Group Assignment 1 (MDB 4213)

Members : 1) Vikneshwaran K. Balakrshnan 20054

2) Navind Tamilselvan 19643

Introduction

Conventional machining processes involves material removal by mechanical means: chip

formation, abrasion, or microchipping. However, there are situations in which mechanical
methods are not satisfactory, economical, or even possible to machine a component with
desired surface finish. Specific surface finish (without burr and sharp edge) and dimensional
tolerance requirements cannot be obtained by conventional machining processes and in some
cases, it is uneconomical through alternative processes. On the other hand, advanced machining
processes remove material not by producing chips as in machining and grinding, but by means
such as chemical dissolution, etching, melting, evaporation, and hydrodynamic action-
sometimes with the assistance of fine abrasive particles. A major advantage of these processes
is that their efficiency is independent of workpiece hardness. When selected and applied
properly, advanced machining processes offer major technical and economic advantages over
more traditional machining methods.

Problem Statement

Holes are required to be drilled on the aerospace component as shown in Figure 1. After the
drilling processes, the drilled holes have burrs, sharp edges and material compression occurs.
Therefore, it effects the quality of the component and might lead to a potential error during the
assembly process.

Figure 1: Aerospace component

Objective

• To determine whether adopting advance manufacturing process would eliminate the

burr issues.
• To identify and state specific examples of the advance manufacturing processes that
can be used to solve the issue.
• To economically justify the process.

Examples of advanced manufacturing processes

• Electrochemical Machining

Electrochemical machining (ECM) process is the reverse of electroplating. An electrolyte is

used as the current carrier, and the high rate of electrolyte movement in the tool-workpiece gap
washes metal ions away from the workpiece (anode) before they have a chance to plate onto
the tool (cathode). The tool used for ECM is made of brass, copper, bronze, or stainless steel.
The electrolyte is a highly conductive inorganic fluid, for example an aqueous solution of
sodium nitrate which is pumped through the passages in the tool at rates of 10 to 16 m/s. ECM
is used to machine complex cavities and shapes in high strength materials, machining and
finishing forging-die cavities (die sinking) and also to produce small holes.
The ECM process leaves a burr-free and bright surface. Besides, it can also be used as a
deburring process. It does not cause any thermal damage to the part, and the absence of tool
forces prevents part distortion. In ECM, there are no cutting forces and the work piece is left
in a stress-free state Since metal removal is by metallic ion exchange. Furthermore, there is no
tool wear since only hydrogen is generated at the cathode, and the process is capable of
producing complex shapes. Therefore, it is a suitable advanced machining process to drill a
hole in the aerospace component without making the drilled holes burred, sharp edged and
developing material compression.

• Waterjet Machining

Figure: Waterjet Machining

Another example of machining process that can be used to solve the issue is Water Jet
Machining. High pressure water jet cutting systems are the ideal solution for the aerospace
industry. The machining process does not affect the material properties or the temper because
instead of heat, ultra-high-pressure waterjet is used for machining. Because the nature of the
cutting stream can be easily modified the water jet can be used in cutting a variety of metal and
non-metal material to a high range of thickness.

All waterjets follow the same principle of using high pressure water focused into a beam by a
nozzle. Most machines accomplish this by first running the water through a high-pressure
pump. The water then travels along the high-pressure tubing to the nozzle of the waterjet.
In the nozzle, the water is focused into a thin beam by a jewel orifice. This beam of water is
ejected from the nozzle, cutting through the material by spraying it with the jet of high-speed
water. The process is the same for abrasive waterjets until the water reaches the nozzle. Here
abrasives such as garnet and aluminium oxide, are fed into the nozzle via an abrasive inlet. The
abrasive then mixes with the water in a mixing tube and is forced out the end at high pressure.

Conclusion

After a short research on advanced manufacturing processes, it can be concluded that these
processes can improve the products quality and overall production capacity. Electrochemical
Machining and Waterjet Machining is the most suitable processes for aerospace components
as it does not affect the material and have a good surface finishing. Besides, the production
cost is economical as it does not require much maintenance for the equipment.