A DVANCED

MACHINING
PROCESSES
• Advanced Machining Processes:
● The strength and hardness of the workpiece material are very high,
typically above 400 HB.
It is often necessary to
machine or finish products ● The workpiece material is too brittle to be machined without damage to
the workpiece. This is typically the case with highly heat treated alloys,
that are made of especially
glass, ceramics, and powder-metallurgy parts.
hard or strong materials. In
● The workpiece material is too brittle to be machined without damage to
that case, the conventional
the workpiece. This is typically the case with highly heat treated alloys,
machining and grinding glass, ceramics, and powder-metallurgy parts.
strategies which are done by
● Special surface finish and dimensional tolerance requirements exist that
mechanical means described cannot be obtained by other manufacturing processes or are
in previous chapters uneconomical through alternative processes.
impractical, not satisfactory, ● The shape of the part is complex, including such features as internal and
not economical, or even external profiles or holes with high length-to-diameter ratios in very hard
possible, for the following materials.
reasons: ● The temperature rise during processing and residual stresses developed
in the workpiece are not desirable or acceptable.
The preceding difficulties led to the development of advanced machining processes that are based on non-
mechanical means of material removal which include chemical, electrical, laser, and high-energy beams as
energy sources for removing material from metallic or nonmetallic workpieces, as outlined in the Table below.
These advanced methods, which in the past have been called nontraditional or unconventional machining,
began to be introduced in the 1940s. As shall be seen, such processes remove material not by producing chips
as in machining and grinding, but by means such as chemical dissolution, etching, melting, evaporation, and
hydrodynamic action-sometimes with the assistance of fine abrasive particles. A major advantage of these
processes is that their efficiency is independent of workpiece hardness. When selected and applied properly,
advanced machining processes offer major technical and economic advantages over more traditional machining
methods.

Laser cutting of sheet Skin panels for

metals. missiles and aircraft.

Typical parts made

using advanced
Nozzles Dies
machining
processes
Cutting of thick
metallic and Turbine blades.
nonmetallic parts.

Parts with complex cavities and small-diameter deep holes.

• Chemical Machining
Chemical machining is the material removal process for the production of desired shapes and dimensions. It is
done by selective or overall removal of material by a controlled chemical attack with acids or alkalies.

• Chemical machining operation types:

Chemical milling Chemical engraving Chemical polishing Photochemical machining

This operation is performed This operation is performed This operation is performed Photochemical machining is
to obtain pockets, contours to reproduce a special to make up a fine finishing a process of manufacturing
on the workpiece or to design on a workpiece with or deburring of the stress-free and crack-free
remove bulk material from a lot of precision. E.g., titles, workpiece. This is possible components. PCM is used
the workpiece. brand names, serial by using of usage of lighter where micro details are to
numbers, etc. diluted chemical reagent. be machined on a
workpiece.
• Chemical machining parts:

The stirrer is used to spread the heat uniformly along

Maskant is material used the etchant, also it helps in the flushing of dissolved
to coat the workpiece for metal from the workpiece simultaneously breaking the
preventing the portion of bubbles formed during machining due to oxidation.
the workpiece from stirrer
etching.

The tank is built of strong metal coated with materials

that are non-reactive to etchant depending on the
maskant Tank applications and concentration of chemical reagent.

