ANVESTIGATION INTO ELECTROCHEMICAL DISCHARGE MACHINING USING VARIOUS TOOL KINEMATIC Chapter t PRODUCTION Advanced developments in Selenee haye led to the development of new materials such ‘ax carbides, coramiles, composites, semiconductors and a variety of glasxew and lamonds, ‘These new materlali provide us with properticn not available in traditionally used materials like high strength (0 weight ratio, high slrength and aliens at elevated temperatures, high corrosion and oxidation resistance and chemical inertness, ‘The dovelopment of new materials has provided engineers with new solutions to traditional problems and have opened the gateway to new possibilities In engineering. However, those materials present thelr own challenges and complications. ‘The very properties that make them so desirable make it difficult 0 machine (howe using, traditional machining methods, hence restrieting thelr use, Hence to unlock their full potential we need to use nonetraditional machining methods, 11. Non-traditional machining processes Non-traditional machining processes (N'TM) are defined as a group of processes that use mechanical, thermal, chemical and electrochemical energies for material removal, ng, tools as in traditional machining processes. but do not use sharp cut ‘The features of non-traditional machining processes are: «Physical foo! may not be present Material removal Is not done by mechanical energy in most NIM processes © There need not be chip formation 11 physical tot is present, its usually weaker than work piece material s be employed when pigce material is too hand or fragile » Worl Shape to be machined is complex Work piece is thr foo slender and flexible (o clamp Material properties are heat sensitive 1.1 aims to give the classification of different NIM proces: Department of MechunicalINVESTIGATION INTO ELECTROCHEMICAL DISCHARGE Us YARTOUS TOOL KINEMATICS: | Nontiaditional 1 ining eS I] | { |Mechanical | | | | ee | USM | WOM | AWJM | uM [Pm Fig 1.1 Classification Chemical & lelectrochemicall + YM processes [1] Mechanical processes: In mechanical NTM processes, hydraulic pressure is used as energy source and high velocity particles act as the transmit medium, Either erosion mechanism or shearing action are responsible for material removal. Abrasive jet machining (AJM), water jet machining (WJM), ultrasonic machining (USM) are examples of mechanical processes. “The major drawbacks of these processes are low material removal rate, high equipment and maintenance costs. ‘Thermal processes: In thermal processes, melting and vaporization removes sources for the material removal ‘the work-piece material. Different processes use different sources of heat mechanism, Plasma beam machining (PBM) and electrical discharge machining (EDM) use plasma as a source of heat, electron beam machining (EBM) uses electrons and laser beam machining (LBM) uses photons. ‘The major obstacles to usage of thermal processes are the considerable equipment cost, long production time and the sizeable power supplies required. Chemical processes: In chemical processes, the surface of the work-piece is covered by a resistant material except for those regions where material must be removed. Then the work-piece is exposed to a chemical agent and material is removed from the uncovered part by the Department of Mechanical Engineering, RV College of Engineering 2INVESTIGATION INTO ELECTROCHEMICAL DISCHARGE MACHINING USING VARIOUS TOOL KINEMATICS | action of chemical etching. Photochemical machining (PCM) and chemical machining (CHM) are example of chemical NTM processes. Major deficiencies of these proces are the troublesome handling of chemicals and their disposal after the process is completed, surface defects and the inability to machine steep narrow cuts and taper. Electrochemical processes: In electrochemical processes, material is removed from the work-piece by ion displacement mechanism. High current is the source of energy and electrolyte is the transfer media. Electrochemical grinding (ECG) and electrochemical machining (ECM) are examples of electrochemical processes. Major drawbacks of these processes are the low material removal rate, difficulties related to handling of electrolyte and problems in machining sharp internal and external edges. 1.1.1. Electrical discharge machining Electrical discharge machining (EDM) is a non-traditional manufacturing method which uses electrical discharges (sparks) for material removal. This spark is generated between the tool-electrode (tool) and work-piece-electrode (work-piece), which are separated by dielectric liquid and subjected to an electrical voltage. A schematic diagram of an EDM setup is shown in Fig 1.2. As the voltage is increased the intensity of the electric field becomes greater than the dielectric, which breaks down, allowing current to pass through, creating a spark. This electric spark generates intense heat, reaching temperatures up to 12000K, melting the work-piece material and resulting in material removal. Here the tool acts as cathode while the work-piece behaves as anode. 1.1.2. Electrochemical machining Electrochemical machining (ECM) is a non-traditional machining process in which material is removed by electrolysis. The principle of ECM is reverse that of clectroplating. The tool works as cathode and the work-piece works as anode, A shaped tool is used in this process. The flow of high current at a relatively low potential difference through the electrolyte causes the work-piece to undergo anodic dissolution at the atomic level due to the tool. A schematic diagram of the ECM arrangement is shown in Fig 1.3. A major advantage of this process is that there is no contact between the tool and the electrode i.e. the machining of the work-piece is not dependent on the strength and hardness of the work-piece. Also, there is no tool wear hence the same can be used for a large number of machining operations. =e Department of Mechanical Engineering, RV College of Engineering