Nontraditional Machining Processes

General Manufacturing Processes Engr.-20.2710 Instructor - Sam Chiappone

Why Nontraditional Processes?

New Materials (1940s)

Stronger Tougher Harder

Applications
Cut tough materials Finish complex surface geometry Surface finish requirements
texture, fine, etc. Rensselaer Polytechnic Institute
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Processes

Mechanical Chemical Electrochemical Thermoelectric

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Mechanical

Ultrasonic Machining - Cutting action is accomplished with an abrasive slurry which is driven by a tool vibrating at high frequency. The tool is the exact shape of the desired shape to be cut into the work. Applications
slots, blind holes, irregular shapes, and through holes.

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Mechanical

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Mechanical

Abrasive Water-Jet Cutting

Similar to sandblasting Process utilizes a high velocity stream of water mixed with an abrasive as the cutting tool Forces the mixture through a nozzle with a hole diameter of .0040 - .012 System pressures range from 30,000 - 50,000 psi Used to cut a variety of materials from wood to tool steel Cutting rate - Alum. Plate - 150 in/min. One disadvantage to note Tolerances typically (+/- .01) Rensselaer Polytechnic Institute
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Mechanical

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Chemical

Chemical Milling
Controlled etching process MRR about .001 cu/in per min ~ .045 cu/in hour Process
Sample part is tested for erosion rate Part to be chem machined is cleaned Mask area you do not want to machine Dip part in chemical solution hot alkaline Remove part Clean part Rensselaer Polytechnic Institute
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Chemical

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Electrochemical

Basically the same principle as plating Differences

Part is the anode (+) and the tool is the cathode (-) Metal is pulled away from work

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Electrochemical

Advantages
Hard to soft materials made of conductive material can be machined Cutting tool can be made from soft material Low heat generated during process No cutting forces Excellent surface finish

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Thermoelectric

Electrical Discharge Machining (EDM)

This process is like a mini-thunderstorm. Flashes of lightning in rapid succession (500 5,000 sparks per second) erode material from the part being machined.

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EDM

Machining action forms a gap between the part and the electrode (tool) which causes a spark which removes the material Electrode is (+) and the part is (-) Electrodes can be made from
Brass Copper Graphite

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EDM

Cutting action takes place in a dielectric fluid which helps to contain the spark and flush away chips Metal removal rates (MRR) are low compared to other process like milling
EDM, MRR= 1 cu/in to 15 cu/in per hr.

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EDM

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EDM

(2) types of machines

Ram Type
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Wire Type
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EDM

Applications
Finish geometry for molds ( die sinking)
Ram

Punch & dies for blanking, shearing, and progressive die tooling
Wire

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