Unit 2

Advances in Non-Conventional Machining Processes

Limitations of Conventional Machining
Methods
• Increased workpiece hardness : decreased economic cutting

• speed. Hence, lower productivity.

• Rapid improvements in the properties of materials (hardness, strength, etc)

• Requires much superior quality of tool materials.

• Tool material hardness should be greater than workpiece hardness.

Evolution of Advanced Machining
Processes(AMPs)
• Many Engineering materials are having much superior properties such as ultra
high strength , hardness, very high temperature resistance difficult to machine by
conventional machining methods.

• Ex :Tungsten Carbide, Stainless Steel, Titanium and its alloys etc

• If work piece material hardness is greater than the tool material hardness. How
are we going to machine such a work piece material ?
Product Requirement

• Complex shapes • High MRR

• Machining in inaccessible areas • High production rate while processing difficult

to machine.
• Low tolerances (say, 0.01 mm)

• Better surface integrity (no surface defects, • Low cost of production .

etc.) • Precision and ultraprecision machining

• High surface finish (Nano-level Ra value) • Requires material removal in the form of atoms
and / or molecules
• Miniaturization of products (examples: landline
phone & mobile, old computers & laptop, etc.)
Machining of Complex Shaped Workpieces
Important characteristics of Advance
Machining Processes
• Process performance is independent of workpiece :Strength & Hardness are not
a barrier.

• Performance depends on thermal, electrical and chemical properties of

workpiece materials.

• Uses deferent kinds of energy in direct form.

• In general, low MRR but better quality products .

• Comparatively high initial investment cost of machine tools and high operating
cost
Classification of AMPs, Based on the Kind of
Energy used
Mechanical Machining
• Abrasive Jet Machining, Ultrasonic Machining (USM) and Waterjet Machining (WJM) are
typical examples of single action, mechanical non traditional machining processes.

• The machining medium is solid grains suspended in an abrasive slurry in the former,
while a fluid is employed in the WJM process.
Abrasive Jet Machining
Abrasive Jet Machining: Machined products
Abrasive jet machining
• In Abrasive Jet Machining (AJM),
abrasive particles are made to impinge
on the work material at a high velocity.
The high velocity abrasive particles
remove the material by micro-cutting
action as well as brittle fracture of the
work material.
• In AJM, the material removal takes place
due to impingement of the ne abrasive
particles.
Mechanics of AJM
• Abrasive particle impinges on the work surface at a high velocity and this impact
causes a tiny brittle fracture and the following air or gas carries away the
dislodged small work piece particle.

• The abrasive particles are typically of 0.025mm diameter and the air discharges at
a pressure of several atmosphere
Mechanics of AJM
• Flaring of the Jet:- Cavity dimension changes with a change in NTD.

• Abrasive particles repeatedly hit on the work surface.

• Brittle fracture separates out tiny particles (wear particles) to produce a cavity. Cavity
width greater than or equal to Nozzle inner diam. (Depends on NTD).

• Cavity depth depends on work piece feed rate, abrasive particle mass (or density) and
pressure (or velocity of the jet).

• Stray Cutting: Due to increase in NTD the jet diameter goes on increasing.

• Flaring of Jet: The worn out nozzle increases the exit diameter (internal).
AJM System
AJM Process Parameters
• For successful utilization of AJM process, it is necessary to analyse the following
process criteria.
• 1. Material removal rate.
• 2. Geometry and surface nish of the workpiece.
• 3. Wear rate of the nozzle.
• AJM processes are generally inuenced by the following process parameters.
Parametric Analysis in AJM
Effect of Nozzle Tip Distance (NTD) on MRR
• The NTD not only effects the MRR from the work surface but
also the shape and size of the cavity produced.

• when the NTD increases, the velocity of the abrasive

particles impinging on the work surface increases due to
their acceleration after they leave the nozzle. This increases
the MRR.

