Special Manufacturing Processes

Dr. Kishor Kumar Gajrani

IIIT DM Kancheepuram, Chennai

Department of Mechanical Engineering

Indian Institute of Information Technology, Design and Manufacturing, Kancheepuram

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MEC333T Special Manufacturing Processes 3-0-0-3
Classification and Mechanical unconventional machining processes (14L)

An overview of unconventional machining, need, classification and selection. Process that make
use of mechanical energy such as ultrasonic machining, water jet and abrasive jet machining
methods with applications

Electrochemical and chemical processes (14L)

Electrochemical and chemical metal removing processes such as electrochemical machining,

electrochemical honing, electrochemical grinding, and chemical machining

Thermal processes (14L)

Thermal metal removal processes methods like plasma arc machining, neutral particle etching,
electric discharge machining, hot machining, electron beam machining and laser beam
machining 2
Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Referred Books, Grading Policy and Important Dates
Text books (Essential Readings):
• P. C. Pandey and H. S. Shan, Modern Machining Processes, 1st edition, McGraw Hill, 2013,
ISBN: 9780070965539.
• V. K. Jain, Advanced Machining Processes, Allied Publishers Pvt. Ltd., 2018. ISBN: 81-
7764-294-4
References:
• F. Gary, Nontraditional Manufacturing Processes, 1st edition, CRC Press, 1987, ISBN:
9780824773526.
• Boothroyd, G. (1989). Non-conventional machining processes. Fundamentals of Machining
and Machine Tools, 491.
Tentative grading policy:
Mid Sem: 30 percent
Project/Assignment: 30 percent Academic dishonesty:
End Sem: 40 percent
ZERO tolerance
Tentative important dates: Will be awarded “U” grade
Mid Sem: 08-March-2022
Project report submission: 01-April-2022
Project presentation: 09-April-2022 3
Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Project Titles
Latest techniques or advanced… Latest techniques or advanced…
• Ultrasonic machining (USM) • Abrasives for unconventional machining
• Abrasive jet machining (AJM) • Abrasive flow finishing processes (AFF)
• Water jet machining (WJM) • Rotational abrasive flow finishing
• Abrasive water jet machining (AWJM) (RAFF)
• Chemical machining (CM) • Magnetorheological abrasive flow
• Electrochemical machining (ECM) finishing process (MRAFF)
• Plasma arc machining (PAM)
• Electric discharge machining (EDM)
• Students in each group: 2
• Hot machining (HM)
• 2 groups can select same topic but
• Electron beam machining (EBM)
their work should be entirely
• Laser beam machining (LBM)
different
• Focused ion beam machining (FIBM)
• Topic selection: first come first fix
• Electrochemical discharge machining (ECDM)
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Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Introduction
Manufacturing processes

• Primary manufacturing
• Secondary manufacturing

Primary manufacturing processes

 Provide basic shape and size to the material as per requirement
 Examples: Casting, forming, rolling, forging, powder metallurgy

Secondary manufacturing processes

 Provide the final shape and size with tighter control on dimension, surface characteristics
etc.
 Material removal processes are mainly the secondary manufacturing processes
 Examples: Conventional and unconventional manufacturing processes

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Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Machining
• Machining is any of various processes in which a piece of raw material is cut into a desired
final shape and size by a controlled material-removal process.

Machining characteristics:

• Metal removal rate

• Tolerance maintained
• Surface finish obtained
• Depth of surface damage
• Power required for machining
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Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Secondary Manufacturing Processes
Material removal/Machining processes

Conventional machining Unconventional machining

Conventional machining

• It involves the direct contact of tool and work piece

• It can be defined as a process using mechanical (motion) energy

• It has many disadvantages like tool wear, gives lower surface finish etc.

Examples: Turning, drilling, boring, shaping, broaching, slotting, grinding etc.

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Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Unconventional Machining
• It does not required the direct contact of tool and workpiece
• Surface finish or tolerance better than those obtainable with conventional processes
• It utilizes various forms of energy such as mechanical, electrical, chemical, thermal, etc.

