Advanced material removal processes

What is the advanced machining process?

Advanced machining processes are the material-removing processes different from
conventional machining processes, in which a well-guided wedge-shaped tool
removes the material in the form of chips by producing contact stresses. There are a
variety of ways in which material is removed using these processes

1. McNeil, I. (1990). Introduction: Basic tools, devices and mechanisms. In I.

McNiel (Eds.), An encyclopedia of the history of technology (pp. 1–43).
Routledge, London.
2. Jadoun, R. S., Kumar, P., Mishra, B. K., & Mehta, R. C. S. (2006).
Manufacturing process optimisation for tool wear rate in ultrasonic drilling
of engineering ceramics using the Taguchi method. International Journal of
Machining and Machinability of Materials, 1, 94–
114. https://doi.org/10.1504/IJMMM.2006.010660.

3. Kennedy, D. C., & Grieve, R. J. (1975). Ultrasonic machining—A

review. Production Engineer, 54, 481–
486. https://doi.org/10.1049/tpe:19750245.

Which material removal process is also known as an advanced material

removal process?
nontraditional machining process
The non-traditional machining process is also known as advanced material removal process. The
Nontraditional machining process are generally non-mechanical, don't produce chips or a lay pattern
on the work surface and often involves new energy modes.

What are the three basic categories of material removal processes?

conventional machining, (2) abrasive processes, and (3) nontraditional processes.

What are the three main electrochemical processes used for material removal?
The three types are electrochemical machining, deburring, and grinding.

1 Why are the nontraditional material removal processes important?

. Reasons for importance of are nontraditional material removal processes (1) the
need to shape new metal alloys and non-metals that are difficult to machine by
conventional processes;

(2) the requirement of unusual and complex work part geometries; and (3) the need
to avoid surface damage which is often associated with conventional machining.

There are four categories of nontraditional machining processes, based on principal

energy form. Name the four categories.
. The four categories are:

(1) mechanical, but not including conventional machining;

(2) electrical; (3) thermal; and (4) chemical.

3 How does the ultrasonic machining process work?

. In ultrasonic machining, abrasives contained in a slurry are driven at high velocity

against the work by a tool vibrating at low amplitude and high frequency. 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. The abrasives, impinging
against the work surface, perform the chip removal.

4 Describe the water jet cutting process.

. Water jet cutting uses a high-pressure, high-velocity stream of water directed at the
work surface to cut the work.

5 What is the difference between water jet cutting, abrasive water jet cutting, and
abrasive jet cutting?
. WJC cuts with a narrow, high velocity water stream; AWJC adds abrasive grits to
the
water stream; and AJM cuts with abrasive particles that have been added to a high
velocity air
stream.
6 Name the three main types of electrochemical machining.
. The three types are electrochemical machining, deburring, and grinding.
7 Identify the two significant disadvantages of electrochemical machining.
. Disadvantages of ECM include (1) cost of electrical power to operate the process,
and (2) cost of disposal of electrolyte sludge.

8 How does increasing discharge current affect metal removal rate and surface
finish in electric
discharge machining?
. As discharge current increases, metal removal rate increases and surface finish is
degraded.

9 What is meant by the term overcut in electric discharge machining?

. Overcut refers to the gap between the electrode (tool) in EDM on each side of the
tool and the machined hole, cavity, or kerf (in wire EDM).

10 Identify two major disadvantages of plasma arc cutting.

. Two disadvantages of PAC are (1) rough surface on cut edge and (2) metallurgical
damage to cut surface.

11 What are some of the fuels used in oxyfuel cutting?

. Principal fuels are acetylene, MAPP (methylacetylene-propadiene), propylene,
propane, and natural gas.

12 Name the four principal steps in chemical machining.

. The four steps are (1) cleaning, (2) masking, (3) etching, and (4) demasking.
13 What are the three methods of performing the masking step in chemical
machining?
. The three masking methods are (1) cut and peel, (2) screen resist, and (3)
photographic resist.
14 What is a photoresist in chemical machining?
. A photoresist is a masking material that is sensitive to light. When exposed, it
chemically transforms and can be removed from the surface of the work, leaving the
desired surface unprotected by the maskant.

15 (Video) What are the three layers of a part's surface after undergoing EDM.
: The three layers are the following: (1) Spheres attached to the surface made of
part material and electrode material that have spattered the surface. This layer is
easily removed.
(2) Recast or white layer where EDM has altered the workpiece metallurgical
structure. It can be reduced by specifying the proper settings and removed by
polishing.

(3) Heat affected zone or annealed layer. It has only been heated, not melted.

16 (Video) What are two other names for ram type EDMs?
: A ram type EDM machines is also called a die sinker and a vertical EDM machine.
17 (Video) Name the four subsystems in a RAM EDM process.
: The four subsystems in a RAM EDM process are (1) power supply, (2) dielectric
system, (3) electrode, and (4) servo system.

18 (Video) Name the four subsystems in a wire EDM process.

: The four subsystems in a wire EDM process are (1) power supply, (2) dielectric
system, (3) wire feeding system, and (4) positioning system.

1 Which of the following processes use mechanical energy as the principal energy
source (three
correct answers): (a) electrochemical grinding, (b) laser beam machining, (c)
conventional milling, (d) ultrasonic machining, (e) water jet cutting, and (f) wire
EDM?
. (c), (d), and (e).