Heating coil A heating coil is mounted at the lowest section of the

Chemical tank to maintain the temperature of the tank at a
reagent constant level. It is practical that in any metal removal
process the heat generation is natural. Also, the coil
Cooling coil does cooling in necessary conditions.
• process of chemical machining:
Cleaning is a preparatory process to ensure that
the surface of the workpiece is free from Washing and drying of the
contaminants, rust, and foreign particles. It is workpiece
usually performed by high-pressure water jets,
alcoholic solutions, and diluted HCl.
It is a process of applying maskant over the
surface of the workpiece. A layer of polymer or
Applying mask on the rubber is coated on the workpiece. Masking is
workpiece done to prevent the area which does not require
This is the process in which the required metal machining from the etching process. Masking is
removal takes place. After perfect masking, the done all over the workpiece except the areas to
workpiece is dipped into the tank of the chemical be machined.
reagent with the heater and the stirrer turned Immersion of the
ON. As soon as the workpiece is dipped, the
etchant starts to react with the non-masked areas
workpiece in etchant
of the workpiece. The highly concentrated acid
begins to react with the workpiece altering its
chemical features. This reaction causes the Taking out the workpiece
predefined portions to melt and separate from Demasking is a process of peeling off the maskant
the workpiece layer by layer.
from etchant and peeling
of mask that was applied before the etching process. Once
the maskant is removed from the workpiece, the
workpiece is again sent to cleaning operation
where any leftover etchant is washed away by
pressurized cold water. The workpiece is then
Washing of the workpiece dried up and ready for final dispatch
• working principle of chemical machining:
The working principle of chemical machining is based on chemical etchant. An etchant is a mixture of strong
chemical acids which are reactive to metal. When the workpiece is dipped in the etchant, the etchant reacts
with the workpiece causing a uniform rate of dissolution of metal from the workpiece.
- Localized machining is achieved by applying a suitable mask on all the areas where we do not want the
etchant to react. Thus, exposing the machining zone for the necessary removal of metal.
 Advantages Disadvantages
• This machining process removes • Less operator safety, a minor spill of
metal uniformly. etchant on the skin can cause harm to the
operator.
• Good surface finish with close
tolerances. • Chances of corrosion after the days of
machining.
• Complex contours can be easily
• Machining of alloys can lead to poor
machined.

• Material removal along all the axes at

Chemical surface finish.

• Process is not eco-friendly.

the same time.
Machining • Disposal of byproducts can cause harm to
• Less skilled operator is required.
the surrounding.
• No mechanical stress is produced on
• Material Removal Rate (MRR) is less in
the workpiece.
comparison with other machining processes.
• Low initial cost. • Chances of bubble formation, which may
result in improper machining.
• Low machining cost.
• Electrochemical Machining
Electrochemical machining (ECM) is a machining process in which electrochemical process is used to remove
materials from the workpiece. In the process, workpiece is taken as anode and tool is taken as cathode. The
two electrodes workpiece and tool is immersed in an electrolyte (such as NaCl). When the voltage is applied
across the two electrodes, the material removal from the workpiece starts. The workpiece and tool is placed
very close to each other without touching. In ECM the material removal takes place at atomic level so it
produces a mirror finish surface.
- This process is used to machine only conductive materials.

• working principle of electrochemical machining:

The working principle of the Electrochemical Machining process is as follows; The workpiece is always
immersed in a fluid called an electrolyte. These electrolytes always flow through the gap between the
equipment and the workpiece. The gap between the workpiece and the equipment through which the
electrolyte passes is known as the inter-electrode gap. Very high current is passed through this difference with
low voltage. In this process, the workpieces are connected to the positives terminal and act as an anode, & the
tool is connected to the negatives terminal and acts as the cathode. As very high currents are used, the
equipment and workpiece are separated from the system to prevent any short-circuiting or leakage of current.
The electrolyte is filtered & made to flow continuously through the workpiece.
• Electrochemical machining parts:
Flow meters are used to
regulate the flow of Pressure gauges are used to control the
electrolyte that is supplied pressure at which the electrolyte is supplied
to the system. to the electrolytic machining system.
The DC power supplies used in
this process ranges from 3 to 30V. D.C power
The DC power supply is used to supply Pressure gauge Filters are used to
make a potential difference filter the electrolyte
between the workpiece & the tool Flow meter Filter Pump and remove unwanted
and make them act as anode & particles from the
cathode, respectively. electrolyte.

Feed
This pump is used to
pump electrolytes the
gap between the
This is used to continuously
cathode and the anode.
move the tool down towards
Electrolyte
the workpiece.

