Content

1. Introduction
2. Principle & Working
3. Mechanism
4. USM system
5. Application
6. Advantages & disadvantages
7. Summary
Can you imagine that?
 Ultrasonic machining
Introduction

Ultrasonic machining is a non-traditional

mechanical means of uniform stock material
removal process

It is applicable to both conductive and

nonconductive materials.

Particularly suited for very hard and/or

brittle materials such as graphite, glass,
carbide, and ceramics.
 Principal and working

• It works on the same principle of ultrasonic

welding .

• Ultrasonic machine generates high frequency

vibrating wave of frequency about 20000 to
30000 Hz and amplitude about 25-50 micron.

• This high frequency vibration transfer to

abrasive particle contains in abrasive slurry.

• This leads indentation of abrasive particle to

brittle work piece and removes metal from the
contact surface
 Principal and working
The process is performed by a cutting tool, which
oscillates at high frequency, typically in kHz, in abrasive
slurry.

The tool is gradually fed with a uniform force.

The high-speed reciprocations of the tool drive the
abrasive grains across a small gap against the
workpiece .

The impact of the abrasive is the energy principally

responsible for material removal in the form of
small wear particles that are carried away by the
abrasive slurry.

The tool material, being tough and ductile, wears out at

a much slower rate.

The shape of the tool corresponds to the shape to be

produced in the workpiece.
 Systematic diagram

Force
feed
motion
Transducer
Acoustichead/toolholder
Workpiece
Slurry to machining
zone

Slurry pump
Return slurry
Slurry tank
 USM System
Subsystems of USM System

A C

E D
 Mechanism
The basic components to the cutting action :
1

33

4
 • Abrasive :
- common types of abrasive
- boron carbide (B4C) good in general, but expensive
- silicon carbide (SiC) glass, germanium, ceramics
- corundum (Al2O3)
- diamond (used for rubies , etc)
- boron silicon-carbide (10% more abrasive than B4C)

• liquid
- water most common
- benzene
- glycerol
- oils
- high viscosity decreases MMR
5.
Process parameters and their effects
The process parameters which govern the ultrasonic machining process have
been identified and the same are listed below along with material parameters

Amplitude of vibration (a) - 15- 50 um

Frequency of vibration (f)-19-25kHz

Volume concentration of abrasive in slurry - C

Abrasive size-15-150um

Feed force (F)

Contact area of the tool - A

Feed pressure (p)

 Applications
It is mainly used for

(1) drilling

(2) grinding,

(3) Welding

(4) Used for machining hard and brittle metallic alloys, semiconductors,
glass, ceramics, carbides etc.

(5) Used for machining round, square, irregular shaped holes and surface
impressions.
 Advantages of USM
• Machining any materials regardless of their conductivity

• USM apply to machining semi-conductor such as silicon,

germanium etc.

• USM is suitable to precise machining brittle material.

• USM does not produce electric, thermal, chemical abnormal

surface.

• Can drill circular or non-circular holes in very hard materials

• Less stress because of its non-thermal characteristics

• Conductive and non-conductive materials

 Disadvantages of USM

• Low material cutting rate. (3-15mm3/min)

• It is quite slower than other mechanical process
• Tool wear is high because abrasive particle affect both work-
piece and tool..
• Machining area and depth is limited in USM.
 Various work samples machined by USM

1- The first picture on the left is a plastic sample that has inner grooves that are machined using
USM.
2- The Second picture (in the middle is a plastic sample that has complex details on the surface
3- The third picture is a coin with the grooving done by USM
 Summary of USM
• Mechanics of material removal - brittle fracture caused by impact of
abrasive grains due to vibrating at high frequency
• Medium - slurry
• Abrasives: B4C; SiC; Al2O3; diamond; 100-800 grit size
• Vibration freq. 15-30 KHz, amplitude 25-100 micro m
• Tool material soft steel , ductile
• Critical parameters - frequency, amplitude, tool material, grit size, abrasive
material, feed force, slurry concentration, slurry viscosity
• Material application - metals and alloys (particularly hard and brittle),
semiconductors, nonmetals, e.g., glass and ceramics
• Shape application - round and irregular holes, impressions
• Limitations - very low MRR, tool wear, depth of holes, and cavities small.
Supervised by: Dr. Abdullah Alharbi
Created by: Majed Bamberok
 Content