• With a further increase in the NTD, the velocity reduces due

to the drag of the atmosphere which initially checks the
increase in MRR and then decreases it.
Effect of Abrasive ow rate on MRR
• As the ow rate increases upto maxima, More
number of abrasive particles hit the surface.
this increases the MRR.

• I If ow rate is greater than the optimum,

velocity of the jet decreases hence MRR also
decreases.
Effect of Nozzle Pressure on MRR
• Little effect on MRR
• I Kinetic Energy removes material: Due to erosive action
• I Certain minimum velocity for the given material of workpiece.
Effect of Mixing Ratio on MRR
• Note: Mixing Ratio(m) is the ratio of volume ow rate of abrasive to the
volume ow rate of carrier gas.( =mass ratio) is the ratio of mass ow rate of
abrasive to the mass flow rate of abrasive and gas carrier
Process Capabilities of AJM

• Low MRR

• Intricate Details Can be Produced

• Narrow Slots (0.12 to 0.25 mm) can be made

• Low Tolerances (􀀀0:12 to +0:12mm) can be obtained

• Minimization of Taper Angle of Nozzle wrt Work Piece

• Thin Sectioned, Brittle Material, Inaccessible areas can be easily machined

• Almost no surface damage

Applications of AJM
• Manufacture of Electronic Devices including Fragile components

• Deburring of Plastics, Nylon, Teflon Parts

• Deaf lashing of Small Casting

• Drilling Glass Wafers, etc.

• Cutting, marking, engraving, cutting thin sectioned.

• Glass frosting
Ultrasonic Machining (USM)
Process
Introduction
• The basic USM process involves a tool vibrating with a low
amplitude and very high frequency and a continuous flow
of an abrasive slurry in the small gap between tool & work
piece.

• The tool is gradually fed with a uniform force.

• The impact of the hard abrasive grains fractures the hard

and brittle work surface, resulting in the removal of the
work material in the form of small wear particles.

• The tool material being tough and ductile wears out at a

much slower rate https://www.youtube.com/watch?v=HTtnAXrzD4w
Mechanics of USM

1. The hammering of the abrasive particles on the work surface by the

tool.

2. The impact of free abrasive particles on the work surface.

3. The erosion due to cavitation.

4. The chemical action associated with the fluid used.

Mechanics of USM
1. The position A indicates the instant the tool face touches the abrasive grain.

2. The period of movement from A to B represents the impact.

3. The indentations, caused by the grain on the tool and the work surface at the
extreme bottom position of the tool from the position A to position B is h (the total
indentation).

https://www.youtube.com/watch?v=qVcwT0FfAIc
 Ultrasonic Machine
• It consists of the following
machine components: The
acoustic head, feeding unit, tool,
abrasive slurry and pump unit,
body with work table.

https://www.youtube.com/watch?v=5w6szZtOg5w
USM Acoustic Head
• The Acoustic heads function is to produce a vibration in the tool.

• It consists of a generator for supplying a high frequency electric current, a

transducer to convert this into a mechanical motion (in form of a high frequency
vibration).
• A concentrator to mechanically amplify the vibration while transmitting it to the
tool.

• I The ultrasonic vibrations are produced by the transducer. The transducer is

driven by suitable signal generator followed by power amplifier. The transducer
for USM works on the following principle:

• Piezoelectric effect, Magnetostrictive effect and Electrostrictive effect

USM Abrasive Slurry
• The most common abrasives are Boron Carbide (B4C), Silicon Carbide (SiC),
Corrundum (Al2O3), Diamond and Boron silicarbide.

• B4C is the best and most efficient among the rest but it is expensive.

• SiC is used on glass, germanium and most ceramics.

• Diamond dust is used only for cutting Diamond and Rubies.

• Water is the most commonly used fluid although other liquids such as Benzene,
Glycerol and oils are also used
Assumptions:
1. The rate of work material removal is proportional to the volume of the work material per impact.