Ultrasonic machining can be used to machine both metallic and nonmetallic

materials: (a) true or (b) false?
. (a).
3 Applications of electron beam machining are limited to metallic work materials due
to the need for
the work to be electrically conductive: (a) true or (b) false?
. (b).
4 Which one of the following is closest to the temperatures used in plasma arc
cutting: (a) 2750°C (5000°F), (b) 5500°C (10,000°F), (c) 8300°C (15,000°F), (d)
11,000°C (20,000°F), or (e) 16,500°C (30,000°F)?
. (d).
5 Chemical milling is used in which of the following applications (two best answers):
(a) drilling holes with high depth-to-diameter ratio, (b) making intricate patterns in
thin sheet metal, (c) removing material to make shallow pockets in metal, (d)
removing metal from aircraft wing panels, and (e) cutting of plastic sheets?
. (c) and (d).

6 Etch factor is equal to which of the following in chemical machining (more than
one): (a) anisotropy, (b) CIt, (c) d/u, and (d) u/d; where C = specific removal rate, d =
depth of cut, I = current, t = time, and u = undercut?
. (a) and (c).

7 Of the following processes, which one is noted for the highest material removal
rates: (a) electric
discharge machining, (b) electrochemical machining, (c) laser beam machining, (d)
oxyfuel cutting, (e) plasma arc cutting, (f) ultrasonic machining, or (g) water jet
cutting?
. (e).
8 Which one of the following processes would be appropriate to drill a hole with a
square cross section, 0.25 inch on a side and 1-inch deep in a steel workpiece: (a)
abrasive jet machining, (b) chemical milling, (c) EDM, (d) laser beam machining, (e)
oxyfuel cutting, (f) water jet cutting, or (g) wire EDM?
. (c).
9 Which of the following processes would be appropriate for cutting a narrow slot,
less than 0.015
inch wide, in a 3/8-in-thick sheet of fiber-reinforced plastic (two best answers): (a)
abrasive jet
machining, (b) chemical milling, (c) EDM, (d) laser beam machining, (e) oxyfuel
cutting, (f) water
jet cutting, and (g) wire EDM?
. (d) and (f).
10 Which one of the following processes would be appropriate for cutting a hole of
0.003 inch
diameter through a plate of aluminum that is 1/16 in thick: (a) abrasive jet
machining, (b) chemical
milling, (c) EDM, (d) laser beam machining, (e) oxyfuel cutting, (f) water jet cutting,
 and (g) wire
EDM?
. (d).
11 Which of the following processes could be used to cut a large piece of 1/2-inch
plate steel into two
sections (two best answers): (a) abrasive jet machining, (b) chemical milling, (c)
EDM, (d) laser
beam machining, (e) oxyfuel cutting, (f) water jet cutting, and (g) wire EDM?
. (e) and (g).

What are the factors affecting material removal rate?

The MRR greatly depends on the process parameters. A higher value of

discharging voltage, peak current, pulse duration, duty cycle, and lower
values of pulse interval can result in higher MRR.

How to calculate material removal rate in EDM?

Material removal rate was calculated using Eq. (1) for all the experimental
conditions. (1) MRR = ( W 1 - W 2 ) × 1000 ρ × t where W1 and W2 are the weight of
workpiece before and after machining respectively (grams), ρ is the density of
workpiece in (gm/cc), t is the machining time in minutes.

What are material removal tools?

 Back to Products Material Removal Tools.
 Beveling Tools.
 Chipping Hammers.
 Circular Cutters.
 Drilling Solutions.
 Pneumatic Saws.
 Riveting Hammers.
 Routers.

What is the material removal in chemical machining process?

 The working principle of chemical machining is based on chemical etching. the part of the wor
piece metal where material is to be removed is brought into contact with a strong corrosive chemica
called etchant. The etchant reacts with the workpiece in the material to be cut and causes the sol
material to be removed.

Which process has the highest material removal rate?

Among the fabrication processes given, plasma arc cutting is regarded as the process having highe
material removal rates. Plasma arc cutting (plasma fusion cutting) is a thermal-based fabrication method that use
a confined, transferred plasma arc to cut structural steel, alloy steel, aluminum, and copper.

What is EDM used for?

EDM is a thermal process for removing unwanted material by applying cycled

discharging sparks in the gap between an electrode and a conductive workpiece.
This method is typically used for machining refractory metals and hard materials,
which are difficult to machine with conventional machining techniques

‫ما مدى أهمية عملية إزالة المواد وفوائدها ومدى تأثيرها في الصناعات التصنيعية؟‬
‫يعد التشطيب الجيد للسطح والجودة وزيادة إزالة المعادن إلى أقصى حد من‬ .1
.‫السمات المميزة لعملية التشغيل اآللي‬
.‫تؤثر متغيرات العملية على خشونة سطح المنتج ومعدل إزالة المعدن‬ .2

‫اإلدارة السليمة لمتغيرات العملية تجعل من السهل خفض تكاليف التصنيع وتحسين‬ .3
.‫جودة المنتج‬
‫يجب الحصول على جودة السطح الالزمة حتى يعمل الجزء على النحو المنشود‬ .4

:‫يعد العثور على حل بسيط ونهج موثوق تماًم ا أمًر ا بالغ األهمية لألسباب التالية‬ .5
 ‫اعتماد عملية آلية جودة السطح‪،‬‬ ‫‪‬‬
‫والعناصر المختلفة التي ال يمكن السيطرة عليها والتي تؤثر على الظواهر ذات‬ ‫‪‬‬
‫الصلة‪.‬‬