 Introduction
 Working principles
 Machine components
 process parameters
 Material removal rate
 Applications
 Advantages and disadvantages
 Reference
 Rotary Ultrasonic
Machining (RUM) is a
non-traditional
machining process that
uses ultrasonic vibrations
and abrasive slurry to
machine hard and brittle
materials . It is a
promising technology
that has the potential to
revolutionize the
manufacturing industry.
❖ Rotary Ultrasonic Machining (RUM) is an advanced machining technique
used for cutting and drilling hard and brittle materials.
❖ RUM combines the principles of ultrasonic machining and rotary motion
to achieve highly precise and efficient material removal.
❖ It is widely employed in industries such as aerospace, automotive,
electronics, and medical, where the demand for machining brittle
materials is high.
 RUM is a mechanical material removal process used to machine hard or brittle
materials by combining the ultrasonic impacts (hammering, extraction, abrasion)
and the grinding action of the diamond abrasives bonded on the tool.
 The key difference between USM and RUM is that in RUM the tool also rotates and
the tool has metal bonded diamond abrasive particles.
 Rotary Ultrasonic Machining
(RUM) is regarded as an
enhancement of UM. The basic
principle is the combination of
conventional UM and CNC
grinding/milling process. The
difference between RUM and UM
is the vibrating object. With high
frequency micro-vibrations, UM
applies in vibrating the abrasive
slurry and makes the particles
remove the materials. The
uncontrollability of liquid and the
limitation of tools and equipment
restrict the further applications of
UM.
 Rotary ultrasonic machining technology
superimposes rotational movement with
20k-40k high frequency vibrations of Z-axis
direction. The rotating diamond-coated
tooltip will directly abrade the materials to
tiny particles and they will be carried away
by coolant. RUM changes continuous
cutting to intermittent movement via low
amplitude micro-oscillations;
therefore, the tool load and the thermal
impact could be significantly
reduced. Additionally, by side and vertical
directions of feed exercised
simultaneously, the material remove rate
could be enlarged.
1) Tool:
◦ The tool is a critical component in RUM and is typically made of a hard material, such
as steel or tungsten carbide, with a diamond abrasive coating.
◦ The tool's cutting edge comes into contact with the workpiece and is responsible for
material removal.
2) Fixture:
◦ The fixture holds the workpiece securely in place during the machining process.
◦ It ensures stability and proper alignment of the workpiece, preventing unwanted
movement or vibrations.
3) Spindle:
◦ The spindle provides the rotational motion to the tool.
◦ It rotates the tool at a controlled speed, allowing for precise material removal and
surface finish.
4) Ultrasonic Transducer:
◦ The ultrasonic transducer generates high-frequency vibrations in the range of 20 kHz
to 40 kHz.
◦ It is responsible for applying axial vibrations to the tool during the machining
process.
◦ The vibrations enhance the cutting action, facilitating material removal and reducing
cutting forces.
5) Coolant System:
◦ RUM generates heat during the machining process, which can affect the
workpiece and tool.
◦ A coolant system, such as a mixture of water and lubricants, is used to cool the
cutting zone, minimizing heat buildup and preventing thermal damage.
6) Control System:
◦ The control system oversees and regulates various parameters of the RUM
process.
◦ It manages the tool speed, feed rate, ultrasonic power, coolant flow, and other
parameters to ensure optimal machining conditions.
7) Chip Evacuation Mechanism:
◦ As material is removed during RUM, chips and debris are generated.
◦ A chip evacuation mechanism, such as suction or compressed air, is employed
to remove the chips from the cutting zone, maintaining a clear path for
machining.
 Vibration The frequency of the ultrasonic vibrations is typically between
frequency: 20 kHz and 40 kHz .

The amplitude of the ultrasonic vibrations is usually between 1

Amplitude:
and 50 microns .

The feed rate is the speed at which the cutting tool moves
Feed rate:
across the workpiece. It is typically between 0.1 and 1 mm/s .

A slurry containing abrasive particles is used as a coolant to

Coolant:
remove debris and cool the workpiece .

Tool The cutting tool is typically made of a hard, abrasive material

material: such as diamond .

