Tool Materials and

Non-traditional Machining Processes

ToolMaterials
Toolfailuremodesidentifytheimportant
propertiesthatatoolmaterialshouldpossess:
Toughness toavoidfracturefailure
Hothardness abilitytoretainhardnessathigh
temperatures
Wearresistance hardnessisthemostimportant
propertytoresistabrasivewear
CubicBoronNitride
Nexttodiamond,cubicboronnitride (cBN)is
hardestmaterialknown
Fabricationintocuttingtoolinsertssameas
SPD:coatingsonWCCoinserts
Applications:machiningsteelandnickelbased
alloys
SPDandcBNtoolsareexpensive
RangeofApplicableCuttingSpeedsand
FeedsforanumberofToolMaterials
.
HotHardness
CuttingFluids
Fluidsaddresstwomajorproblems:
Heatgenerationattheshearzone
Frictionatthetoolchipinterfaceandtool
workinterface
Types:
Coolants(Oilwatermixtures)
Lubricants(Speciallubricantsthatinvolves
formationofthinsolidsaltlayersonthehot
andcleanmaterialsurfacebyreaction.
CuttingFluids
Cuttingoil(petroleum,animal,vegetable
mineraloils)
Emulsifiedoils(Oildropletssuspendedinwater)
Chemicalfluids(Chemicalsinwater)
Semichemicalfluids(Smallamountsof
emulsifiedoiladdedtoincreaselubrication
characteristics
NONCONVENTIONALMACHINING
Whydoweneedit?
Veryhighhardness/strengthmaterial
Complexshapesorsmalldiameterholesasin
turbinebladesandfuelinjectionnozzles
Veryrigoroussurfacefinishanddimensional
tolerancerequirements
Temperatureandresidualstressesinthe
workpiecenotdesirable/acceptable
TurbineBladeMachining
MechanicalEnergyProcess
UltrasonicMachining (UM)
Water(WJC)andAbrasiveJetMachining
ElectricalEnergyProcesses
ElectrochemicalMachining(ECM)
ElectrochemicalGrinding(ECG)
ThermalEnergyProcesses
ElectricDischargeProcess(EDM)
ElectronBeamMachining(EBM)
LaserBeamMachining(LBM)
ChemicalProcess
ChemicalMachining(CHM)
NonConventionalMachining
Ultrasonic Machining
Tool is excited at a frequency of 20,000 Hz with a magnetostrictive transducer.
Ultrasonic Machining
Magnetostriction
Water Jet or Abrasive Water Jet Machining
A fine (0.1 0.4 mm dia.), high pressure (400 MPa), high velocity ( 900 m/s)
stream of water is directed at the work surface to cause cutting.
Plastic, Textile, Composites, Tile, Carpet, Leather and Cardboard
Water Jet or Abrasive Water Jet Machining
Complex shapes can be machined using CNC WJC
ElectrochemicalMachining(ECM)
Machiningbypassageofcurrent,thatis
electrochemicaldissolution.Itisbasicallyde
platingprocess.
Generallyusedtomachinecomplexcavities,
particularlyintheaerospaceindustryforthe
massproductionofturbineblades,jetengine
partsandnozzles
ElectrochemicalMachining(ECM)
Tool : Copper, Brass, Stainless steel
Electrolyte: NaCl solution, HCl, or H
2
SO
4
Electrolytepumpedatveryhighflowratesto
removedissolvedmetalionstoprevent
precipitationanddepositionatcathode.
DCvoltage:5 25V;Current:5 40000A
ElectrochemicalMachining(ECM)
Top:Turbineblademadeofanickelalloy
(b)Thinslotson4340steelrollerbearingcage
(c)Integralairfoilsonacompressordisk
4
3
1
2
5
ElectrochemicalMachining(ECM)
Electrochemical Machining set up at ME dept
ElectricDischargeMachining(EDM)
Basic EDM system consists of a shaped tool
and work piece connected to a DC power
supply.
Tool: Usually graphite, Brass, Cu, CuW;
Diameter can be as low as 0.1 mm
Dielectric fluid (mineral oil, kerosene, distilled
and deionized water) between tool and work
piece
Apply high enough voltage to create spark
discharges through the fluid
Small amount of material is removed from the
work piece surface
Voltage: 50 380 V; Current: 0.1 500 A
Discharge is repeated at rates between 50
and 500 kHz
ElectricDischargeMachining(EDM)
ElectricDischargeMachining(EDM)
23 . 1
T
KI
MRR =
EDMWireCutting
Uses
Productionofdiecavitiesforforlarge
automotivebodycomponents
Deepsmalldiameterholes
Narrowslotsinturbineblades
EDMWireCutting
Laser Machining
Micro pattern machined
on a steel plate
200 micron holes on
Ti6Al4V alloy
Laser Micromachining
Process
Resolution
m
Surface
Roughness m
Side Effects
Mechanical 100 6.3-1.6 Burring, requires
polishing
EDM 100 4.75-1.6 Electrode wear, rough
finish, slow and unclean
process
Chemical
Etch
250 6.3-1.6 Undercutting
LIGA 5 1-2 Synchrotron source:
very expensive
Nd: YAG
Laser
50 1 Redeposition
Excimer
Laser
5 > 1 m (nm
range)
Recast Layer, aspect
ratios
Ultrafast
Laser
< 1 nm range Higher power ranges
may require vacuum
environment
Laser Micromachining
Process
Parameters
Effect
Wavelength,
Focal length of lens
Feature size
Beam shape
(Gaussian/square
wave)
Feature shape
Beam energy,
Pulse width
Size of heat affected
zone
Depth of focus Aspect ratio
Vacuum or inert gas
environment
Amount of
redeposition, size of
recast layer
(a) Array of shots (b) Thru-hole drilled after 33 shots at a
pulse energy of 14J
Micromachining in 18m Thick Aluminum Foil
Thru-holes Drilled in 25m Thick
Brass Foil
56J /pulse 27J /pulse
ChemicalMachining
Oldestnontraditionalprocess.Usedto
engravemetalsandhardstones,and
deburring
Morerecentlyusedintheproductionof
printedcircuitboardandmicroprocessor
chips
Usestheconceptofchemicaldissolutionof
metalsformachining
ChemicalMachining
Thisisbasicallyetchingusingstrongchemical
Steps
Cleaning
Masking
Etching
Demasking
Variouspartsmadebychemicalmachining
(L) Missile skinpanel contoured by chemical machining
(R) Weight reduction of space launch vehicles by chemical machining
aluminiumalloy plates
The best of the best guys from all over the country join IITK. Now in a
competitive grading system, though the class is consisted of the best guys there
must be some guys who will not do as good as the rest... does that mean they
are not up to... ?? Assume a class consisting of Einstein, Dirac, Feynman, S N
Bose , Lagrange.... you put them in a system like this.... some of them are
definitely going to get 'F' grade. Do the present grading system .. that mostly
measure how much better or how much poorer you are compared to your
neighbor in the class... is justified enough??