The electrolyte is used to

establish the electrical
Workpiece
Fixture relationship between the
anode & the cathode so that
It is the object from which the material is to be removed. positive & negative ions can
The workpiece is connected to the positive terminals of the flow from both of them.
DC power supply and acts as an anode
• process of electrochemical machining:

the workpiece is assembled in the fixture and the tool is

brought close to the workpiece. The tool and workpiece is
immersed in a suitable electrolyte.

a potential difference is applied across the workpiece

(anode) and tool (cathode). The removal of material
starts. The material is removed in the same manner.

Tool feed system advances the tool towards the workpiece

and always keeps a required gap in between them. The
material from the workpiece comes out as positive ions
and combine with the ions present in the electrolyte and
precipitates as sludge.

The sludge from the tank is taken out and separated from
the electrolyte. The electrolyte after filtration again
transported to the tank for the ECM process.
Advantages of Electrochemical Machining Disadvantages of Electrochemical Machining

• Complex concave curvatures component can • Workpiece materials must be electrically

easily be produced using complex concave conductive.
curvature devices.
• Out of all the Non-traditional machinings
• Due to ion displacement, the surface finish methods, electrochemical machinings require
produced is excellent. the highest specific cuttings energy. Therefore,
the cost of machinings will be high.
• Because no forces are acting, no residual
stress will be present. Due to generating no • It is better for production only, but not for
heat, no thermal effect exists on the holes.
workpiece.

• Due to no equipment wear, the same

equipment can be used to produce an infinite
number of components.
• Electrochemical Grinding
The term grinding refers to a machining process in which the material is removed from the surface of the
workpiece. And the term electrochemical resembles the mode of energy used for the machining process.
Electrochemical grinding is a combination of electrochemical machining and grinding processes.
The major difference between ECM and ECG is that In ECG grinding wheel is used instead of a cutting tool.
Electrochemical grinding is done when there is a need to remove the material from the surface of the
workpiece. It is generally used when the mechanical or traditional grinding of a workpiece takes a lot of effort
due to the hardness of the workpiece.

• working principle of electrochemical grinding:

The working principle of electrochemical grinding is When a metal surface is acted upon with an electrolyte
under a high current, the metal surface gets oxidized to form an oxide layer (corrosive layer). This layer is
removed with the action of a flowing electrolyte and rotating grinding wheel. Metal is removed in the form of
an oxide layer to obtain an n surface finish.
• Electrochemical grinding parts:
A DC power supply with low voltage and high
Pressure gauge and flow meter are safety
current is used for providing electrical energy to DC Power Pressure Gauge equipment that shows pressure and flow of the
the setup. The voltage is kept low to avoid the supply and flow meter electrolyte respectively.
generation of heat and for safety purposes as well.

The worktable provides rigid support to the A nozzle is a device with decreasing cross-
Work Table Nozzle
workpiece and fixtures are used to clamp the section area, which is used to direct the
workpiece. and Fixture electrolyte to the correct position.

An electrolyte tank is a reservoir in which the

electrolyte is stored. An electrolyte is a A sleeve is used to transfer electrical energy to
Electrolyte tank Sleeve
conducting solution that plays an important role the grinding wheel.
in electrochemical grinding.

The grinding wheel is connected to the negative

A pump is used to carry the electrolyte from
terminal of the power supply and acts as the
the electrolyte tank to the nozzle. The pump Pump Grinding wheel cathode. And it is made of insulating materials
used is generally electrically driven.
such as diamond and aluminum oxide.

The electrolyte passes through a filter where A collecting tank is used to collect all the used
all the micro impurities get filtered and pure Filter Collecting tank electrolyte which is then disposed or reused as
Electrolyte is obtained. per the requirement.
• process of electrochemical grinding:

The workpiece to be machined is first kept on the worktable and then clamped using fixtures.

The grinding wheel is placed at the required position. A gap is maintained between the workpiece and
the grinding wheel. This gap is generally 0.02mm.
Now the power supply is switched on. The pump is then driven to supply the electrolyte to the
required position.
the electrolyte passes through a filter where all the impurities are filtered. Then the electrolyte is
passed through a pressure gauge where the operator checks for the correct pressure.