2. The rate of work material removal is proportional to the no. of particles making impact per cycle.

3. The rate of work material removal is proportional to the frequency (no. of cycles per unit time).

4. All impacts are identical.

5. All abrasive grains are identical and spherical in shape.

Thus, volume of work material removal rate (Q)

Note:V = volume of the work material removal per impact, Z = number of particles making impact
per cycle, = frequency
USM Process Parameters

• Frequency

• I Amplitude

• I Static loading (feed force),

• I Hardness ratio of the tool and the workpiece,

• I Grain size,

• I Concentration of the abrasive in the slurry.

USM MRR vs Frequency and Amplitude
• With an increase in frequency of the tool head
the MRR should increase proportionally.

• However, there is a slight variation in the MRR

with frequency.

• When the amplitude of the vibration increases

the MRR is expected to increase.

• The actual nature of the variation is shown in

Figure
USM MRR vs abrasive diameter and
concentration
• MRR should also rise proportionately with the mean grain diameter 0d0.

• When 0d0 becomes too large, the crushing tendency increases.

• Concentration of the abrasives directly controls the number of grains producing

impact per cycle. MRR is proportional to C1=4 so after C rises to 30 percentage MRR
increase is not very fast
USM MRR vs Feed Force

• MRR increases with increasing feed force but after a certain critical
feed force it decreases because the abrasive grains get crushed under
heavy load
USM, Dependence of Surface Finish on Grain
Size
• The Figure shows that the surface finish is more sensitive to grain size in case of
glass which is softer than tungsten carbide. This is because in case of a harder
material the size of the fragments dislodged through a brittle fracture does not
depend much on the size of the impacting particles
Summary of USM
Water jet machining
Introduction
• The abrasive water jet cutting (AWJC) process is a high-potential process applicable to
both metals as well as non-metals. In this process, a high-velocity.

• water jet mixed with fine abrasive particles hits the workpiece surface (Figure 11.6).

• The velocity of the abrasive mixed water jet is very high, hence the kinetic energy with
which the abrasive particles and the water jet hit the workpiece surface is very high (as
high as 900 m/s in special cases) and hence it leads to the erosion of the work surface.
Introduction
• Depending upon the type of the workpiece material being cut and the depth at which cutting is
taking place, material removal occurs due to erosion, shear or failure under a rapidly changing
localized stress field. The pressure at which a water jet operates is about 400 Mpa.

• Such a high-velocity jet is able to cut materials such as céramiques, composites, rocks, métal etc.

• This process does not produce dust, thermal defects, and fire hazards.

• Recycling of water and abrasives is possible to some extent.

• It is a good process for shaping and cutting of composite materials, and creates almost no
delamination.
Water jet machine

• Abrasive water jet cutting machines have four basic elements: a pumping system, abrasive feed
system, abrasive water jet nozzle and catcher.
• Sapphire, tungsten carbide, or boron carbide can be used as the nozzle material
Process Parameters
• Independent process parameters include water (pressure, flow rate), abrasive (type, size,
flow rate), nozzle, traverse rate, the stand-off distance and workpiece material.

• For a specified workpiece material and process parameters, there is a minimum pressure
(i.e., critical pressure or threshold pressure) below which no cutting will take place [6].

• The machined depth increases as the pressure increases, and this relationship becomes
steeper as the abrasive flow rate increases.

• An increase in abrasive flow rate increases the machined depth, but beyond the critical
value of abrasive flow rate the machined depth starts to decrease
Process Parameters
• Various types of abrasive particles can be used during AWJC, viz. Al2O3, SiC, silica sand, garnet
sand, etc.

• It is also found that, with an increase in traverse rate (relative motion between the water abrasive
jet and workpiece) and stand-off distance (the distance between the nozzle tip and the workpiece
surface being cut) the machined depth decreases.

• Under certain circumstances, more than one pass of cutting may be required
Applications
• This process has been applied to cut both metals as well as non-metals.

• This process is good to cut honeycomb material, corrugated structures, etc.

• This process is gaining acceptability as a standard cutting tool in industries such as

aerospace, nuclear, oil, foundry, automotive, construction etc.
Thermoelectric Advanced Machining
Processes
• Some processes are good only for electrically conductive materials while others
are excellent for making thousands of holes in a square centimeter area of
metallic as well as non-metallic materials.

