CHRIST UNIVERSITY, BANGALORE 560 029

MID SEMESTER EXAMINATION: AUGUST 2017

V Semester (UG)
Answer Key

PROGRAMME NAME: B.Tech MAX .MARKS:50

CODE AND COURSE NAME: ME532-Non Traditional Machining TIME: 2 HRS

1. Discuss about the criteria recommended in selection of non-traditional machining

processes. (10 marks)
Very high hardness and strength of the material. (Above 400 HB.)
The work piece is too flexible or slender to support the cutting or grinding forces.
The shape of the part is complex, such as internal and external profiles, or small diameter holes.
Surface finish or tolerance better than those obtainable conventional process. Temperature rise or
residual stress in the work piece are undesirable.
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.
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.
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.
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.
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.
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.
(1 mark for each point)

2. Describe the Ultra Sonic Machining Process with a neat sketch. Also list the
advantages and disadvantages of the process.
(10 marks)

(4 marks for the sketch)

WORKING PRINCIPLE OF USM (4 Marks)
Ultrasonic machining is a non-traditional process. In this process abrasives contained in the
slurry are driven against the work by a tool oscillating at low amplitude (25100 microns)
and high frequency (1530 kHz). Ultrasonic refers to waves of high frequency above the
audible range of 20 kHz. The ultrasonic machining was proposed by L Balamuth in 1945.
It was developed for finishing of electro spark machine parts. The USM process consists
of tool made of ductile and tough material. Tool oscillates with high frequency, and the
continuous abrasive slurry is fed between the tool and workpiece. The impact of the hard
abrasive particles fractures the workpiece thus removing the small particles from the
work surface.

ADVANTAGES:
1. It can be used to machine hard, brittle, fragile and non-conductive materials.
2. No heat is generated in work, therefore, no significant changes in physical
structure of the work material.
3. Non-metal (because of the poor electrical conductivity) that cannot be machined
by EDM and ECM can very well be machined by USM.
4. It is a burr less and distortion less processes.
5. It can be adopted in conjunction with other new technologies like EDM, ECG,
ECM.
6. High accuracy with good surface finish can be achieved.
7. Possesses the capability of drilling circular and non-circular holes in very hard
materials like ceramics and other brittle materials.

DISADVANTAGES OF USM
1. Low metal removal rate.
2. It is difficult to drill deep holes, as slurry movement is restricted.
3. Frontal and side tool wear rate is high due to abrasive particles, especially when
cutting steel and carbides. Side wear produces less accurate holes and cavities.
4. Tools made from brass, tungsten carbide, MS or tool steel wear from the action of
abrasive grit with a ratio that ranges from 1:1 to 200:1.
5. USM can be used only when the hardness of the work is more than 45 HRC.
6. It is not economical for soft materials.
7. Not suitable for heavy stock removal.
8. USM is not useful of machining holes and cavities with lateral extension of more
than 2530 mm with a limited depth of cut.
9. Every job needs a specific tool. Therefore, tool cost is high.
10. The abrasive slurry should be changed regularly to replace worn out particles.
Therefore additional cost is involved.
11. Sharp corners are difficult to make using USM
{ANY 4 advantages and disadvantages (2 MARKS)}

3. Mention the function of components used in the Water Jet Machining Process. (10 Marks)
Water Jet Machining (WJM) is a mechanical energy based non-traditional machining process used to cut and
machine soft and non-metallic materials. It involves the use of high velocity water jet to smoothly cut a soft
workpiece. It is similar to Abrasive Jet Machining (AJM).
In water jet machining, high velocity water jet is allowed to strike a given workpiece. During this process, its
kinetic energy is converted to pressure energy. This induces a stress on the workpiece. When this induced stress
is high enough, unwanted particles of the workpiece are automatically removed.
This article contains the following sections:
The apparatus of water jet machining consists of the following components:
1. Reservoir: It is used for storing water that is to be used in the machining operation.
2. Pump: It pumps the water from the reservoir.
3. Intensifier: It is connected to the pump. It pressurizes the water acquired from the pump to a desired level.
4. Accumulator: It is used for temporarily storing the pressurized water. It is connected to the flow regulator
through a control valve.
5. Control Valve: It controls the direction and pressure of pressurized water that is to be supplied to the
nozzle.
6. Flow regulator: It is used to regulate the flow of water.
7. Nozzle: It renders the pressurized water as a water jet at high velocity. (10 MARKS)
4. List the applications of the following processes:
i. Ultra Sonic Machining
ii. Water Jet Machining
iii. Abrasive Jet Machining (10 marks)
1. Ultra sonic machining:
This machining is used to machine hard and brittle material like carbide, ceramic, glass etc.
This is used in machining of die and tool of drill, wire drawing machine etc.
Used in fabrication of silicon nitrite turbine blade.
It is used to cut diamond in desire shape.
It is used machining of machining non-conductive hard material which cannot be machined by ECM or
EDM due to poor conductivity.
(4 Marks)
2. Water jet machining
Engine components (aluminium, titanium, heat-resistant alloys)
Aluminium body parts
Custom control panels and structural components for special purpose aircraft such as crop-dusters and
float planes
Rough trimming of turbine blades on jet engines
Aluminium skin, struts, seats, shim stock, brake components, titanium & exotic metals used in
manufacturing landing gear
Robot water jet can cut an automobile interior in any angles and separate Scraps automatically
Flanges for custom exhaust systems
Specialty metal gaskets for antique automobiles
Specialty clutch components for racing cars
Specialty brake disks and components for racing cars
(3 marks)
3. Abrasive Jet Machining
1. AJM is used for abrading and frosting glass, ceramics and refractories more economically as compared to
etching or grinding.
2. Cleaning of metallic smears on ceramics, oxides on metals, resistive coating, etc.
3. AJM is useful in manufacture of electronic devices, drilling of glass wafers, deburring of plastics, making of
nylon and teflon parts, permanent marking on rubber stencils, cutting titanium foils.
4. De flashing small castings and trimming of parting lines of injection moulded parts and forgings.
5. Use for engraving registration numbers on toughened glass used for car windows.
6. Used for cutting thin fragile components like germanium, silicon, quartz, mica, etc.
7. Micro module fabrication for electrical contact, semiconductor processing can be done effectively.
8. Used for drilling, cutting, deburring etching and polishing of hard and brittle materials.
9. Most suitable for machining brittle and heat-sensitive materials like glass, quartz, sapphire, mica, ceramics,
germanium, silicon and gallium.
10. It is also good for deburring small holes like in hypodermic needles and for small milled slots in hard
metallic components.
(3 marks)
5. Discuss the maskants and etchants used for Chemical Machining process. (10 marks)
Maskants
Masking material which is called maskant is used to protect workpiece surface from chemical etchant. Polymer
or rubber based materials are generally used for masking procedure. The selected maskant material should have
following properties.
1. Tough enough to withstand handling
2. Well adhering to the workpiece surface
3. Easy scribing
4. Inert to the chemical reagent used
5. Able to withstand the heat used during chemical machining
6. Easy and inexpensive removal after chemical machining etching

