RAHIM Under The Guidance of : Pro. RAYAPPA MAHALE What is machining? Machining is a material removal processes in which a cutting tool removes unwanted material from a work piece to produce the desired shape Basically there are two main types of machining 1. Traditional machining(TM) 2. Non-traditional machining(NTM)
DEVELOPMENT OF NTM In The Development of harder and difficult to machine materials such as , waspalloy, nimonics, carbides, stainless steel, heat resisting steels and many other high strength temperature resistance HSTR alloys.
Used in aerospace industry, nuclear
engineering and other industries owing to their high strength to weight ratio, hardness and heat resisting quality. CLASSIFICATION 1) Thermo electric a) laser beam machining
2) Mechanical a)abrasive jet machining
3)Chemical Laser beam machining Laser stands for Light Amplification by Stimulated Emission of Radiation .
It produces monochromatic light which is in the
form of an almost collimated beam that can be focused optically on to very small spot of less than (0.002mm)diameter.
LBM is deals with machining and material
processing like heat treatment alloying cladding ,sheet metal bending Laser construction
The laser materials used in this process are
ruby, neodymium glass (Nd-glass) and neodymium-yttrium aluminium garnet (Nd-YAG). Cutting rate (mm/min)= kp/EAt K= constant characteristics of material and conversion efficiency of laser energy into material mm/min P=laser power incident on surface,W E=vaporized energy of material ,W/mm3 A=area of laser beam at focal point ,mm2 t =thickness of material ,mm systems of lasers are found to be powerful enough for application in machining operations. These are 1) solid state pulsed laser Advantages LBM The ability to cut almost all materials No limit to cutting paths as the laser point can move in any paths. No cutting lubricants are required As there is an absence of direct contact between the tool and work piece; thus no forces are induced and as a result it is not necessary to provide the work holding system to hold the work piece. The fragile materials are easy to cut on a laser without any support. Laser cutting Flexibility exists in precision cutting of simple or complex parts. There is no tooling cost or associated wear costs due to it. Laser produces high quality cuts without extra finishing requirements Disadvantages: Laser processes involve high capital investments and high operating costs. It cannot drill blind holes to precise depths. Hence there is limitation on its thickness. Heat affected through the lasers may change the mechanical properties of the metallic materials and alloys The processing time in larger holes is slower due to trepanning action (process) involved in it. Reflected laser lights can lead to safety hazards. Assist or cover gases are required for safety purposes. Application of LBM Laser can be used in wide range of manufacturing applications Laser can be used for cutting as well as drilling..
It is used for cutting complex profile.
It is used for welding of thin metal sheet.
LBM can make very accurate holes as small as 0.005 mm in refractory metals Laser welding Abrasive jet machining In AJM use of high speed stream of abrasive particle carried by a high pressure gas , air or water on the work surface through nozzle. The metal remove due to erosion occur by abrasive particle when impact at high speed on work piece. Abrasive use are aluminum oxide(Al 2o3), silicon carbide(sic) ,glass powder. The abrasive and air mixture emerged from nozzle at a speed of 150 to 300 m/s. particle size varies from 10 to 50 micro meter. Construction of AJM
The nozzle is made of tungsten carbide
and gases used are nitrogen carbon dioxide or clean air. AJM Nozzle
(NTD) nozzle tip distance is kept about 0.7 to
1.0 mm Working of AJM advantages Ability to cut intricate hole shapes in material of any hardness and brittleness Ability to cut heat fragile and heat- sensitive material without damage as no heat is generated due to air. Low capital cost Power consumption is also low Disadvantages
The used abrasive powder is cannot be
reused Material removal rate is low Machining accuracy is poor Addition cleaning of the work piece may occur as there is possibility of sticking of abrasive grain on softer material Application of AJM Major application of AJM process is in machining of essentially brittle and heat sensitive material like glass semiconductor material ,mica and ceramics. In cutting slots, grooving, polishing, cleaning hard material
For producing intricate shapes in hard and
brittle material.
etching of marking on glass cylinder.
Product of AJM Chemical machining Chemical machining is stock removing process for producing desired shapes by controlled chemical attack with acid or alkalis( etchant)
the maskant or resist is applied over
area you dont want to machine. Control temperature and time of exposure to control material removal First the material is cleaned in trichloroethylene vapour and followed by washing in clean water. Material removal rate is 0.025 to 0.1 mm/min
For maskant material (butyl rubber) or
polymer is used. The etchant solution (feCl3)ferric chloride is used at 500c or HCL:HNO3 hydrochloric acid: nitric acid is used at 55 0c Chemical machining advantages Surface finish obtain in the range of 0.5 to 2 micron Major advantage is that manufacturing is burr free No stress introduction to the work Several component can be produce simultaneously. No effect of work piece materials properties such as hardness disadvantages Difficult to get sharp corner Etchant disposals are very expensive Etchants are very dangerous for workers Scribing accuracy is very limited, causes less dimensional accuracy Application chemical machining has been applied successfully in a great number of usages where the depth of material is critical to a few microns and the tolerance are closed This method is used to get high surface finish conclusion non-traditional machining processes like, laser beam machining, abrasive jet machining, and chemical machining. Which is useful for producing complex and intricate components which is very hard or not possible by traditional machining? References 1. Tata Mc Graw-hill education private limited, New Delhi Production technology hmt
2. Element of workshop technology vol:2 machine tools
By s.k. Hajra choudhury, s.k. bose, A.K.Hajra choudhury and Nitjhar Roy Media promoters & publishers PVT.LMT.
3. Dr.R.S.parmar welding processes and technology
Published by chander khanna for KHANNA PUBLISHERS
4. Jain V K, Non-conventional machining, Pmc First SERC
School Adv Manu fact Techno (Indian Institute of Technology, Kanpur) (1996) 88-91 Thank you