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Chemical Machining Processes

Mechanical energy processes use mechanical energy rather than conventional cutting tools to remove material. These processes include ultrasonic machining, water jet cutting, abrasive water jet cutting, and abrasive jet machining. Ultrasonic machining uses a tool vibrating at high frequency to drive abrasives against the workpiece. Water jet cutting uses a high pressure stream of water, while abrasive water jet cutting adds abrasive particles to cut metals. Abrasive jet machining uses a high velocity gas stream carrying abrasives to remove material through finishing processes like deburring.

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67 views

Chemical Machining Processes

Mechanical energy processes use mechanical energy rather than conventional cutting tools to remove material. These processes include ultrasonic machining, water jet cutting, abrasive water jet cutting, and abrasive jet machining. Ultrasonic machining uses a tool vibrating at high frequency to drive abrasives against the workpiece. Water jet cutting uses a high pressure stream of water, while abrasive water jet cutting adds abrasive particles to cut metals. Abrasive jet machining uses a high velocity gas stream carrying abrasives to remove material through finishing processes like deburring.

Uploaded by

MuhammadHamza
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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REG NO.

14PWMEC3789

MECHANICAL ENERGY PROCESSES


Erosion of the work material by a high velocity stream of abrasives or fluid (or both) is a typical
form of mechanical action in these processes. Mechanical energy in some form other than the
action of a conventional cutting tool is used in these nontraditional processes.
Mechanical energy processes are:
1. Ultrasonic machining
2. Water jet cutting
3. Abrasive water jet cutting
4. Abrasive jet machining

1. Ultrasonic Machining:
Ultrasonic machining (USM) is a nontraditional machining process in which abrasives
contained in a slurry are driven at high velocity against the work by a tool vibrating at low
amplitude and high frequency. The amplitudes are around 0.075 mm (0.003 in), and the
frequencies are approximately 20,000 Hz. The tool oscillates in a direction perpendicular to
the work surface, and is fed slowly into the work, so that the shape of the tool is formed in
the part.
Applications:
a. Work materials can be hard and brittle such as ceramics, glass, and carbides
b. Work materials can be certain metals, such as stainless steel and titanium
c. Shapes include non-round holes, holes along a curved axis
d. “Coining operations” - pattern on tool is imparted to a flat work surface

2. Water Jet Cutting:


Water jet cutting (WJC) uses a fine, high-pressure, high-velocity stream of water directed at
the work surface to cause cutting of the work. To obtain the fine stream of water a small
nozzle opening of diameter 0.1 to 0.4 mm (0.004 to 0.016 in) is used. To provide the stream
with sufficient energy for cutting, pressures up to 400 MPa(60,000 lb/in2) are used, and the
jet reaches velocities up to 900 m/s(3000 ft/sec).
Applications:
a. Usually automated by CNC or industrial robots to manipulate nozzle along desired
trajectory
b. Used to cut narrow slits in flat stock such as plastic, textiles, composites, floor tile,
carpet, leather, and cardboard
c. Not suitable for brittle materials (e.g., glass)
d. WJC advantages: no crushing or burning of work surface, minimum material loss, no
environmental pollution, and ease of automation

3. Abrasive Water Jet Cutting:


When WJC is used on metallic workparts, abrasive particles must usually be added to the jet
stream to facilitate cutting. This process is therefore called abrasive water jet cutting
(AWJC). Introduction of abrasive particles into the stream complicates the process by adding
to the number of parameters that must be controlled.
REG NO. 14PWMEC3789

Applications:
a. Abrasive water jets provide extremely accurate cuts with a high degree of repeatability
over a wide range of materials and shapes.
b. Abrasive water jets are ideal for cutting metals, stone, ceramic tile, glass, plastic and
other hard materials.
c. Abrasive water jet cutting machines use a combination of water and garnet to cut through
materials considered "unmachineable" by conventional cutting methods.
d. Abrasive water jet cutting avoids thermal damage or heat-affected zones which can
adversely affect metallurgic properties in materials being cut.

4. Abrasive Jet Machining:


Abrasive jet machining (AJM) is a material removal process caused by the action of a high
velocity stream of gas containing small abrasive particles. The gas is dry, and pressures of
0.2 to 1.4 MPa (25 to 200 lb/in2) are used to propel it through nozzle orifices of diameter
0.075 to 1.0 mm(0.003 to 0.040 in) at velocities of 2.5 to 5.0 m/s (500 to 1000 ft/min). Gases
include dry air, nitrogen, carbon dioxide, and helium.
Applications:
a. Usually performed manually by operator who directs nozzle
b. Normally used as a finishing process rather than cutting process
c. Applications: deburring, trimming and deflashing, cleaning, and polishing
d. Work materials: thin flat stock of hard, brittle materials (e.g., glass, silicon, mica,
ceramics)

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