Non-Traditional Machining (NTM)...
Transcript of Non-Traditional Machining (NTM)...
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Non-Traditional Machining
(NTM) processes
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Samples Objects
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Types
• Chemical: Chemical reaction between liquid
reagent and workpiece: etching
• Electrochemical: Electrolytic reaction at
workpiece surface
• Mechanical: High velocity liquid or abrasives
remove material
• Thermal: Evaporation due to localized high
temperature
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Summary of NTM processesFeed, mm/m(ipm)
Roughness, AA
um(uin)
Accuracy mm(in) Feature size cm(in)
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Contd..Feed, mm/m(ipm)
Accuracy mm(in) Feature size cm(in)Roughness, AA
um(uin)
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NTM Finishing Processes
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Roughness and Tolerance variation
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Chemical Machining (CHM): Steps
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Inconel 718 engine parts: Chemical milling to
remove weight
Formed work piece liquid rubber coated
template scribed finished part
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Missile skin panel weight reduction
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Typical CHM Defects
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Photochemical machining
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Etch Methods and undercutting
Etch Factor, E=U/d
Anisotropy, A = d/U = 1/E
Wm = Wf – 2*E*d
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Different Etchants
min
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Electrochemical Machining (ECM)
tIKn n-number of moles removed
I-current
t-time of current applied
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ECM Relation
Parts
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Typical parts made by electrochemical machining. (a) Turbine blade made of a nickel alloy, 360 HB; note the shape of the electrode on the right. Source: ASM International. (b) Thin slots on a 4340-steel roller-bearing cage. (c) Integral airfoils on a compressor disk.
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Types of ECM
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Mechanical NTM processes
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Ultrasonic Machining
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Waterjet Cutting
Waterjet machining
Hydrodynamic
machiningPressure: 60000 psi
Jet dia: 0.003-0.20in
Velocity: 3000ft/sec
Nozzle: Synthetic sapphire (wear
resistant)
Impinging pressure > compressive
stress
Soft non-metals, plastics, etc.
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Water-Jet Machining
(a) Schematic illustration of water-jet machining. (b) A computer-controlled, water-jet cutting machine cutting a granite plate. (c) Examples of various nonmetallic parts produced by the water-jet cutting process. Source: Courtesy of Possis Corporation.
(c)
(a) (b)
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Abrasive Waterjet cutting
Metals, plastics, rubber, glass, ceramics,
composites, etc.
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Abrasive Flow
MachiningEdge finishing, deburring,
polishing, mirror surface
finishing..
Abrasives: Al.oxide, SiC,
BC, diamond.
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Thermal NTM Processes
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Electrical Discharge Machining
(EDM)
1000s of sparks/second.
Spark Erosion
Complex shapes
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EDM principles
Erosion size depends on Current
and Time
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Stepped EDM
•Coordinate x-y-z movement
•Special attachments
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Wire EDM
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E-Beam Machining
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Laser Beam Machining
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Types of Lasers
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Micro/nano
fabrication