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Modern machining methods are also named as non-conventional machining methods. Non
traditional machining processes, are employed where traditional machining processes are not
feasible, satisfactory or economical due to special reasons as outlined. The complexity of the
job profile, hard materials, need for smooth surface finish, closer dimensional tolerance and
higher accuracy has led to the unconventional machining processes more important
Characteristics of unconventional process
1. Very hard and brittle can be machined
2. Flexible or slender work piece be machined, due to absence of physical contact of
tool and work (less cutting force)
3. Complex part geometries that can be produced
4. Provide very good quality of surface finish and dimensional accuracy
5. Stress free components are possible
6. Less tool wear due the absence of tool contact
Disadvantages of non-conventional machining:
1) High cost
2) complex set-up
3) skilled operator required
Conventional machining involves the direct contact of tool and work -piece, whereas
unconventional machining does not require the direct contact of tool and work piece.
Conventional machining has many disadvantages like tool wear which are not present in non-
conventional machining.
Machining performance characteristics of non conventional process
The machining characteristics of non-conventional processes can be analyzed with respect to:
(i) Metal removal rate
(ii) Tool wear rate
(iii) Surface finish and Tolerance obtained
(iv) Depth of surface damage
(v) Power required for machining
Classification of non-conventional machining processes
Classification based on principle of working and energy is described below. The suitability of
application of any of the processes is dependent upon various performance factors.
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The outcome of these electrochemical reactions is that the iron ions combine with other ions
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resistivity before spark discharge and the ability to recover rapidly after the discharge.
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machining operations.
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t t on t off
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Advantages
1. Accuracy and precision of dimensions are of very good quality.
2. No force is experienced by the workpiece. It does not impose any force to workpiece so
used for very delicated and thin workpieces
3. Hardness and toughness of workpiece do not create problems in machining operation
4. Efficient Production Capabilities - Because of the precision and high-speed of wire
EDM machines, many parts can be more economically produced with wire EDM,
rather than with conventional machining.(gears, cams and dies etc)
Disadvantages and Limitations of WEDM
1. The major disadvantages of this process are that only electrically conducting materials
can be machined. This process is costly so recommended for use specifically at
limited operations.
Differences between EDM and ECM
ECM EDM
Medium Electrolyte Dielectric
Removal mechanism Removal Chemical action removal by melting
Tool wear No tool wears tool wear
Removal rate High MRR Low MRR
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Advantages of EBM
1. There is no mechanical contact between too land work piece, hence no tool wear.
2. Very small holes can be machined in every type of material with high accuracy
3. Drilling holes with high depth/diameter ratios, greater than 100:1
4. A wide range of materials like steel, stainless steel, Ti and Ni super-alloys, aluminium
as well as plastics, ceramics can be machined successfully using electron beam.
5. EBM does not apply any cutting force on the workpieces. Thus very simple work
holding is required. This enables machining of fragile and brittle materials by EBM.
Disadvantages of EBM
1. Cost of equipment is high.
2. Rate of material removal is low.
3. It can be used for small cuts only.
4. Vacuum requirements limits the size ofwork piece.
Application of EBM
1. Drilling of holes in pressure differential devices used in nuclear reactors, air craft engine
2. Machining of wire drawing dies having small cross sectional area
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The LBM process does not involve mass material removal, but does provide rapid material removal
with an easily controlled, non-contact, non wearing tool.
The lens then focuses the beam into the desired geometry
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vibrates over the workpiece, the abrasive particles act as the indenters and indent both the
work material and the tool. The abrasive particles as they indent the work piece, material get
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of nickel, nickel alloy sheets. The maximum change in length can be achieved is about 25
microns.
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Cutting Tool
Tool of USM vibrates with small amplitude at high frequency to vibrate abrasive slurry to cut
the work-piece material. The tool is attached to the arbor (tool holder) by brazing or
mechanical means. . The tool is made of relatively soft material.