Tool The geometry of the cutting tool can vary depending on the
geometry: application.
 Tool
Speed

During the machining

The tool speed can vary process, the tool speed
depending on the specific can be adjusted using
machining requirements, Determining the optimal
tool speed involves the machine's spindle
workpiece material, and control system to find
tooling used. There is no considering factors such
as material hardness, the balance between
fixed "number" that efficient cutting and
represents the tool speed cutting efficiency, heat
generation, and surface minimizing heat
in RUM as it can range generation. The actual
from a few hundred RPM finish requirements. It is
typically determined tool speed used will
(revolutions per minute) depend on the specific
to several thousand RPM. through experimentation,
taking into account the conditions and material
specific application and being machined.
desired outcomes.
 (MRR) in rotary ultrasonic machining (RUM) refers to the amount of
material that is removed during a given period of time. It is a crucial
parameter that determines the efficiency and productivity of the
machining process.

is influenced by several factors, including the feed rate, tool speed,

ultrasonic power, and the properties of the workpiece material.
Material Higher feed rates and tool speeds generally result in higher
Removal
material removal rates. Additionally, higher ultrasonic power can
enhance the cutting action and contribute to a higher MRR.
Rate
is typically measured in terms of volume or weight of material
removed per unit of time (e.g., cubic millimeters per minute or
grams per minute). The actual material removal rate in RUM will
vary based on the specific application, workpiece material, tooling,
and process parameters employed.

it is important to strike a balance between achieving a high

material removal rate and maintaining the desired surface finish
and dimensional accuracy. Increasing the material removal rate too
much can result in compromised surface quality or increased tool
wear.
Aerospace Automotive Optics
Industry Industry Industry
Electronics Medical Energy
Industry Industry Industry
 Suitable for machining hard and brittle materials, such as ceramics, glass,
composites, and hardened metals.
 Precise shaping and finishing of these materials
 Excellent surface finish due to the combination of rotary motion and
ultrasonic vibrations.
 Saving time and cost.
 Higher material removal rate compared to traditional grinding or milling
processes.
 The ultrasonic vibrations in RUM help in breaking up the chips and reducing
the contact between the tool and the workpiece. This leads to reduced tool
wear, extended tool life, and lower tooling costs.
 Complex and intricate geometries with high precision
 Requires specialized equipment that incorporates ultrasonic
transducers, rotary spindles, and control systems.
 Not effective for soft materials, as it is for hard and brittle
materials.
 Setting up and fine-tuning the process can be complex and
time-consuming.
 Large or bulky workpieces may pose challenges in
implementing RUM effectively.
 Rotary Ultrasonic Machining Ultrasonic Machining
Aspect
(RUM) (USM)
Machining Combination of rotary and ultrasonic
Vibrational motion of the tool
Mechanism motion

Cutting Grinding action through abrasive Chipping or erosion action through

Action particles abrasive slurry

Hard tool with abrasive working Soft tool made of materials like tool
Tooling
surface steel or titanium

Material Suitable for softer materials, less

Efficient for hard and brittle materials
Removal effective for hard ones

Aerospace, automotive, medical, Electronics, microfabrication, mold-

Applications
electronics, optics making, softer materials
 https://core.ac.uk/download/pdf/322824582.pdf
 https://slideplayer.com/slide/14591458/
 https://www.hit-tw.com/newsdetails.aspx?nid=262
 https://link.springer.com/referenceworkentry/10.100
7/978-1-4471-4670-4_76
 https://www.numerade.com
LASER BEAM MACHINING

Jeddah College of Technology

2023
 CONTENT
Introduction

Working principle

Types of laser

Parameter Affecting

Advantages & Disadvantages

Applications

References
 INTRODUCTION
Laser beam machining is a non-conventional machining method in which the operation is
performed by laser light. The laser light has maximum temperature strikes on the workpiece, due
to high temp the workpiece melts. The process uses thermal energy to remove material from a
metallic surface

Since the rays of a laser beam are monochromatic and parallel it can be focused to a very small
diameter and can produce energy as high as 100 MW of energy for a square millimeter of area.