Examples: Merits

• Ultrasonic machining (USM) • High accuracy and surface finish

• Water jet machining (WJM) • Less / no wear
• Abrasive jet machining (AJM) • Tool life is more
• Chemical machining (CM) • Quieter operation
• Electrochemical machining (ECM)
• Plasma arc machining (PAM) Demerits
• Electric discharge machining (EDM) • High cost
• Hot machining (HM) • Complex set-up
• Electron beam machining (EBM) • Skilled operator required
• Laser beam machining (LBM) 8
Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Unconventional Machining
• Various forms of energy used in unconventional machining operations
 Mechanical: Erosion of the work material by a high velocity stream of abrasives or fluids
 Electrochemical/Chemical: Mechanism is reverse of electroplating
 Chemical: Most materials (specifically metals) are susceptible to chemical attack by certain
acids or other etchants
 Thermal: the thermal energy is applied to a very small portion of the work surface, causing that
portion to be removed by fusion and/or vaporization of the material.
Unconventional machining processes

Mechanical Chemical/Electrochemical Electro-thermal

 Ultrasonic machining • Chemical machining • Plasma arc machining
 Water jet machining • Electrochemical machining • Electric discharge machining
 Abrasive jet machining • Hot machining
• Electron beam machining
• Laser beam machining 9
Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Ultrasonic Machining (USM)
Unconventional machining processes

Mechanical Chemical/Electrochemical Electro-thermal

 Ultrasonic machining
 Water jet machining
 Abrasive jet machining

1. Ultrasonic machining (USM) https://www.youtube.com/watch?v=Xt5Oo8vsmn8

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Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Ultrasonic Machining (USM)
Workpiece Abrasive slurry
Fixture Transducer
Tool
Base
Tool motion

Abrasive slurry

Image courtesy: Shivansh Dhaka

 The basic USM process involves a tool (made of a ductile and tough material) vibrating with
a low amplitude and very high frequency and a continuous flow of an abrasive slurry in
the small gap between the tool and workpiece
 The tool is gradually fed with a uniform force
 The impact of the hard abrasive grains fractures the hard and brittle work surface, resulting
in the removal of the work material in the form of small worn out particles
 The tool material being tough and ductile worn out at a much slower rate 11
Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Ultrasonic Machining (USM): Abrasives
Abrasives

Image courtesy: Alsoufi, M. S. (2017). State-of-the-Art in abrasive water jet cutting technology and the promise for micro-and nano machining. International
Journal of Mechanical Engineering and Applications, 5(1), 1. 12
Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Abrasives
Abrasive Particles:
• The abrasive should have a sharp and irregular shape

• Fine enough to remain suspended in slurry

• It should have excellent flow characteristics

• The most common abrasives are silicon carbide (SiC), boron carbide (B4C), Corrundum

(Al2O3) and diamond

• Al2O3 is usually used for cleaning, cutting and deburring operations, SiC is for similar

applications as Al2O3 but for harder material

• B4C is generally used for cleaning, cutting and deburring of soft materials. It is the best and

most efficient among the rest but it is expensive.

• Glass beads are usually used for matt finish operations.

• Water is the most commonly used fluid for abrasive slurry 13

Dr. Kishor Kumar Gajrani IIITDM Kancheepuram SiC
 Abrasives
Abrasive

• Size in the range of 5 to 15 micrometer (µm)

• Small size for cleaning and polishing

• Large size for cutting operations

Reuse

• Reuse of the particles is not recommended

• Cutting ability will be reduced

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Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Basic Mechanical Structure of USM
• The basic mechanical structure of an USM is very similar to a drill press.
• However, it has additional features to carry out USM of brittle work material.

 The typical elements of

an USM are:
 Slurry delivery and
return system
 Feed mechanism to
provide a downward
feed force on the
tool during
machining
 The transducer,
which generates the
ultrasonic vibration
Schematic view of an Ultrasonic machine 15
Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Mechanics of Ultrasonic machining
 The reasons for material removal in an USM process are as follows:
• The hammering of the abrasive particles on the work surface by the tool.
• The impact of free abrasive particles on the work surface.
• The erosion due to cavitation.
• The chemical action associated with the fluid used.
M. C. Shaw’s model of ultrasonic machining mechanics
In this model the direct impact of the tool on the grains in
contact with the workpiece is taken into consideration.
Also, the assumptions made are:
 The rate of work material removal is proportional to the
 Volume of the work material per impact
 Number of particles making impact per cycle
 Frequency (number of cycles/unit time)
 All impacts are identical
 All abrasive grains are identical and spherical in shape 16
Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Mechanics of Ultrasonic machining
Volume of work material removal rate (Q):
QαVZv
where, V represents volume of the work material per impact
Z denotes the number of particles making impact per cycle
v is the frequency
Various tool positions during a USM cycle

 The position ‘A’ indicates the instant when tool face touches the abrasive grain.
 The period of movement from ‘A’ to ‘B’ represents the impact.
 The indentations caused by the grain on the tool (the total indentation).

Image courtesy: Advanced Machining Processes by V. K. Jain 17

Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Mechanics of Ultrasonic machining
Indentations of tool and work surface at bottom position of the tool:

Image courtesy: Advanced Machining Processes by V. K. Jain 18

Dr. Kishor Kumar Gajrani IIITDM Kancheepuram
 Happy Learning!

Dr. Kishor Kumar Gajrani IIITDM Kancheepuram 19