Then electrolyte is passed through a flow meter where flow is checked by the operator.

After passing through all the stages the electrolyte reaches the nozzle. Nozzle increases the velocity of
the electrolyte and sprays it over the workpiece.
As soon as the electrolyte comes in contact with the workpiece and the grinding wheel, the circuit is
completed which results in Oxidation of the metal surface.
This forms a layer of oxide which is removed by the flow of electrolyte and the Abrasive particles in the
grinding wheel. After the grinding is done, the flow is stopped and the power supply is switched off.

The workpiece is then unclamped and the remaining electrolyte is wiped out from the surface.
 Advantages of Electrochemical Grinding Disadvantages of Electrochemical Grinding
• The accuracy of electrochemical grinding is very • The metal removal rate is low, about 15mm/s
high. As there is no contact of the tool with the
workpiece. • Power consumption is very high as there is a
need to drive the grinding wheel and pump as
• A high tolerance can be obtained.
well.
• The process does not leave any scratches on the
surface of the workpiece. • The initial cost of the equipment is also high.

• The heat generated during the operation is very less. • The production rate is low.
• The electrolyte also acts as a coolant.
• Disposing of waste electrolytes becomes a
• There are no internal stresses developed in the problem, which makes the process non-eco-
workpiece. friendly.
• Hard materials can be grinded easily.
• A large area is required for setup.
• Cleans edges can be obtained.
• No or very little wear of the grinding wheel takes
place.
• Electrical-discharge Machining
Electrical discharge machining, EDM, is a manufacturing process where material is removed from a workpiece
using a rapid sequence of electrical current discharges between electrodes submerged in a dielectric liquid. The
process is used to manufacture parts that are impossible to machine. EDM is an exceptionally precise process
that is ideal for forming complex and intricate shapes and is capable of shaping hard metals such as titanium.
The materials shaped using EDM must be electrically conductive for the process to be successful.

• working principle of Electrical-discharge Machining:

The process consists of two main parts: the electrode and the workpiece/material. Each is connected to one
end of the power supply. The electrode carries one side of the charge and the workpiece carries the other side
of the charge. When the two get close, a white hot electrical spark jumps from the electrode to the workpiece
due to the high potential difference between the two. This creates temperatures between 8,000 and 12,000
degrees Celsius in the spark gap which causes the material to melt and, therefore, erode. Such high
temperatures necessitate the use of an insulating or dielectric fluid. The electrode and the workpiece are
immersed in the dielectric fluid for the duration of the process. The dielectric fluid controls the electric spark. It
also acts as the process coolant and flushes away the tiny particles that are eroded in the process.
• Electrical-discharge Machining parts:
 DC Power Generator The Dielectric Workpiece Component

A DC power generator is the power The dielectric plays a key role in the A workpiece is the part to be
supply for the EDM machining process. functioning of the EDM Machining machined. It’s fixed in the dielectric
The negative terminal is connected to process. Usually, the dielectric fluid is container using a fixture and is
the tool while the positive terminal is hydrocarbon oil with low viscosity. connected to the positive terminal of
connected to the part being machined. The dielectric serves to separate the the power supply.
workpiece and the electrode.

An ammeter is used to The voltmeter is a device A filter removes any

measure or check the for measuring voltage. irregularities or dust
Ammeter flow of current. The Voltmeters are used to particles that may be
Voltmeter
Measuring ammeter must be measure voltage in the Filter present in the dielectric
Device
Device connected in order for us EDM system. medium. The filter is
to check whether the situated just above the
current is flowing or not. pump.
 Electrode Tool Tool Feed Control Servo Controlled Feed
Any electrical conducting material can During the course of the EDM A servo control mechanism
work as an electrode tool in EDM machining process, the material is automatically maintains a constant gap
machining. The shape of the tool is removed from the part to be machined that is about the thickness of human
transferred in the cavity cut during and the electrode tool. This increases hair between the work material and
machining in EDM machining processes. the gap that is between the work and the tool. This mechanism is found in
the tool. The tool must be fed properly both wire and vertical EDM machines.
using a device that controls the feed in It is important to ensure that there is
order to maintain a constant gap and no physical contact of the electrode
arcing voltage to prevent the and the work, otherwise arcing would
occurrence of a short circuit. occur.