Lasers can be used to cut, drill, weld and mark. LBM is particularly suitable for making accurately
placed holes.
The underline working principle of laser was first put forward
by Albert Einstein in 1917 though the first industrial laser for
experimentation was developed around 1960s

ALBERT EINSTEIN THEODORE HAROLD MAIMAN

 HISTORY

• The underline working principle of laser was first put forward by Albert
Einstein in 1917.
• In 1965, the first production laser cutting machine was used to drill holes in
diamond dies. This machine was made by the Western Electric Engineering
Research Center.
• In 1967, the British pioneered laser-assisted oxygen jet cutting for metals.
• In the early 1970s, this technology was put into production to cut titanium for
aerospace applications. At the same time CO2 lasers were adapted to cut
non-metals, such as textiles, because, at the time, CO2 lasers were not
powerful enough to overcome the thermal conductivity of metals.
 WORKING PRINCIPLE

• Laser Beam Machining works on the principle of conversion

of electrical energy of flash lamp into heat energy to emit the
laser beam by pumping the energy

• Laser Beam is focused on a lens to give high energy to helps

the melting of metal. It works on the principle that when a
high temperature laser beam strikes on the workpiece, the
metal starts melting due to high temperature and high speed.

• The high frequency of monochromatic light will fall on the

surface then heating, melting, and vaporizing of the material.
Laser Beam Machine !
 MAIN PARTS

The various main parts used in the laser beam machining are

Capacitor
Workpiece

Lenses
Flash Tube/Flash Lamp:

Reflecting Mirror

Power Supply
Power Supply
A high voltage is required for Laser to work.

Flash Lamps
Flash lamps are used for providing white and coherent light for a very short duration.

Capacitor
A capacitor is used for storing and releasing the charge.

Reflecting Mirror
A reflecting Mirror is used to reflect the light directly toward the workpiece.

Lenses

Lenses are provided for vision purposes. It shows the image in a bigger size so that it will be easy to operate
on the given workpiece.
Workpiece
• In laser beam machining, a variety of laser types are employed, each suited for specific
applications. The choice of laser depends on several factors, including the material being
machined, the desired precision, and the specific machining process

Gas
Lasers

Types
of
Excimer Laser Solid
State
Lasers
 PARAMETER AFFECTING
The process of laser cutting involved many parameters, which can be generally divided into two main categories—
beam parameters and process parameters

power, continue
types of wave and
Beam wavelength intensity and
spot size beam pulsed
parameters power

focusing of process stand-off Nozzle cutting

Process laser
beams
gas and
pressure distance diameter, speed
parameters
 Advantages Disadvantages

Requires
Non Contact specially trained
operators
Any Material holes Not for mass
material can no tool wear may be taper metal removal
be from entry to processes
machined exit.

Complex heat-
surface can affected Consumes much life of the flash
be zone is very energy lamp is short
produced small
production Expensive
rate is high equipment
 APPLICATIONS
-

Heavy Manufacturing
Seam &
spot -
welding Engraving
Drilling -

Electronics
-
holes as

Light Manufacturing
Cladding Skiving of
small as circuits - Cosmetic

Medical
& drilling
0.005 mm -Surgery
-
Wire -Hair
stripping removal
 CONCLUSION

• In conclusion, laser beam machining has emerged as a highly effective and

efficient technique for precision cutting and drilling of various materials. With
its ability to achieve high levels of accuracy and precision, laser beam
machining has become increasingly popular in various industries such as
aerospace, automotive, and medical.
 REFERENCES

• http://www.google.com
• http://en.wikipedia.org/wiki/laser_cutting
• http://osp.mans.edu.eg/s-hazem/NTM/LBM.html
• https://en.wikipedia.org/wiki/Laser_beam_machining
• http://web.iitd.ac.in/~suniljha/LaserBeamMachining.pdf
PLASMA ARC MACHINING

Presented by
Abdullah Alharbi
Jeddah College of Technology
 CONTENTS
• Introduction
• Working Principle of PAM
• Process Details of PAM
• Material Removal Rate
• Applications of PAM
• Advantages of PAM Process
• Disadvantages of PAM Process
• Conclusion
 INTRODUCTION
What is Plasma?

Plasma is often called the fourth state of the matter. The first three are:
• Solid
• Liquid
• Gas
 What is Plasma Arc Machining?

