal distortion. machine alloys. for delicate or intricate parts.
Laser Beam Machining (LBM)

Laser Beam Machining (LBM) is a highly precise and non-contact unconventional machining process that utilizes a
focused beam of high-energy laser light to melt, vaporize, or ablate material. This technique is capable of
producing intricate and complex shapes with exceptional accuracy and minimal thermal distortion.

The laser beam, typically a CO2 or Nd:YAG laser, is precisely controlled and directed at the workpiece, causing the
material to rapidly heat, melt, and vaporize. This process allows for the creation of features with micron-level
precision, making LBM ideal for applications such as micro-machining, drilling, and cutting of high-strength and
hard-to-machine materials.
Plasma Arc Machining (PAM)

Principle Process Advantages Applications

Plasma arc machining In PAM, the plasma


uses a high- arc is directed at the PAM offers high Plasma arc machining
temperature, high- workpiece, rapidly precision, fast is commonly used in
velocity plasma arc to melting and removing material removal industries such as
melt and vaporize material. This allows rates, and the ability aerospace,
material from the for the creation of to machine hard-to- automotive, and
workpiece. The complex shapes and machine materials. electronics for
plasma arc is created features in a wide The process also applications like
by ionizing a gas, such range of materials, generates minimal drilling, cutting, and
as nitrogen or argon, including metals, heat-affected zones engraving. It is
using a high-voltage ceramics, and and can be used for particularly well-
electric current. composites. both conductive and suited for producing
non-conductive intricate parts and
materials. prototypes.
Electron Beam Machining (EBM)

High Precision
1 Extremely accurate, with micron-level tolerances

High Speed
2
Rapid material removal rates for efficient processing

Versatile
3
Can handle a wide range of conductive materials

Electron Beam Machining (EBM) is a highly specialized unconventional machining process that uses a focused
beam of high-energy electrons to remove material from a workpiece. The electron beam's intense heat and kinetic
energy allow for precise, high-speed material removal with excellent surface finishes, making it well-suited for
applications requiring intricate details and tight tolerances.
Advantages of Unconventional Machining

1 Precise Shaping 2 Material Versatility


Unconventional processes can create intricate These techniques can work with a wide range
shapes and complex geometries that are of materials, including hard, brittle, and heat-
difficult or impossible to achieve with sensitive materials that pose challenges for
traditional machining. conventional methods.

3 Reduced Tool Wear 4 Increased Productivity


The non-contact nature of many
unconventional processes minimizes tool wear, Faster machining speeds and the ability to
resulting in extended tool life and lower handle complex parts can significantly improve
maintenance costs. manufacturing throughput and efficiency.
Applications and Future Trends

Unconventional machining processes have a wide range of applications in various industries, from aerospace and
automotive to medical and electronics. These advanced techniques enable the fabrication of complex parts, the
machining of exotic materials, and the creation of high-precision components.

Aerospace Fabrication of intricate engine components,


turbine blades, and complex geometrical parts.

Automotive Production of fuel injectors, engine valves, and


other high-precision automotive parts.

Medical Manufacture of surgical implants, prosthetic


devices, and micro-instruments for minimally
invasive procedures.

Electronics Machining of semiconductor wafers, printed


circuit boards, and micro-electromechanical
systems (MEMS).

As technology continues to advance, the future of unconventional machining processes promises even more
exciting developments. Advancements in automation, robotics, and computer-aided design (CAD) will further
enhance the capabilities of these techniques, leading to even more precise, efficient, and cost-effective
manufacturing solutions.
THANK YOU

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