Non Conventional machining processes

Machining… with a difference!!

That’s what Non-conventional Machining is all about…!!!!

Objective of Presentation

At the end of this presentation, audience will be aware of merits of Non conventional machining processes over their traditional counter-parts.

Need

Why NCM?

• In-House machining of complex and less machinable jobs.

• Economical and Faster than purchasing readymade job.

• Processes are computer-controlled, so negligible human intervention during machining,

Outline

– Ultrasonic Machining– Water Jet Machining– Electro-chemical Machining– Electro-chemical Grinding– Electrodischarge Machining– Conclusion

Ultrasonic Machining

• Ultrasonic vibration (20,000 Hz) of very small amplitudes (0.04-0.08 mm) drive the form tool of ductile material (usually soft steel)

• An abrasive slurry is flowed through the work area

• Used for brittle materials like glass.

Water Jet Machining

• High pressure water (20,000-60,000 psi)

• Induct abrasive into stream• Tight tolerances achievable• Can cut extremely thick parts (5-10

inches possible)

Water Jet Machining Products

Electro-Chemical Machining (ECM)

• Works on the principle of electrolysis

• Die is progressively lowered into workpiece as workpiece is dissociated into ions by electrolysis

• Low DC voltage, very High current (700 amps)

• Used to machine Dies, easily deformable and bittle materials.

Electrochemical grinding

• Combines electrochemical machining with conventional grinding

• Grinding wheel is the cathode

• Metal bonded wheel with diamond or Al2O3 abrasive

• Majority of material removal from electrolytic action (95%) therefore very low wheel wear

• Much faster than conventional grinding

• Used to grind brittle and thin jobs.

Electrical Discharge Machining (EDM)

• The tool acts as a cathode (typically copper and graphite) is immersed in a Dielectric fluid with conductive workpiece

• DC voltage 40-400V is applied. • Sparking at around 12,000 deg F.• Cycle repeated at 200,000-500,000 Hz• Dielectric:

– Acts as an insulator – Cools tool and workpiece– Flushes out debris from work area

Die Sinker vs. Wire EDM

• Die sinker EDM– The die sinks into the part as

it sparks away the workpiece

– Most common Injection molding die process

• Wire EDM– The electrode is a wire that

traverses through the part

– Common for Extrusion Dies

EDM Products

Conclusion

Non Conventional machining processes are used when required attributes are impossible to achieve with traditional machining processes.

Any Queries???

Thank You!!!