• Processes such as electrical discharge machining (EDM), travelling-wire EDM,

laser beam machining (LBM) and EBM fall into the category of thermal AMP in
which material removal takes place by melting or melting and vaporization.

• The energy source for material removal is in the form of heat.

Electric Discharge Machining (EDM):Products
 Introduction
• Electro Discharge Machining (EDM) is
an electro-thermal non-traditional
machining process, where electrical
energy is used to generate electrical
spark and material removal mainly
occurs due to thermal energy of the
spark.
Introduction
• I EDM is mainly used to machine difficult-
to-machine materials and high strength
temperature resistant alloys. EDM can be
used to machine difficult geometries in
small batches or even on job-shop basis.

• I Work material to be machined by EDM

has to be electrically conductive.
Elements of EDM Process
• Tool Electrode:

1. Good Electric conductivity, High thermal Diffusivity, High melting and boiling point, good
machinability etc

2. Examples are graphite, brass, copper, tungsten etc

• Work piece Material: Any material which is electrically conductive can be machined through EDM

• Power Supply: Resistance capacitance(RC) and Transistor type circuits are used. Transistor
circuits(TC) are incapable to produce nano pulses. TC is used where high MRR required.

• Servo System: To maintain a constant spark gap between electrodes.

• Dielectric Fluid: It acts as the insulator medium between tool and work piece. Examples are
Kerosene, De-ionized Water, air, mineral oil etc.
EDM: How Material removal Takes Place?
EDM: How Material removal Takes Place?
• Usually, 80–100 V DC pulses at approximately 5 kHz are passed through the electrodes.

• Negatively charged particles (electrons) break loose from the cathode surface under the influence of electric

field forces. These electrons collide with the neutral molecules of the dielectric (kerosene, oil, or water) and

produce electrons and ions, resulting in further ionization.

• In this ionized narrow channel, there is a continuous flow of a considerable number of electrons towards

the anode and of ions towards the cathode. When these particles hit the electrodes their kinetic energy (KE)

is converted into heat energy due to the bombardment of electrons onto the anode and ions on the

cathode.

• Finally, localized high temperature at the electrodes results in the melting and/or vaporization of electrodes.

Usually, a component made by EDM is machined in two stages, viz. rough machining (high MRR and high Ra

value) and finish machining (low MRR and low Ra value).

Process Capabilities and Applications
• It can perform various kinds of operations such as drilling, cutting, 3D shaping and sizing (wire
EDM) and spark-assisted grinding (EDDG).

• It gives good repeatability and accuracy of the order of 25–125 μm. The tolerances that can be
achieved are ±2.5 μm. This has been used to produce as good as 100:1 aspect ratio holes.

• Under normal conditions, the volumetric material removal rate (MRRv) is in the range of 0.1–10
mm3/min. The surface finish produced during EDM is usually in the range 0.8–3 μm, depending
upon the machining conditions

• used. The machined surface normally has a recast layer which should be removed before fitting
the part into the assembly or sub-assembly
EDM Surface Integrity
• Due to the high temperature, metallurgical changes occur in the subsurface layers
of the EDM workpiece. Commonly there are three zones that can be observed:

(1) Recast zone

(2) Heat-affected zone

(3) Conversion zone.

General Characteristics of MRR in EDM
Laser Beam Machining

Sun rays and a lens, burn a piece of paper

Introduction
• A laser is a device that emits light through a process of optical amplification based on

the stimulated emission of electromagnetic radiation. The term "laser" originated as an

acronym for: Light amplification by Stimulated Emission of Radiation

 Introduction

• Lasing process describes the basic operation of

laser, i.e. generation of coherent (both temporal
and spatial) beam of light by "light amplification"
using "stimulated emission".

