MAYURBHANJ SCHOOL OF ENGINEERING, BARIPADA

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• Branch : Mechanical Engineering
• Semester: 6th
• Subject :Advance Manufacturing Process
• Topic :Non-Conventional MachiningCAD/CAM
• Faculty :Er. Suchismita Parida

NONTRADITIONAL MACHINING PROCESSES

HISTORY OF MATERIAL DEVELOPMENT

THE REQUIREMENTS THAT LEAD TO THE DEVELOPMENT OF NONTRADITIONAL MACHINING

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• Very high hardness and strength of the material. (above 400 HB.)

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• The work piece is too flexible or slender to support the cutting or grinding forces.

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• The shape of the part is complex, such as internal and external profiles, or small diameter holes.

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• Surface finish or tolerance better than those obtainable conventional process.

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• Temperature rise or residual stress in the work piece are undesirable.

CONVENTIONAL MACHINING VS NONCONVENTIONAL MACHINING

• The cutting tool and workpiece are always in physical contact, with a relative motion against each other, which results in friction and a significant tool wear.

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• In non-traditional processes, there is no physical contact between the tool and workpiece. Although in some non-traditional processes tool wear exists, it rarely is a significant problem.

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• Material removal rate of the traditional processes is limited by the mechanical properties of the work material. Non-traditional processes easily deal with such difficult-to-cut materials like ceramics and ceramic based tool materials, fiber reinforced materials, carbides, titanium-based alloys.

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CONTINUE…

• In traditional processes, the relative motion between the tool and work piece is typically rotary or reciprocating. Thus, the shape of the work surfaces is limited to circular or flat shapes. In spite of widely used CNC systems, machining of three-dimensional surfaces is still a difficult task. Most non-traditional processes were develop just to solve this problem.

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• Machining of small cavities, slits, blind or through holes is difficult with traditional processes, whereas it is a simple work for some non-traditional processes.

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• Traditional processes are well established, use relatively simple and inexpensive machinery and readily available cutting tools. Non-traditional processes require expensive equipment and tooling as well as skilled labor, which increases significantly the production cost.

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CLASSIFICATION OF PROCESSES

• Mechanical Metal removal Processes
• It is characterized by the fact that the material removal is due to the application of mechanical energy in the form of high frequency vibrations or kinetic energy of an abrasive jet.

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• 1. Ultra sonic Machining (USM).

2. Abrasive Jet Machining (AJM).

3. Water Jet Machining (WJM).

CONTINUE…

• Electro-Chemical
• It is based on electro-chemical dissolution of materials by an electrolyte under the influence of an externally applied electrical potential.

1. Electro-Chemical Machining (ECM).

2. ECG

3 ECD

CONTINUE…

• Thermal Method

The material is removed due to controlled, localized heating of the work piece. It result into material removal by melting and evaporation.

The source of heat generation in such cases can be widely different.

1.Electric Discharge Machining (EDM).

2. Plasma Arc Machining (PAM).

3. EBM 4. LBM

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• MECHANICAL METHOD�THE MATERIAL IS REMOVED DUE TO MECHANICAL FORCE WHICH IS APPLIED INDIRECTLY ON THE WORK PIECE SURFACE.�USM�AJM�AWJM�WJM����

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