Manufacturing

Manufacturing Engineering Technology in SI Units, 6th Edition
Chapter 27:
Advanced Machining Processes
Copyright © 2010 Pearson Education South Asia Pte Ltd

Chapter Outline
1. Introduction
2. Chemical Machining
3. Electrochemical Machining
4. Electrochemical Grinding
5. Electrical-discharge Machining
6. Laser-beam Machining
7. Water-jet Machining
8. Abrasive-jet Machining
9. Hybrid Machining Systems

Introduction
 Machining processes involved material removal by
mechanical means: chip formation, abrasion, or
microchipping
 Situations where mechanical methods are not
satisfactory, economical or possible:
 Very high strength and hardness
 Material is too brittle
 Workpiece is too flexible
 Shape of the part is complex
 Surface finish and dimensional
tolerance requirements
 Temperature rise during processing
Introduction

Chemical Machining
 Chemical machining (CM) is the process where
chemicals attacking and etching metals, stones, and
some ceramics, and remove small amounts of material
from the surface
 Carried out by chemical dissolution using reagents or
etchants
Chemical Milling
 Shallow cavities are produced on plates, sheets,
forgings and extrusions
 Overall reduction of weight

Chemical Machining
Chemical Milling

Chemical Machining
Design Considerations for Chemical Machining
 Design guidelines for chemical machining are:
1. Sharp corners, deep and narrow cavities, severe
tapers, folded seams, or porous workpiece materials
should be avoided
2. 10% tolerance thickness should maintained
3. Bulk of the workpiece should be shaped by other
processes prior to chemical machining
4. Controlling work environment and artwork
5. Protocol should be compatible with the equipment

Electrochemical Machining
 The reverse of electroplating
 An electrolyte acts as current carrier and the high rate
of electrolyte movement in the tool washes metal ions
away from the workpiece (anode) before they have a
chance to plate onto the tool (cathode)
 The material-removal rate (MRR) in electrochemical
machining is
MMR = CI
I = current in amperes
C = material constant

Process Capabilities
 Used to machine complex cavities and shapes in high-
strength materials
 Aerospace industry for the mass production of turbine
blades, jet-engine parts and nozzles
 ECM process leaves a burr-free, bright surface and can
be used as a deburring process
 Available as numerically controlled machining centers
with high production rates, high flexibility, and close
dimensional tolerances

CASE STUDY 27.1
Electrochemical Machining of a Biomedical Implant
a) 2 total knee-replacement systems, showing metal
implants (top pieces) with an ultrahigh-molecular-
weight polyethylene insert (bottom pieces)
b) Cross section of the ECM process as applied to the
metal implant

Electrochemical Grinding
 The process combines electrochemical machining with

conventional grinding
 Similar to a conventional grinder but the wheel is a
rotating cathode embedded with abrasive particles

Electrochemical Grinding
 The abrasives have 2 functions:

1. Serve as insulators between the wheel and the
workpiece
2. Mechanically remove electrolytic products from the
working area
 ECG process is suitable for applications similar to
those for milling, grinding and sawing but not cavity-
sinking operations

Electrical-discharge Machining
 Process is based on the erosion of metals by spark

discharges
 When two current-conducting wires are allowed to
touch each other, an arc is produced
 At the point of contact between the two wires, a small
portion of the metal eroded away and leave a small
crater

Principle of Operation
 EDM system consists of a electrode and the workpiece,
connected to a DC power supply and placed in a
dielectric fluid
 When the potential difference is high, the dielectric
breaks down and a transient spark discharges through
the fluid, removing a small amount of metal
 Can be used on any material that is an electrical
conductor
 The material-removal rate can be estimated from
MMR = 4 10 4 ITw−1.23 I = current in amperes
Tw = melting point
Principle of Operation

Dielectric Fluids
 The functions of the dielectric fluid are to:
1. Act as an insulator until the potential is sufficiently high
2. Provide a cooling medium
3. Act as a flushing medium and carry away the debris in
the gap
Electrodes
 Electrodes are made of graphite, brass, copper or
copper–tungsten alloys

 Stepped cavities can be produced by controlling the
relative movements of the workpiece in relation to the
electrode
 High rates of material removal produce rough surface
finish with poor surface integrity and low fatigue
properties

Design Considerations for EDM

 General design guidelines:
1. Parts should be designed so that the required
electrodes can be shaped properly and economically
2. Deep slots and narrow openings should be avoided
3. The surface finish specified should not be too fine.
4. Bulk of material removal should be done by
conventional processes

Electrical-discharge Machining:
Wire EDM
 Similar to contour cutting with a band saw
 A slowly moving wire travels along a prescribed path
will cut the workpiece
 Wire is made of brass, copper, tungsten, molybdenum,
zinc- or brass-coated or multicoated

Laser-beam Machining
 The source of energy is a laser which focuses optical

energy on the surface of the workpiece
 The highly focused, high-density energy source melts
and evaporates portions of the workpiece in a
controlled manner


 It is used for drilling, trepanning, and cutting metals,
nonmetallic materials, ceramics, and composite
materials
 Laser-beam machining is being used increasingly in
the electronics and automotive industries
 Also used for welding, small-scale and localized heat
treating of metals and ceramics, and marking of parts

Design Considerations for LBM

 General design guidelines:
1. Sharp corners should be avoided
2. Deep cuts will produce tapered walls
3. Reflectivity of the workpiece surface
4. Adverse effects on the properties of the machined
materials

Water-jet Machining
 Force is utilized in cutting and deburring operations
 Advantages of this process:
1. Cuts can be started at any location
2. No heat is produced
3. No deflection of the workpiece
4. Little wetting of the workpiece takes place
5. The burr produced is minimal
6. Environmentally safe manufacturing process

Water-jet Machining

Abrasive-jet Machining
 A high-velocity jet of dry air, nitrogen, or carbon dioxide
containing abrasive particles is aimed at the workpiece
surface under controlled conditions

Hybrid Machining Systems
 Able to handle a variety of materials, including metals,
ceramics, polymers, and composites
 Examples of integration of systems:
1. Abrasive machining and electrochemical machining
2. Abrasive machining and electrical discharge machining
3. Abrasive machining and electrochemical finishing
4. Water-jet cutting and wire EDM
5. Machining and blasting
6. Combinations of various forming, machining, and
joining processes

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Manufacturing Engineering Technology in SI Units, 6th Edition

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 The process combines electrochemical machining with

Copyright © 2010 Pearson Education South Asia Pte Ltd

 The abrasives have 2 functions:

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Process is based on the erosion of metals by spark

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Design Considerations for EDM

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 The source of energy is a laser which focuses optical

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Design Considerations for LBM

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

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