DC Power Generator Tool Holder Spark Generation Pump Component

The fixture is used for The tool holder serves to Between the tool and the A pump is used as a
holding the workpiece hold the tool properly. part to be machined, a passage for the dielectric
properly in the dielectric spark is generated, in the fluid to flow from the
container. presence of a dielectric base of the container to
medium. Therefore, the the tool and the part to
removal of material be machined such that
occurs from the surface more MRR takes place.
of the workpiece.
• process of Electrical-discharge Machining:

1 2 3

In the first step of this process, The die is slowly lowered As the series of high-
an electrode is produced in towards the workpiece until frequency sparks repeatedly
the reverse shape of the ‘electric breakdown’ occurs removes a small amount of
required cavity. This forms the and a spark jumps the ‘spark material from the workpiece,
die. A voltage is then induced gap’. This vaporises and melts the desired shape will begin to
between the die and the material from the workpiece take place and be precisely cut
electrically conductive while dielectric fluid out.
workpiece while submerged in subsequently carries any
a dielectric fluid like oil. ejected particles away. A small
amount of the electrode is
also often eroded during this
process.
• types of Electrical-discharge Machining:

Die sinking EDM Wire EDM Hole drilling EDM

The die sinking EDM process is the best Wire EDM, otherwise known as wire As the name implies, Hole drilling EDM is
Electro Discharge Machining for creating erosion, is commonly used to produce used to machine holes. However, this
parts with complex cavities. It is also the extrusion dies. It cuts using the same technique can accurately machine
method chosen for solving the sharp mechanism as die-sinking. However, the die extremely small and deep holes that don't
internal corner issue when CNC is replaced with a very fine electrically require deburring compared to traditional
machining.it uses a die in the negative charged wire which will work as the hole drilling methods. This method also
shape of the desired cut as the electrode. electrode. This machining method is uses the same fundamental principles as
This die is brought in contact or ‘sunk’ into comparable to a cheese cutter, making a die-sinking EDM. However, the cut is made
the workpiece in the presence of a two-dimensional cut in a three-dimensional with a pulsing cylindrical electrode with
dielectric fluid. This creates a negative part and produce incredibly precise cuts. dielectric fluid fed into the cutting area
impression of the die in the workpiece while moving deeper into the workpiece.
through a series of electrical discharges
between the electrode and the workpiece.
• Advantages of EDM Machining
• It can be used even in the heat-treated condition, and for any • Mechanical stresses are not developed in this process (the tool and
hard material. work do not have contact).

• Complicated shapes made on the tool are able to be • The tool life is longer due to proper lubrication and cooling.
reproduced.
• Hard surfaces that are also resistant to erosion can be developed
• A high accuracy can be achieved; about 0.005 mm. easily on the dies.

• Economically, a good surface finish can be achieved; up to 0.2 • It can be applied to any material that is electrically conductive.
microns.

• Machining time is not more than the conventional machining

process.
• Disadvantages of EDM Machining
• Excessive wear of the tool • Requirement for redressing of a tool for deep holes

• Reproduction of the sharp corner is not possible • Over-cut is formed

• Change in metallurgical properties of materials due to the • Expert machinists are hard to find
development of high heat.

• The material to be machined must be an electrical conductor

• Laser-Beam Machining
LBM is a form of machining that uses heat directed from a laser beam, This process uses thermal energy to
remove material from metallic or nonmetallic surfaces, Laser beam machining is best suited for brittle
materials with low conductivity, but can be used on most materials.

