CLASSIFICATION OF UCM
PROCESSES:
1. Mechanical Processes
• Abrasive Jet Machining (AJM)
• Abrasive Water Jet Machining (AWJM)
• Water Jet Machining (WJM)
• Ultrasonic Machining (USM)
Electrochemical Processes
Electrochemical Machining (ECM)
Electro Chemical Grinding (ECG)
Electro Jet Drilling (EJD)
Electro-Thermal Processes
Electro-discharge machining (EDM)
Laser Jet Machining (LJM)
Electron Beam Machining (EBM)
Chemical Processes
Chemical Milling (CHM)
Photochemical Milling (PCM)
BRIEF OVERVIEW
1. ULTRA SONIC MACHINING
USM is a mechanical material removal process in which the material is removed by
repetitive impact of abrasive particles carried in liquid medium on to the work surface,
by a
shaped tool, vibrating at ultrasonic frequency.
2 .ABRASIVE JET MACHINING
It is the material removal process where the material is removed or machined by the
impact erosion of the high velocity stream of air or gas and abrasive mixture, which is
focused
on to the work piece.
LASER BEAM MACHINING
Laser-beam machining is a thermal material-removal process that utilizes a high-
Energy,
Coherent light beam to melt and vaporize particles on the surface of metallic and
non- Metallic work
pieces. Lasers can be used to cut, drill, weld and mark. LBM is particularly
suitable for making
accurately placed holes
ELECTRON BEAM MACHINING
It is the thermo-electrical material removal process on which the material is
removed by the high velocity electron beam emitted from the tungsten filament
made to
impinge on the work surface, where kinetic energy of the beam is transferred to
the work
piece material, producing intense heat, which makes the material to melt or
vaporize it locally.
ELECTRO CHEMICAL MACHINING
It is the controlled removal of metals by the anodic dissolution in an electrolytic
medium, where
the work piece (anode) and the tool (cathode) are connected to the electrolytic
circuit, which is kept,
immersed in the electrolytic medium
ELECTO CHEMICAL GRINDING
ECG is the material removal process in which the material is removed by the
combination of
Electro- Chemical decomposition as in ECM process and abrasive due to
grinding.
7. PLASMA ARC MACHINING
Plasma is defined as the gas, which has been heated to a sufficiently high
temperature to
Become ionized.
Unit II :MECHANICAL ENERGY
BASED MACHINING
ABRASIVE JET MACHINING (AJM)
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, generally, the abrasive particles of around 50 μm grit size would impinge
on the work material at velocity of 200 m/s from a nozzle of I.D. of 0.5 mm with
a standoff distance of around 2 mm. The kinetic energy of the abrasive particles
would be sufficient to provide material removal due to brittle fracture of the work
piece or even micro cutting by the abrasives.
SCHEMATIC DIAGRAM OF AJM
Process Parameters and Machining
Characteristics
Abrasive: Material – Al2O3 / SiC / glass beads
Shape – irregular / spherical
Size – 10 ~ 50 μm
Mass flow rate – 2 ~ 20 gm/min
Carrier gas : Composition – Air, CO2, N2 Density – Air ~ 1.3kg/m3
Velocity – 500 ~ 700m/s
Pressure – 2 ~ 10 bar Flow rate – 5 ~ 30 lpm
Abrasive Jet : Velocity – 100 ~ 300 m/s
Mixing ratio – mass flow ratio of abrasive to gas
Stand-off distance – 0.5 ~ 5 mm
Impingement Angle – 600 ~ 900 Nozzle :
Material – WC
Diameter –(Internal) 0.2 ~ 0.8 mm
Life–10~300hours Modelling of material removal
Material removal in AJM takes place due to brittle fracture of the work material
due to impact of high velocity abrasive particles.