• In laser beam machining, a laser beam is focused

onto the target/workpiece surface, resulting in an
energy density of the order of 103 W/mm2 (or
more in some cases), which is enough to melt and
vaporize materials such as diamond.
Principle of LASER
• The electrons at ground state can be excited to higher state of energy by absorbing energy form external
sources like increase in electronic vibration at elevated temperature, through chemical reaction as well as
via absorbing energy of the photon.

• I The electron moves from a lower energy level to a higher energy level.

• I On reaching the higher energy level, the electron reaches an unstable energy band. And it comes back to
its ground state within a very small time by releasing a photon. This is called spontaneous emission.
LASER beam cutting process

• Beam Parameters:
Wavelength, Spatial mode
structure, Brightness, Position,
beam waist, Polarization, and
Spot size
Change in cut front with increase in cutting
speed
LASER beam and depth of focus
Machining with long pulse lasers and short
pulse laser
Process characteristics
Power Density and MRR in LBM
Power Density and MRR in LBM
Power Density and MRR in LBM
Parametric Analysis
LBM Application
• LBM is capable of machining refectory, brittle, hard, metallic and non-metallic materials.
As long as the laser beam path is not obstructed, it can be used to machine in otherwise
inaccessible areas.

• LBM is suitable for drilling very small diameter holes with a reasonable large aspect ratio.

• LBM is used for drilling, trepanning, trimming, marking, welding and similar other
operations. It is used for both micromachining as well as macro machining.

• LBM has also been used for 3D machining, namely, threading, turning, grooving etc
Electrochemical Machining: Products
introduction
• Electrochemical machining is one of the most unconventional machining processes.

• The process is actually the reverse of electroplating with some modifications.

• It is based on the principle of electrolysis.

• In a metal, electricity is conducted by free electrons but in a solution the conduction of electricity
is achieved through the movement of ions.

• Thus the ow of current through an electrolyte is always accompanied by the movement of matter.

• In the ECM process the work-piece is connected to a positive electrode and the tool to the
negative terminal for metal removal.
• An ECM machine tool consists of four main subsystems: the power source, the
electrolyte cleaning and supply system, the tool and tool feed system and the work and
work holding system.

• The electrolyte supply and cleaning system consists of a pump, filters, piping, control
valves, heating/cooling coils, pressure gauge and a tank/reservoir.

• These elements should be made of anti-corrosive materials because the electrolyte used
is corrosive in nature. Tools are also required to operate in a corrosive environment for a
long period of time.
• Copper, brass and stainless steel are commonly used materials for making ECM tools
• However, work holding devices are made of electrically non-conducting materials
having good thermal stability, corrosive resistance and low moisture absorption.

• Glass-fibrereinforced plastics (GFRP), Perspex and plastics are some such

materials that can be used to fabricate work holding devices.
Polarization Curve
 Electrochemistry of ECM process
• The electrolysis process is governed by the following twolaws proposed by Faraday

• I The amount of chemical change produced by an electric current, that is, the amount of
any material dissolved or deposited, is proportional to the quantity of electricity passed.

• I The amounts of different substances dissolved or deposited by the same quantity of

electricity are proportional to their chemical equivalent weights.

• where m is the mass of dissolved metal, I is the current, t is time and E is the gram
chemical equivalent (E = A=Z), A is the atomic mass of anode and Z is the valency of
dissolution of anode
Design Considerations for Electrochemical
Machining.

The following are general design guidelines for electrochemical machining:

• Electrochemical machining is not suited for producing sharp square corners or flat
bottoms, because of the tendency for the electrolyte to erode away sharp
profiles.
• Controlling the electrolyte flow may be difficult, hence irregular cavities may not
be produced to the desired shape and with acceptable dimensional accuracy.
• Part designs should make provision for a small taper for holes and cavities to be
machined.
Applications of ECM
• Die sinking

• I Profiling and contouring

• I Trepanning

• I Grinding, Drilling and Micro-machining

Summary
Abrasive Jet Machining
AJM - Equipment
• AJM consists four majour system

1. Gas propulsion system – provides steady supply of clean, dry gas used to propel abrasive particles

• Most common gas is nitrogen and carbon dioxide.