• working principle of Laser-Beam Machining:

A very high-energy laser beam is produced by laser machines, focuses on the workpiece to mechanize this laser
beam produced, when the laser beam hits the surfaces of the workpiece, the thermal energy of the laser beam
is transferred to the surfaces of the workpiece, it heats, melts, evaporates, and eventually makes the material a
workpiece, this is how laser beam machining works.

Types of Laser-Beam Machining

Metal vapor Chemical Solid state Semiconductor

Gas lasers
lasers lasers lasers lasers
• Laser-Beam Machining parts: The electric current or power is
supplied to the system. A high voltage
It is the electric arc lamp that is used power system is used in laser beam
to produce extremely intense machining. It will give initial power to
production of white light which is a the system after that reaction starts in
coherent high-intensity beam. It is a laser that will machine the material.
filled with gases that ionize to form There is a high voltage supply so that
great energy that will melt and 100 % Reflecting pulses can be initiated easily
vaporizes the material of the mirror
Power supply During the major portion of the
workpiece.
cycle, a capacitor bank charges
Flash lamps
and releases the energy during
Reflecting Mirror are two main
the flashing process. The
types of internal and external. capacitor capacitor is used for the pulsed
Internal mirrors also called a
mode for charging and
resonator that is used to generate
partially Ruby crystal discharging.
maintain and amplify the laser
Reflecting mirror
beam. It is used to direct the laser
beam towards the workpiece. Laser light beam Ruby laser produces a series of
Lens coherent pulses which is deep red in
It is the beam of radiation produced by color. It achieves by the concept of
the laser through the process of optical population inversion. It is a three-
amplification based on the coherence of level solid-state laser.
light created by the bombarding of Workpiece
active material. Lenses are used to focus the laser beam onto the
workpiece. First laser light will enter into the
expanding lens and then into the collimating lens
The workpiece can be metallic or non-metallic.
which makes the light rays parallel and the
In this machining process, any material can be
expanding lens expands the laser beams to the
machined.
desired size.
• Process of Laser-Beam Machining:

Negatively charged The laser has one This will heat then
electrons in the Every orbital of 100% reflector and melt, vaporize, and
High voltage is The laser beam
atomic model electrons is the other one is a finally, the material
The electrons at applied at the ends produced is
rotate around the associated with partial reflector. will be removed
the ground state that leads to focused on the
positively charged different energy 100% the reflector from the
move to a higher discharge and gas workpiece that has
nucleus in orbital levels. An atom is directs the photons workpiece. So laser
state of energy by plasma will be to be machined.
paths. It depends considered to be at inside the gas tube machining is a
absorbing energy formed. Population When the laser
on the number of ground level at and the partial thermal material
like an increase in inversion and lasing strikes the
electrons, electron absolute zero reflector allows removal process
electronic vibration action will take workpiece, the
structure, temperature at only some part of that uses a
at elevated takes place due to thermal energy
neighboring atoms, this, all electrons the laser beam that coherent beam of
temperatures. energy impinges on the
and the occupy their lowest will be used for the light to machine
transformation. workpiece.
electromagnetic potential energy. processing of the workpiece very
field. materials. precisely.
 Advantages Disadvantages

• It can be focused on very small diameters. • High initial cost.

It produces a huge amount of energy, about
100 MW per square mm area. • Laser beam machining requires a
highly trained worker to operate the
• It can produce a very accurately placed machine.
hole.

• There is no physical contact between the

equipment and the workpiece.
Laser-Beam • Low production rate because it is
not designed for mass production.

• The wear and tear in this machining

process are very low and therefore requires
Machining • The machining process requires a
lot of energy.
a low maintenance cost. This machining
process produces an object of very high
precision.

• Most items do not require additional

finishing.

• It has the ability to engraves or cut almost

all types of material. But it is best suited for
brittle materials with low conductivity.
• Electron-Beam Machining
Electron beam machining is a thermal process that is used to remove metals, during the machining process a
high velocity focused beam of electrons is used to remove the metal from the workpiece. These electrons are
travelling at half the velocity of light. This process is best suited for the micro-cutting of materials.