Modelling has been done with the following assumptions:
a) Abrasives are spherical in shape and rigid. The particles are characterized by the
mean grit diameter
b) The kinetic energy of the abrasives are fully utilized in removing material
c) Brittlematerialsareconsideredtofailduetobrittlefractureandthefracturevolumeis
considered to be hemispherical with diameter equal to choral length of the
indentation
Water Jet Machining (WJM)
Introduction
Water jet cutting can reduce the costs and speed up the processes by eliminating
or reducing expensive secondary machining process. Since no heat is applied on
the materials, cut edges are clean with minimal burr. Problems such as cracked
edge defects, crystallisation, hardening, reduced weald ability and machinability
are reduced in this process.
Water jet technology uses the principle of pressurizing
water to extremely high pressures, and allowing the water
to escape through a very small opening called “orifice” or
“jewel”. Water jet cutting uses the beam of water exiting
the orifice to cut soft materials. This method is not suitable
for cutting hard materials. The inlet water is typically
pressurized between
1300 – 4000 bars. This high pressure is forced through a
tiny hole in which is typically to 0.4 mm in diameter. A
picture of water jet machining process
WATER JET MACHINING PROCESS
Water jet cutting Technology Continue:
Applications
Water jet cutting is mostly used to cut lower strength materials such as wood,
plastics and aluminium. When abrasives are added, (abrasive water jet cutting)
stronger materials such as steel and tool steel.
Advantages of water jet cutting
a) There is no heat generated in water jet cutting; which is especially useful for
cutting tool steel and other metals where excessive heat may change the properties
of the material.
b) Unlike machining or grinding, water jet cutting does not produce any dust or
particles that are harmful if inhaled.
c) Other advantages are similar to abrasive water jet cutting
Disadvantages of water jet cutting
a) One of the main disadvantages of water jet cutting is that a limited number of materials can
be cut economically.
b) Thick parts cannot be cut by this process economically and accurately
c) Taper is also a problem with water jet cutting in very thick materials. Taper is when the jet
exits the part at different angle than it enters the part, and cause dimensional inaccuracy.
ABRASIVE WATER-JET
MACHINING (AWJM)
Introduction
Abrasive water jet cutting is an extended version of water jet cutting; in which the
water jet contains abrasive particles such as silicon carbide or aluminium oxide in
order to increase the material removal rate above that of water jet machining.
Almost any type of material ranging from hard brittle materials such as ceramics,
metals and glass to extremely soft materials such as foam and rubbers can be cut
by abrasive water jet cutting. The narrow cutting stream and computer controlled
movement enables this process to produce parts accurately and efficiently.
This machining process is especially ideal for cutting
materials that cannot be cut by laser or thermal cut.
Metallic, non-metallic and advanced composite
materials of various thicknesses can be cut by this
process. This process is particularly suitable for heat
sensitive materials that cannot be machined by
processes that produce heat while machining.
The schematic of abrasive water jet cutting is shown in
Figure which is similar to water jet cutting apart from some
more features underneath the jewel; namely abrasive,
guard and mixing tube. In this process, high velocity water
exiting the jewel creates a vacuum which sucks abrasive
from the abrasive line, which mixes with the water in the
mixing tube to form a high velocity beam of abrasives.
SCHEMATIC OF AWJM
Applications
Abrasive water jet cutting is highly used in aerospace, automotive and
electronics industries. In aerospace industries, parts such as titanium
bodies for military aircrafts, engine components (aluminium, titanium,
and heat resistant alloys), aluminium body parts and interior cabin parts
are made using abrasive water jet cutting.
In automotive industries, parts like interior trim (head liners, trunk
liners, door panels) and fibre glass body components and bumpers are
made by this process. Similarly, in electronics industries, circuit boards
and cable stripping are made by abrasive water jet cutting.
Advantages of abrasive water jet cutting
In most of the cases, no secondary finishing required
a) No cutter induced distortion
b) Low cutting forces on work pieces
c) Limited tooling requirements
d) Little to no cutting burr
e) Typical finish 125-250microns
f) Smaller kerf size reduces material wastages
a) No heat affected zone
b) Localizes structural changes
c) No cutter induced metal contamination
d) Eliminates thermal distortion
e) No slag or cutting dross
f) Precise, multi plane cutting of contours, shapes, and bevels of any angle.
