Modern Manufacturing Technology

Introduction
Modern Manufacturing Technology

Ms Shikha Kashyap
Assistant Professor
Dept of Mechanical Engineering
The NorthCap University, Gurgaon
Need For Unconventional Machining Methods
Last few decades have witnessed a rapid growth in the development of

harder and difficult to machine metal and alloys.
It has been realized that such materials are difficult to machine by

conventional methods, and therefore their machining is not only costly
but also results into poor surface finish and shorter tool life.
To overcome these difficulties a number of Newer Machining Methods

have been developed.
Machining of intricate and complicated shapes, thin and fragile

components and accurate and economical forming of very hard, high
strength materials which are being extensively used in aerospace and
nuclear industries, have forced the scientists, engineers and
technologists to search for new techniques of machining which can
readily provide an effective solution to these problems.
As a result of research and development for the last fifty years or so,
several new methods of machining have emerged which can be
grouped under the name of:
Continue..
Unconventional machining methods, or
Non-traditional machining methods, or
Physical machining process, or
New technologies, or
Modern machining methods
Characteristic features of modern machining processes

that
distinguish them from conventional machining processes:
The following are the characteristic features of non-traditional

machining processes when compared with traditional or conventional
machining processes:
Material is removed from the work piece without mechanical contact

(with work piece).
In many processes, material removal rate is independent of the

hardness of the work piece.
Cutting forces are independent of the hardness of the work material.
The tool material need not be harder than the work material.( In
many cases, softer materials can be used as tool material)
Almost any work material irrespective of its hardness and strength

can be machined.
Continue.
Generally tool wear is negligible; hence tool wear is not a problem.
No burr is left on the work piece.
Generally no residual stresses are left on the surfaces machined.
In most of the cases entire shape can be obtained in one stage or in

one setting. This is possible since material removal takes place
uniformly over the entire area below the tool simultaneously.
In majority of cases surface integrity" (Surface integrity is the

surface condition of a work piece after being modified by a
process.) of the surfaces produced by modern machining methods is
superior.
Modern machining methods can be integrated easily with microprocessors and numeric controls for better control of the processes
and for improving the versatility and productivity of the machines.
Intricately shaped contours and fine machining of precision holes

are possible.
Basic Principle of New Machining Methods
The basic principle of machining by these new methods is to

apply some form of energy to the work piece directly without
almost any physical contact between the tool and the work piece
and have the desired shape by material removal from the work
piece.
Different forms of energy applied to the work piece are:

1) Mechanical Energy
2) Electrical (Electro-chemical energy)
3) Thermal Energy
4) Chemical Energy
The actual mechanism or mode of metal removal for different

processes are given below:
Predominant Mechanism of
Metal Removal
Machining Process
1.
Shear failure of work

material
2.
Erosion of work material.
2.
Abrasive jet machining (AJM) 3.
Erosion of work material.
3.
Ultrasonic Machining
Cavitation phenomenon.
4.
Chemical Machining
1.
Conventional Machining
Process (e.g. turning, milling,
drilling)
4.
Etching
Conti
5.
Electrochemical
Machining
6.
Electrochemical
Grinding
7.
Spark Erosion
Machining
8.
Electron beam
machining
9.
Laser beam machining
10.
Ion beam machining
11.
Plasma Arc Machining
5.
Ion Displacement
6.
Ion Displacement, Erosion

of work material (due to
grinding action of abrasive
wheel)
7.
Vaporization of work metal
8.
9.
10.
11.
Fusion of work metal
Advantages of Non-traditional
Material removed without mechanical contact with the work piece.

(ECM, EDM,LBM,CHM)
Material removal rate is independent of work piece hardness. (ECM,

EDM,LBM)
Cutting forces are independent of work piece hardness. (ECM,

EDM,LBM,CHM)
Tool material need not be harder than work piece material. (ECM,
EDM,LBM,CHM,USM)
Tool wear is not a problem. (ECM, LBM,CHM)
Ability to machine any material. (LBM)
Burr-free machining. (ECM,EDM,CHM)
Stress-free machining. (ECM, ECG, CHM)
Continue.
Uniform material removal over the entire area below the tool
surface simultaneously. (ECM,CHM)
Superior surface integrity possible. (ECM,CHM,ECG)
Intricately shaped, very hard and fragile materials can be

machined. (USM)
Finely focused micro-machining possible. (EDM,LBM,EBM)
Easy compatibility with numeric control and computer controls.

