This document discusses various machining processes categorized as electrical, thermal, chemical, and mechanical energy processes. It provides details on electrochemical machining (ECM) including the underlying principle of material removal, typical applications like die sinking and multiple hole drilling, advantages like little surface damage and low tool wear, and disadvantages like high electrical power costs and electrolyte disposal issues. It also summarizes photochemical machining and considerations for selecting processes based on workpiece geometry features, materials, and when conventional methods are impractical.
This document discusses various machining processes categorized as electrical, thermal, chemical, and mechanical energy processes. It provides details on electrochemical machining (ECM) including the underlying principle of material removal, typical applications like die sinking and multiple hole drilling, advantages like little surface damage and low tool wear, and disadvantages like high electrical power costs and electrolyte disposal issues. It also summarizes photochemical machining and considerations for selecting processes based on workpiece geometry features, materials, and when conventional methods are impractical.
This document discusses various machining processes categorized as electrical, thermal, chemical, and mechanical energy processes. It provides details on electrochemical machining (ECM) including the underlying principle of material removal, typical applications like die sinking and multiple hole drilling, advantages like little surface damage and low tool wear, and disadvantages like high electrical power costs and electrolyte disposal issues. It also summarizes photochemical machining and considerations for selecting processes based on workpiece geometry features, materials, and when conventional methods are impractical.
This document discusses various machining processes categorized as electrical, thermal, chemical, and mechanical energy processes. It provides details on electrochemical machining (ECM) including the underlying principle of material removal, typical applications like die sinking and multiple hole drilling, advantages like little surface damage and low tool wear, and disadvantages like high electrical power costs and electrolyte disposal issues. It also summarizes photochemical machining and considerations for selecting processes based on workpiece geometry features, materials, and when conventional methods are impractical.
Chemical CHM - chemical machining ELP - electropolish PCM - photochemical machining TCM - thermochemical machining TEM - thermal energy machining While many processes are available, only the most commercially important processes are discussed here
Mechanical Energy Processes Ultrasonic machining (USM) Abrasives contained in a slurry are driven at high velocity against the work by a tool vibrating at low amplitude (.003in) and high frequency (20-100khz) The tool oscillates in a direction perpendicular to the workpiece surface and is fed slowly into the workpiece so that the shape of the tool is formed in the part
The action of the abrasives impinging against the work surface performs the cutting Tool materials - soft steel, stainless steel Abrasive materials - boron nitride, boron carbide, aluminum oxide, silicon carbide and diamond The vibration amplitude should be set approximately equal to the grit size, and the gap size should be maintained at about two times the grit size
Electrochemical Machining Processes Electrochemical machining (ECM) It removes metal from an electrically conductive workpiece by anodic dissolution, in which the shape of the workpiece is obtained by a formed electrode tool in close proximity to, but separated from the work by a rapidly flowing electrolyte Underlying principle: material is deplated from the anode and deposited onto the cathode in the presence of an electrolyte bath
The difference in ECM is that the electrolyte bath flows rapidly between the two poles to carry off the deplated material The electrode tool, usually made of copper, brass or stainless steel, is designed to posses approximately the inverse of the desired final shape of the part Gap distance: usually from 0.003 - 0.030 in A water solution of sodium chloride is commonly used as the electrolyte
Electrolyte serves for: Carrying off the material that has been removed from the workpiece Removing hear and hydrogen bubbles created in the chemical reactions of the process Removed material in the form of microscopic particles must be separated from the electrolyte through centrifuge, sedimentation or other means Large amount of electrical power is required to perform ECM
Voltage is kept relatively low to minimize arcing across the gap Use when: The material is very hard or difficult to machine or Where the workpiece geometry is difficult or impossible to accomplish by conventional machining methods Typical ECM applications Die sinking Multiple hole drilling Holes that are not round Deburring
Advantages: Little surface damage to the work part No burrs as in conventional machining Low tool wear Relatively high metal removal rates for hard and difficult to machine metals Disadvantages Significant cost of electrical power to drive the operation Problems of disposing of the electrolyte sludge Chemical Engraving A chemical machining process used for making flat panels that have lettering and/or artwork on one side Can be used to make raised or recessed lettering by reversing the portions of the panel to be etched Masking done by either photoresist or screen resist methods Filling operation to apply paint or other coating follows etching Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Knee Implants Figure 27.8 (a) Two total knee replacement systems showing metal implants (top pieces) with an ultra-high molecular-weight polyethylene insert (bottom pieces). (b) Cross-section of the ECM process as applies to the metal implant. Source: Courtesy of Biomet, Inc. Photochemical Machining (PCM) Chemical machining in which the photoresist masking method is used Employed in metalworking when close tolerances and/or intricate patterns are required Used extensively in electronics industry (makes VLSI possible) Photoresist materials in current use are sensitive to UV light, but not other wavelengths No need to carry out process in a darkroom Anisotropy: depth of cut d divided by undercut u; reciprocal of the etch factor A=1/F e = d/u A: degree of anisotropy F e : etch factor
Application Considerations Workpart Geometry Features Very small holes - (below 0.005 in. in diameter) use LBM Holes with large depth/diameter ratios - (d/D > 20) use ECM and EDM Nonround holes - use EDM and ECM Narrow slots that are not straight - use EBM, LBM, wire EDM, WJC and AWJC Micromachining - use PCM, LBM and EBM Shallow pockets and surface details in flat parts - use CHM and its variations Creation of special contoured shapes for mold and die applications - (die sinking) use EDM and ECM Work Materials Performance of Nontraditional Processes Nontraditional processes are generally used when conventional methods are not practical or economical
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