Multiple maskant coatings are used to provide a higher etchant resistance. Long exposure time is needed
when thicker and rougher dip or spray coatings are used. Various maskant application methods can be used such
as dip, brush, spray, roller, and electro coating as well as adhesive tapes. When higher machined part
dimensional accuracy is needed, spraying the mask on the workpiece through silk screen would provide a better
result. Thin maskant coating would cause severe problems such as notwithstanding rough handling or long
exposure times to the etchant. The application of photoresist masks which are generally used in photochemical
machining operation, produce high accuracy, ease of repetition for multiple-part etching, and ease of
modification. Possible maskant materials for different workpiece materials were given in Table 1.

(5 Marks)
Etchants
Etchants are the most influential factor in the chemical machining of any material. Various etchant are
available due to workpiece material. The best possible etchant should have properties as follows
a. High etch rate
b. Good surface finish
c. Minimum undercut
d. Compatibility with commonly used maskants,
e. High dissolved-material capacity
f. Economic regeneration
g. Etched material recovery
h. Easy control of process.
Personal safety maintenance
Different etchants are commercially available or the required etchant can be prepared in shop. Ferric
chloride (FeCl3) is the most widely used etchant in chemical machining. It is mainly used for etching iron-based
alloys as well as copper and its alloys, aluminium, etc. Cupric chloride (CuCl 2) is generally applied for copper
and copper based alloys in electronics industry because various regeneration systems are available for the waste
etchant. Alkaline etchants are introduced to the fabrication of electronic components such as printed circuit
board. There are some other etchants can be named, but the industrial application of chemical machining is
generally used these three etchants, even most of the companies use only ferric chloride due to economic
considerations.

(5 Marks)
6. Explain the need for non-traditional machining process and how it benefits
the manufacturing industries. (10
marks)
Non-traditional manufacturing processes is defined as a group of processes that remove excess material by
various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these
energies but do not use a sharp cutting tools as it needs to be used for traditional manufacturing processes.
Extremely hard and brittle materials are difficult to machine by traditional machining processes such as
 turning, drilling, shaping and milling. Non-traditional machining processes, also called advanced
manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory
or economical due to special reasons as outlined below.

Very hard fragile materials difficult to clamp for traditional machining

When the work piece is too flexible or slender
When the shape of the part is too complex
Several types of non-traditional machining processes have been developed to meet extra required
machining conditions. When these processes are employed properly, they offer many advantages over
non-traditional machining processes. The common non-traditional machining processes are described
in this section. (4 marks)
Definition:
A machining process is called non-traditional if its material removal mechanism is basically different than those
in the traditional processes, i.e. a different form of energy (other than the excessive forces exercised by a tool,
which is in physical contact with the work piece) is applied to remove the excess material from the work
surface, or to separate the workpiece into smaller parts. (1
mark)
Need for development of Non-Conventional Processes
The strength of steel alloys has increased five folds due to continuous R and D effort. In aero-space requirement
of High strength at elevated temperature with light weight led to development and use of hard titanium alloys,
nimonic alloys, and other HSTR alloys. The ultimate tensile strength has been improved by as much as 20
times. Development of cutting tools which has hardness of 80 to 85 HRC which cannot be machined
economically in conventional methods led to development of non traditional machining methods.
1. Technologically advanced industries like aerospace, nuclear power, ,wafer fabrication, automobiles has
ever increasing use of High strength temperature resistant (HSTR) alloys (having high strength to weight
ratio) and other difficult to machine materials like titanium, SST, nimonics, ceramics and semiconductors. It
is no longer possible to use conventional process to machine these alloys.
2. Production and processing parts of complicated shapes (in HSTR and other hard to machine alloys) is
difficult, time consuming an uneconomical by conventional methods of machining
3. Innovative geometric design of products and components made of new exotic materials with desired
tolerance, surface finish cannot be produced economically by conventional machining.
The following examples are provided where NTM processes are preferred over the conventional machining
process:
1. Intricate shaped blind hole e.g. square hole of 15 mmx15 mm with a depth of 30 mm with a tolerance of
100 microns
2. Difficult to machine material e.g. Inconel, Ti-alloys or carbides, Ceramics, composites , HSTR alloys,
satellites etc.,
3. Low Stress Grinding Electrochemical Grinding is preferred as compared to conventional grinding
4. Deep hole with small hole diameter e.g. 1.5 mm hole with l/d = 20
5. Machining of composites (5 Marks)