2. Metering system – must inject s uniform, adjustable flow of abrasive particles into the gas stream.

• Generally accomplished by powder hopper that feeds into a vibrating chamber, which allow powder to
be metered uniformly into the jet stream.

3. Delivery system –

4. Abrasive collection system – some time used to draw the dust particles from the exhausted
chamber and keep operator’s viewing clean.
AJM - Equipment
Nozzle

• Made of tungsten carbide or sapphire.

• Either round or rectangular holes.

• Round nozzles with diameter 0.12-1.25 mm.

• Rectangular nozzles from 0.07*0.5 mm to 0.17 * 3.8 mm.

• Life of nozzle depends on its application

• Cutting operation requires nozzle change more often

• As nozzle wear, the jet stream tends to diffuse faster, resulting in material damage outside the
intended line of cut. – known as Overspray.

• Rectangular nozzle covers less overspray

Mask

• Masks are used to control overspray or to produce large holes and intricate detail

without having to move nozzle and trace shape.

• Mask can be fabricated from rubber or metal.

• Rubber – easy to fabricate but poor edge definition

• Metal mask – better definition but erode faster.

• Abrasive particle size 10 to 50 micron. Smaller size more useful for polishing and

cleaning- larger for cutting and peening

Abrasives

• Aluminium oxide – most common – used to clean, cut and deburr

• Silicon carbide – harder abrasive – same application – used when workpiece material is hard

• Glass beads – for polishing surface to matt finish or peening surface

• Crushed glass – sharper edges than glass beads – hence used for heavier cleaning and

peening operation.

• Sodium bicarbonate – soft powder - for lightest duty application such as the cleaning,

cutting, and deburring of soft materials

Process parameters
Process parameters
Water jet machining
Water Jet Machining - Equipment
Nozzle

• Initially, Water mixed with long chain polymers, such as polyethylene oxide to reduce fluid flow friction and to
give water more cohesive property.

• But even a tight, coherent water jet could be obtained by using properly designed nozzle.

• Externally nozzle hole diameter range from – 0.07 – 0.5 mm or 1.0mm.

• Large Dia. nozzle not used because of prohibitively large size of the pump and motor required to maintain
proper flow.

• Material – synthetic sapphire – easily Machin able and resistant to wear.

• Failure of nozzle – either chipping from dirt particle in the water.

• Life of nozzle – 250-500 hr even by using water treatment such as softeners or deionizers.
Water Jet Machining - Equipment
Catchers

• Catcher – to minimize the exposed length of the jet for safety purposes and to minimize the process noise.

• Water Jet – travelling at 2 to 3 times the speed of sound.

• Water breaks into mist and droplets at this speed and into open area produces sound loud as 130 dBA.

• Hence to minimise noise – Tube or slot – type catcher is used.

• Tube catcher – most common, 300-600 mm long attached to draining hose.

• This length is sufficient to allow the water jet to break up completely before it reaches the bottom of the

tube.

• If not possible short tube catcher can be used.

• Some times slot type catcher – but less effective.

Process parameters
• Four : Pressure, Nozzle diameter, Traverse rate and standoff distance.

• Standoff distance is least critical – can kept as fixed

• Nozzle to workpiece standoff distance less than 25 mm and optimally 30 mm.

• Rest parameters varied depending upon the material and thickness being cut.

• In general – as the power of water jet is increased, the ability to cut faster and
thicker will increase.

• It can achieve by inc. the pressure, inc the nozzle dia, or dec. the travel rate.
AWJM
AWJM - equipment

Pumping system

• To produce the high-velocity water jet that will transfer its momentum to the abrasives.

• Pumping system is similar to WJM.

• Water jet is pressurised to 415 Mpa by means of intensifier.

• 56Kw of hydraulic power – to produce the highest level of pressure.

• High pressure seal in pumping system lasts – 250 to 750 hr and required 15 min to change.