Plasma arc machining is a metal removal process in which the metal is removed by
focusing a high-velocity jet of high temperature

•If a gas is heated to a temperature of more than 5500 ° C

•The gas is partially ionized and turns into positive ions, negative ions and
neutral ions and this mixture is termed as plasma
•Further heat the gas above 11000ºC then, it completely ionises.
•When such an ionized gas is directed on the workpiece through a high
velocity jet, the metal is removed by melting
•The plasma arc machining process is used for cutting alloy steels,
stainless steel, cast iron, copper, nickel, titanium, and aluminum, etc.
History of PAM
Working Principle of PAM

• In the plasma arc machining process, the

material is removed by directing a high-

velocity jet of ionized gas at high

temperatures (11000 ° C to 28,000 ° C)

on the workpiece.

• This high-temperature plasma jet melts

the contents of the workpiece.

PROCESS DETAILS OF PAM
 PROCESS DETAILS OF PAM
❑ Plasma Gun
• The plasma gun consists of a tungsten electrode fitted in the
chamber.
• The electrode is given negative polarity and nozzle of the gun
is given positive polarity.
• A strong arc is established between the two terminals anode
and cathode.
• There is a collision between molecules of gas and electrons
of the established arc.
• As a result of this collision, Gas molecules get ionized and
plasma state is formed.
• This hot and ionized gas called plasma is directed to the
workpiece with high velocity
 Power Supply and Terminals
❑ Power supply (DC) is used to develop two terminals
in the plasma gun.

❑ A tungsten electrode is inserted to the gun and made

cathode and nozzle of the gun is made anode.

❑ Heavy potential difference is applied across the

electrodes to develop plasma state of gases.
 Cooling Mechanism
❑ Hot gases continuously comes out of nozzle so
there are chances of its over heating.

❑ A water jacket is used to surround the nozzle

to avoid its overheating.

Work piece
❑ Work piece of different materials can be
processed by PAM process.
❑ Ex: aluminum, magnesium, stainless steels
and carbon and alloy steels.
 WORKING OF PAM
❑ When a D.C power is given to the circuit, a strong arc is produced between the electrode
(cathode) and the nozzle (anode).

❑ A gas usually hydrogen (H2) or Nitrogen (N2) is passed into the chamber.

❑ This gas is heated to a sufficiently high temperature of the order of 11,000°C to 28,000°C by
using an electric arc produced between the electrode and the nozzle.

❑ In this high temperature, the gases are ionized and a large amount of thermal energy is
liberated.

❑ This high velocity and high-temperature ionized gas (plasma) is directed on the workpiece
surface through the nozzle.

❑ This plasma jet melts the metal of the workpiece and the high-velocity gas stream effectively
blows the molten metal away.

❑ The heating of workpiece material is not due to any chemical reaction, but due. to the
continuous attack of plasma on the workpiece material. So, it can be safely used for machining
of any metal including those which can be subjected to the chemical reaction.
MATERIAL REMOVAL RATE
 Applications of PAM

❑ used in mill applications

❑ It is also used in the nuclear submarine pipe system.

❑ Used in welding of stainless steel tubes.

❑ Used in welding rocket motor case.

❑ It is used for profile cutting.

 Advantages of PAM Process

▪ It gives faster production rate.

▪ Very hard and brittle metals can be

machined.

▪ Small cavities can be machined with good

dimensional accuracy.

▪ It can be applied to almost all types of metal

 Disadvantages of PAM Process

▪ Its initial cost is very high.

▪ It is uneconomical for bigger cavities to be
machined.
▪ Inert gas consumption is high.
▪ The process requires over safety precautions which
further enhance the initial cost of the setup.
▪ Some of the workpiece materials are very much
prone to metallurgical changes on excessive heating
 Conclusion
❑ Plasma Arc Machining (PAM) is one such advanced machining process
where thermal energy (heat) is primarily used to melt down and
vaporize material from the workpiece.

❑ A high temperature jet of thermal plasma is first obtained by intensely

heating a suitable gas (such as air, helium, nitrogen, argon) with the
help of an electric arc.

❑ This high velocity plasma jet is then directed towards the workpiece
using a nozzle. PAM plasma temperature can reach 20,000°C or even
more.

❑ When the plasma jet having such a high temperature strikes the work
surface, the workpiece material at that spot quickly melts down and
vaporizes owing to this extreme temperature of the plasma.

❑ PAM can be applied to electrically conductive as well as non-

conductive materials