Feed Mechanism
Tool is fed to the machining zone of workpiece. The tool is shaped as same to the cavity of be
produced into the workpiece. The tool is fed to the machining area. The feed rate is
maintained equal to the rate of enlargement of the cavity to be produced.
Advantages of USM
1. Its main advantage is the workpiece after machining is free from any residual
stress as to concentrated force or heat is subject to it during the machining
process.
2. Extremely hard and brittle materials can be machined, their machining is very
difficult by conventional methods.
3. Very good dimensional accuracy and surface finish can be obtained.
4. Operational cost is low.
5. The process is environmental friendly as it is noiseless and no chemical and
heating is used.
Disadvantages of USM
1. Its metal removal rate (MRR) is very low and it can not be used for large
machining cavities.
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2. Its initial setup cost and cost of tool is very high, frequency tool replacement is
required as tool wear takes place in this operation.
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Applications
Used for machining hard and brittle metallic alloys, semiconductors, glass, ceramics,
carbides etc.
Used for machining round, square, irregular shaped holes and surface impressions.
Machining, wire drawing, punching or small blanking dies.
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Working
Dry air or gas is filtered, compressed and regulated (pressure and flow rate) while passed into
the mixing chamber. In the mixing chamber, abrasive powder is fed and is thoroughly mixed
with air. The nozzle increases the velocity of the mixture at the expense of its pressure.
Nozzles direct abrasive jet in a controlled manner onto work material. The velocity of the
abrasive stream ejected through the nozzle is generally of the order of 330m/sec.
Advantages of Abrasive Jet Machining (process capabilities)
1. Surface of the workpiece is cleaned automatically.
2. Smooth surface finish can be obtained.
3. Equipment cost is low.
4. Hard materials and materials of high strength can be easily machined.
5. Narrow slot can be produced
Plasma Gun
The plasma gun consists of a tungsten electrode fitted in the chamber. The electrode is given
negative polarity and nozzle of the gun is given positive polarity. Supply of gases is
maintained into the gun. A strong arc is established between the two terminals anode and
cathode. Gases are used to create plasma like, nitrogen, argon, hydrogen or mixture of these
gases. There is a collision between molecules of gas and electrons of the established arc. As
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a result of this collision gas molecules get ionized and heat is evolved. This hot and ionized
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Cooling Mechanism
As we know that hot gases continuously comes out of nozzle so there are chances of its
overheating. A water jacket is used to surround the nozzle to avoid its overheating.
The metals usually cut with this process are the aluminium and stainless steels. The process
can also be used for cutting carbon steels, copper alloys, and nickel alloys
Applications of PAM
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Transferred In the transferred system the arc is completed by making contact with the
workpiece.
Non-transferred In the non-transferred system the arc is completed by making contact with
nozzle, it can produce an arc without touching the grounded workpiece and can be very
dangerous
Rapid prototyping
The term rapid prototyping (RP) refers to a class of technologies that can automatically
construct physical models from Computer-Aided Design (CAD) data for the purpose of
testing the various design features, ideas, concepts, functionality, output and performance.
Rapid Prototyping technology employs various engineering, computer control and software
techniques directly to produce a physical model layer by layer (Layer Manufacturing) in
accordance with the geometrical data derived from a 3D CAD model.
A virtual prototype (a CAD model of the part) may not be sufficient for the designer
to visualize the part adequately
Using RP to make the prototype, the designer can see and feel the part and assess its
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Rapid Prototyping (RP), also known as Solid Freeform Fabrication (SFF) builds complex
shapes through additive processes, producing components without the use of tools.
The advantages of RP
1. Physical models of parts can be manufactured in a matter of hours and allow the rapid
evaluation of manufacturability and design effectiveness. In this way, rapid
prototyping serves as an important tool for visualialization and concept verification.
This helps the user in knowing how the final product will look like.
2. As the development costs are reduced, Rapid prototyping proves to be cost effective.
3. The process itself reduces waste, as unused materials can be recycled.
4. It is easier to find the design flaws in the early developmental stages.
5. There is better communication between the user and designer as the requirements and
expectations are expressed in the beginning itself.