• High pressure check valve can have life of 500 to 1000 hrs.
AWJM - equipment
Abrasive feed system

• It must deliver a precisely controlled flow of abrasive particles

• It deliver a dry abrasives to the nozzle.

• Flow rate is established by selecting proper diameter of orifice.

• Delivery of abrasive over long distance is difficult

• Alternative – abrasive slurry.

• More power would required for abrasive slurry system.

Water Jet

• Same as WJM.

• Water is fabricated of Sapphire and can last 250-500 hrs.

AWJM - equipment
• Abrasive jet nozzle

• Provide efficient mixing – form the high-velocity abrasive water jet combination.

• Made form tungsten carbide or boron carbide – to avoid wear.

• Two concept:

1. Single jet side feed nozzle : doesn’t provide optimum mixing efficiency and experiences rapid wear of exit

section.

• Problem - Abrasive flow can be stopped and the system will function as a conventional WJM system.

2. Multiple jet, central feed nozzle: Centrally located abrasive feed bind with multiple water jet.

• Increases the life of the mixing section

• Difficult to fabricate.
AWJM - equipment
• Catcher : it requires where the nozzle is stationary and workpiece moves. Same as WJM.

• Cather used for AWJM are lined with ceramic to resist the abrasives.
Process parameters
• Multiple passes can be used to increase the
depth of cut but single pass is more efficient
way.

• When mixing is efficient along with process

parameters – a deviation in standoff distance up
to +-12.5 mm can be tolerated.

• If standoff distance are increased to 80mm, the

process will no longer cut but will clean and
descale surfaces.
Process parameters
• Pressure can be high as 415 Mpa but normally within
172 – 275 Mpa.

• Relationship between pressure and depth is linear.

• Abrasive mass flow m and nozzle dia dm were changed

• All the lines converge to common point – is the critical

pressure (pc) required to cut the material.

• No relation between critical pressure and material

properties.
Process parameters
• As flow rate inc. the slope of the curve dec. because
saturation point reached.

• As nozzle dia inc. and water flow rate inc. the rate of
increase in the particle velocity reduced hence depth of
cut reduced.

• Abrasive flow rate vs depth of cut – linear relationship but

above critical flow rate, the cutting efficiency decreases.
Because > as particle velocity begins to decrease faster
than rate, number of abrasive particle impact increases.
Process parameters
• Common abrasive particle size 100 to 150 grit.

• Size range is wider for brittle material such as glass.

• Common abrasive: Garnet, silica and silicon carbide.

• Selection of abrasive particle depends upon hardness of the material to be cut.

• The harder the material the harder the abrasive particle must be.

• Recycling is feasible for some workpiece-abrasive combination such as silicon carbide and mild

steel – still it’s a research area to explore.

• Traverse rate increased the depth of cut decrease.

• If traverse rate is not maintained at relative uniform velocity, a rough edge will result due to the

nature of process.
Questions
• Explain the material removal mechanism of any one thermal type nontraditional machining process with neat
sketch.
• Write the difference between mechanical and electrochemical type nontraditional machining processes.
• Enlist the advantages of simulation of non-conventional processes.
• Write the criteria of tool design for electrical discharge machining (EDM) process.
• Write the criteria of tool design for any one non-traditional machining process.
• Explain the material removal mechanism of any one mechanical type nontraditional machining process with
neat sketch.
• Explain the material removal mechanism of electrochemical type non-traditional machining with neat sketch.
• Enlist the tool design criteria of tools use for EDM process.
• Enlist the advantages and disadvantages of thermal type nonconventional machining processes
• Explain the material removal process in ECM. How the micro-ECM defer from ECM process?
• Enlist the advantages and disadvantages of thermal and mechanical type non-conventional process group.
• Write the criteria of tool design for electrical discharge machining (EDM) process.
• Yash Shah
• 1:15 PM
• [email protected]
• HARIT PRAJAPRATI
• 1:15 PM
• [email protected]
• Himalay Prajapati
• 1:15 PM
• [email protected]
• Kaush
• 1:15 PM
• [email protected]