Non-Traditional

Machining
Chapter 28

Non-Traditional
Machining

Chemical
Electrochemical
Mechanical
Thermal

Chemical Machining

Multi-step process

Prepare surface
Mask
Etch
Remove Mask
Finish

Chemical Machining

Applications

Printed circuit boards

Cutting of very thin parts
Integrated circuits
Thinning of parts for weight reduction

Samples

Electrochemical Machining

Deplating Process
Tool Cathode; copper,
brass, stainless steel
Workpiece Anode
Electrolyte: Highly
conductive solution of
inorganic salt. Flowrate:
50-200 ft/sec
Current Density: 1500
to 2000 amps/in2
MRR: 0.1 in3/min/1000
Amps
Voltage: 2-30 VDC

Electrochemical Machining

Applications

Complex shapes in hard alloys

Produces stress-free surface
Polishing / Deburring (feed is halted)

Electrochemical Drilling

Very small holes produced using acid.

Hole diameters: 0.004 to 0.050
Depth-to-diameter ratio: 50:1 in nickel and
cobalt alloys. (Depths to 24 possible)
Application: Cooling holes in turbine blades for
jet engines.

Electrochemical Machining

Electrochemical Grinding
Grinding wheel replaces the tool.
Advantages:

Lack of heat damage, burrs, residual stress

Low grinding wheel wear

Applications:

Fragile honeycomb parts

Surgical needles
Tips of assembled turbine blades
Tungsten carbide tool grinding

Mechanical NTM
Processes

Ultrasonic
Machining
Ultrasonically
vibrating tool used
with an abrasive
slurry.
Frequency: 20,000
Hz
Amplitude of
vibrations: 0.003

Application:
Machining hard
materials, Rc>40

Mechanical NTM
Processes

Ultrasonic Machining Applications

Drilling, milling, slicing, shaping
Materials

Silicon
Silicon carbide
Silicon nitride
Sapphire
Glass
Quartz
Piezoelectrics
Ceramic composites

Mechanical NTM
Processes

Waterjet Machining
High velocity water
used to cut nonmetals
fiberglass, leather,
rubber, plastics,
asbestos.
Pressure: 10K-60K psi
Jet Diameter: 0.003
0.020
Jet Velocity: 3000 ft/sec

Mechanical NTM
Processes

Abrasive
Waterjet
Machining

Abrasive grit
added to waterjet
Used for cutting
metals and
nonmetals.
Especially good for
cutting composites

Sample Parts

Thermal Processes
Electrical Discharge Machining
(EDM)

Electrical Discharge
Machining (EDM)

Most used of the NTM processes

Metal is removed by electrical discharge current
between the tool and workpiece.
1000s of electrical sparks per second produced.
The spark melts and vaporizes the metal.
80-90% of EDM is used in tool and die sets
Matt finish produced
Tool Materials: graphite, copper, brass, aluminum alloys
Dielectric:

Insulation between tool and workpiece

spark conductor
coolant
flushing agent

Thermal Processes

Wire EDM

Electron Beam

Tool is replaced with a moving wire.

Micromachining: holes, cutting, welding

Laser Beam Machining

Cutting Thin Materials

Drilling of micro-sized holes
Welding

Thermal Processes

Plasma Arc Cutting

Plasma: superheated, electrically ionized gas

Gas Temperature: 30,000 to 60,000 F
Cutting of conductive metals (Stainless
steel, aluminum most common)
Advantages:

Very fast cutting

Small heat-affected zone
Smooth cuts free from contaminants