6. High quality product is easily delivered by way of Rapid prototyping.
In short why use Rapid Prototyping
1. To increase effective communication.
2. To decrease development time.
3. To decrease costly mistakes.
4. To minimize sustaining engineering changes.
5. To extend product lifetime by adding or eliminating features early in the design.
draws the image of the object on the surface of liquid plastic. The laser takes passes at hitting
CAD drawings into physical parts. FDM works on an "additive" principle which extrudes
material in layers. Plastic or wax is melted and liquefied in the extrusion head and extruded
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through a nozzle. The nozzle is made to move over a trail identified by the CAD design to
Advantages
1. FDM process part can be high strength, it is cost-effective and waterproof.
2. Easy material change
3. Thin parts can be made
4. Tolerance of +/- 0.005
5. Low temperature operation
Disadvantages
1. Part strength is weak perpendicular to build axis
2. Seam line between layers
3. Temperature fluctuation during production lead to de-lamination
4. Support requirement is difficult
Application
Used for making concept and functional models in many industries.
Concept models Test form and fit, communicate design intent
Functional prototypes Tough prototypes that can be used for functional tests
Typical applications include automotive, aerospace or any application where your part needs
to be functionally tested in an environment of heat or chemicals.
prevents melting and a coherent mass is produce. In SLS, metallic or non-metallic powders
are sintered using a CAD program guided laser that selectively fuses the powdered material.
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It works with a high powered laser as the laser selectively moves over the surface of
Department of Mechanical Engineering SSET 2014
thermoplastic powder it fuses cross-sections of the material layer by layer. As one layer is
completed, the process is repeated by lowering the powdered bed and adding a fresh layer of
material.
First cylinder moves up so that a layer of material can be send to the second cylinder. In
second cylinder after recieving a layer of material, it is processed using laser beam. Then
second cylinder moves down to receive the next layer from the first cylinder as it moves up to
supply the next layer of materials. The processes continue till final product forms.
Advantages
1. SLS offers the freedom to quickly build complex parts that are more durable and
provide better functionality over other rapid prototyping technologies.
2. Fabricated prototypes are porous (typically 60% of the density of molded parts) thus
impairing their strength and surface finish.
3. Fast build times
4. Variety of materials can be processed
Disadvantages/ Limitations
1. Typical SLS parts have little rough & porous surface finish which is not as smooth as
SLA
2. The larger shrink rates of SLS increase the tendency for the prototype to warp, bow or
curl subject to the part geometry.
3. Material changeover difficult compared to FDM & SLA.
4. Some post-processing / finishing required
together and cut to shape with a knife or laser cutter. The main components of the system are
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a feed mechanism that advances a sheet over a build platform, a heated roller to apply
Advantages
1. Dimensional accuracy is slightly less than that of stereolithography and selective laser
sintering but no milling step is necessary.
2. Relatively large parts may be made, because no chemical reaction is necessary
3. Low cost due to readily available raw material
Laser engineered net shaping (LENS)
This process is similar to other rapid prototyping technologies in its approach to fabricate a
solid component by layer additive methods. The laser creates a molten pool of metal on the
substrate, into which powder feeder injects powders into the melt pool. The metal powder
rapidly solidifies forming lines of deposited material on the substrate. Lines are sequentially
deposited adjacent to one another until an entire layer is fabricated. The laser focal point is
then moved in the positive Z direction to begin depositing the next layer. An inert gas is used
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to shield the metal from atmospheric gases. It uses a layered approach to manufacture the
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Advantages of LBW
1. Laser beam can be transmitted through air rather than requiring a vacuum,
2. The process is easily automated
3. LBW results in higher quality welds.
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Step involved
1. Apply resist and X-ray exposure through mask,
2. Remove exposed portions of resist,
3. Electrodeposition to fill openings in resist,
4. Strip resist for (a) mold or (b) metal part
In the process, an X-ray sensitive polymer photoresist, typically PMMA, (Poly methyl
methacrylate), a transparent thermoplastic bonded to an electrically conductive substrate, is
exposed to parallel beams of high-energy X-rays from a radiation source through a mask
partly covered with a strong X-ray absorbing material. Chemical removal of exposed (or
unexposed) photoresist results in a three-dimensional structure, which can be filled by the
electrodeposition of metal. The resist is chemically stripped away to produce a metallic mold
insert. The mold insert can be used to produce parts in polymers or ceramics through
injection molding.