(EDM,LBM,EBM,ECM)
Limitations of Non-traditional Machining Processes

All modern machining processes are generally costly. Their
specific power consumption(kW/cm3/min) is quite high. The
following are some of the specific limitations of the nontraditional machining process:
Work piece and tool must be electrically conductive (EDM,ECM)
Depth of hole drilled is limited. (LBM)
Heat-affected zones
(EDM,LBM,EBM)
(HAZ)
produced
are
not
desirable.
For this purpose the compatibility of the process with the

metallurgical state of the work piece material can be studied before
using a particular non-traditional machining process for production
work.
There may be taper in the sidewalls of holes or cavities

(EDM,LBM)
Most of these limitations can be overcome and controlled, that the
advantages can be obtained with good product quality assurance.
Classification of new machining methods

The classification is done on the basis of the type of energy used
I the working zone for material removal action. Four distinct
type of energy used are:
Mechanical Energy
Electrical Energy (Electro-chemical energy)
Thermal Energy (Thermo- electric energy)
Chemical Energy
Mechanical Energy
Conventional machining
Abrasive Jet Machining (AJM)
Water Jet machining (WJM)
Ultrasonic machining (USM)
Electrical Energy
Electro-chemical machining
Electro-chemical grinding
Electro-chemical Deburring
Electro-chemical Honing
Thermal Energy
Spark erosion machining or Electro-discharge machining (EDM)
Electron-Beam machining (EBM)
Ion-Beam machining
Laser-Beam machining
Plasma-Arc machining
Chemical Energy
Chemical machining
Electro-polishing
Photo-chemical machining
Abbreviations used for Unconventional Machining Methods

USM - Ultrasonic machining
ECM - Electro-chemical machining
AJM - Abrasive Jet Machining
EDM - Electro-discharge machining
LBM - Laser-Beam machining
EBM Electron-Beam machining
PAM Plasma-Arc machining
ECG Electrochemical grinding
Thank you

Modern Manufacturing Technology

Uploaded by

Copyright:

Available Formats

Modern Manufacturing Technology

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Modern Manufacturing Technology

Uploaded by

Copyright:

Available Formats

Introduction

Modern Manufacturing Technology

Need For Unconventional Machining Methods

Last few decades have witnessed a rapid growth in the development of

It has been realized that such materials are difficult to machine by

To overcome these difficulties a number of Newer Machining Methods

Machining of intricate and complicated shapes, thin and fragile

Unconventional machining methods, or

Non-traditional machining methods, or

Physical machining process, or

Modern machining methods

Characteristic features of modern machining processes

The following are the characteristic features of non-traditional

Material is removed from the work piece without mechanical contact

In many processes, material removal rate is independent of the

Cutting forces are independent of the hardness of the work material.

Almost any work material irrespective of its hardness and strength

Generally tool wear is negligible; hence tool wear is not a problem.

No burr is left on the work piece.

Generally no residual stresses are left on the surfaces machined.

In most of the cases entire shape can be obtained in one stage or in

In majority of cases surface integrity" (Surface integrity is the

Intricately shaped contours and fine machining of precision holes

Basic Principle of New Machining Methods

The basic principle of machining by these new methods is to

Different forms of energy applied to the work piece are:

The actual mechanism or mode of metal removal for different

Shear failure of work

Erosion of work material.

Abrasive jet machining (AJM) 3.

Erosion of work material.

Laser beam machining

Ion beam machining

Plasma Arc Machining

Ion Displacement, Erosion

Vaporization of work metal

Vaporization of work metal

Vaporization of work metal

Vaporization of work metal

Fusion of work metal

Material removed without mechanical contact with the work piece.

Material removal rate is independent of work piece hardness. (ECM,

Cutting forces are independent of work piece hardness. (ECM,

Tool wear is not a problem. (ECM, LBM,CHM)

Ability to machine any material. (LBM)

Burr-free machining. (ECM,EDM,CHM)

Stress-free machining. (ECM, ECG, CHM)

Superior surface integrity possible. (ECM,CHM,ECG)

Intricately shaped, very hard and fragile materials can be

Finely focused micro-machining possible. (EDM,LBM,EBM)

Easy compatibility with numeric control and computer controls.

Limitations of Non-traditional Machining Processes

Work piece and tool must be electrically conductive (EDM,ECM)

Depth of hole drilled is limited. (LBM)

For this purpose the compatibility of the process with the

There may be taper in the sidewalls of holes or cavities

Classification of new machining methods

Electrical Energy (Electro-chemical energy)

Thermal Energy (Thermo- electric energy)