Advantages
1. The primary advantage of LIGA process is its capability to make large aspect
ratio structures(can be up to 1000 m thick while only several micron wide/large
height-to-width ratios in the fabricated part)
2. LIGA is a versatile process it can produce parts by several different methods
3. Wide range of part sizes is feasible
4. Close tolerances are possible and highsurface finish.
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Applications
MEMS Components
Sensors
Actuators
Trajectory Sensing Devices
Mass Spectrometers
Microoptical Components
Components such as micro lenses, mirrors, and filters
benefit from low surface roughness to reduce scattering.
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29. Draw and explain the construction and working of the Electron Beam Illustrate the 4
steps leading to material removal by EBM and explain the process. (12 marks)
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36. What is meant by kerfwidth in AJM? How does it relate to the nozzle tip distance?
37. Illustrate and explain the Abrasive Water Jet Machining process and state the
advantages, limitations and applications of the process.
38. Draw graphs to relate the following process parameters to the material removal rate in
abrasive jet machining
a. Nozzle tip distance.
b. Abrasive flow rate.
c. Abrasive grain size
39. Discuss abrasive water jet machine.
40. List any two advantages of AJ M process.
41. Discuss any four process parameters involved in AJM.
42. List the various elements of AJM process and explain their influence on process
parameters.
43. Explain the process parameters which influence Metal Removal rate in Abrasive Jet
Machining
44. What are the limitations of abrasive jet machining
45. Describe, in detail, metal removal by abrasive jet machining.
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46. Why are abrasive slurry is used in ultrasonic machining? _
47. Sketch and explain Ultrasonic Machining.
48. Explain the principle of ultrasonic machining. What are the limitations of USM
49. Why is frequency tuning a must in Ultrasonic Machining?
50. What is the function of a concentrator in Ultrasonic Machining?
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51. `What is rapid proto-typing?
52. Briefly explain the types, process and advantages of Rapid prototyping process.
53. Explain the fused deposition modelling and laminated object manufacturing methods
used in Prototyping process.
54. List out the any four advantages of Rapid. Prototyping.
55. What do you meant by Virtual and Physical prototyping?
56. Name the different types of Rapid prototyping.
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57. Explain basic steps involved in Rapid prototyping with flow diagram.
58. What are the advantages of` rapid prototyping
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turbine propellers, tools stamps, moulds, dies. The technique is suitable for drilling small
holes and cutting into hard materials
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Cost- low
Virtual prototyping
Virtual prototyping involves using computer-aided design (CAD) and computer-aided
engineering (CAE) software to validate a design before committing to making a physical
prototype. This is done by creating (usually 3D) computer generated geometrical shapes
(parts) and either combining them into an "assembly" and testing different mechanical
motions, fit and function or just aesthetic appeal. Physical and virtual prototypes are not
competitive technologies. They are complementary. The strengths and advantage of one
technology will address the weaknesses and limitations of the other.
Forming methods (high energy forming)
In these forming processes large amount of energy is applied for a very short interval of time.
Many metals tend to deform more readily under extra fast application of load which make
these processes useful to form large size parts. Hydroforming is a specialized type of die
forming that uses a high pressure hydraulic fluid to press room temperature working material
into a die.
Different types of metal forming operations are used. During electrohydraulic forming
stored electric energy is suddenly discharged through a spark gap so that the surrounding
working medium (e.g. water) is ionized and vaporizes, initiating a shockwave.
Electro Magnetic Forming: This process utilizes the energy of the magnetic field to deform
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the metal.
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