• working principle of Electron-Beam Machining:

When the high-velocity beams of electrons strike the workpieces, their kinetic energy is converted into heat.
This concentric heat increases the temperature of the workpiece material and evaporates a small amount of it,
resulting in the removal of materials from the workpiece.

• Types of Electron-Beam Machining:

The electron beam causes The electron beam is used to

melting and evaporation of 2\ Non- cause the chemical reaction on
1\ Thermal material. EBM material removal the material.
Thermal
EBM usually is due to evaporation. EBM
• Electron-Beam machining parts:
Cathode
The cathode is negatively charged and is used to produce electrons. Vacuum chamber Electron gun

Grid cup
Annular Bias Grid
It is present next to the cathode. An annular bias grid is a spherical-shaped
Tungsten
bias grid and prevents the bend of electrons produced by the cathode. It
filament
acts as a switch and operates the electron gun in pulse mode.
Anode D.C power
Anode supply
It is placed after the annulus bias grid. It is positively charged. An annular Diaphragm
anode attracts the electron beam towards it, and gradually, the velocity of
the electron increases. As the electron beam leaves the anode segment,
its velocity becomes half of the velocity of light.
Lenses
Magnetic Lenses
Magnetic lenses reduce the deviation of electron beams and give them
shape. It only allows convergent electrons to pass and occupy electrons Deflector coil
with low energy deviations. This improves the quality of the beam.
Beam
Electromagnetic Lens Workpiece
This helps to focus the electron beam to the desired location.
Table
Deflector Coils
The deflector coil carefully guides the high-velocity electron beam to the
desired location on the workpiece and improves the pore size.
• Process of Electron-Beam Machining:

first the electron is

From the annular bias grid,
generated by the cathode
the electron produced by
and an annular biased grid
the cathode is attracted
does not allows the electron
towards the anode and After that, it passes to the
to diverge.
gradually its velocity series of magnetic lenses.
increases. As the electron The magnetic lenses allows
beam leaves the anode only convergent beam to
section, its velocity reaches pass through it and captures
to half of the velocity of the the divergent beam from The electromagnetic lens
light the fringes. And then a high focuses the electron beam
quality electron beam is to the desired spot on the
made to pass through the workpiece. The deflector
electromagnetic lens and carefully guides the beam to
deflector coils. the desired locations and
improves the shape hole.
Advantages of Electron-Beam Machining Disadvantages of Electron-Beam Machining

 It can produce bolts of small sizes.  High equipment cost.

 High accuracy and better surface finish.  Low metal removal rate.

 High skilled operator.

 Almost all types of materials can be
machined.  High power consumption.

 Highly reactive metals such as Al and Mg can  Not applicable to produce perfectly
be machined easily. cylindrical deep holes

 As it does not apply any mechanical cutting

forces on the workpiece, so cost of work
holding and fixtures is reduced.
• Water Jet Machining
The machining process in which water jets are used to extract material from the workpiece is called water jet
machinings (WJM). In this process, water jets are used, which acts as a device in the form of a water saw. In this
process, the water is raised very rapidly and further focused on the target workpiece.
At a high velocity and pressure, it is capable of using some abrasive particles mixed in water jet materials and
some metals. In some processes, no abrasive is used, & these processes are known as pure water jet machining
processes.

• working principle of Water Jet Machining:

It is based on the principles of water erosion. When a high-velocity jet of water hits the surface, the material is
expelled. Pure water jets are used to machine soft materials. But to cut hard materials, some abrasive particles
are mixed with water for machining, and it is called AWJM (Abrasive Water Jet Machining).

Abrasive Types of
Pure water
Water jet Water Jet
jet machining
machining Machining
• Water Jet machining parts:
 This control valve
controls the water
pressure as well as the
amount of water and
The reservoir is used directs it towards the
to store water that will flow regulator. This is This pump will soak up
be used as a jet. From where the pressure the water from the
the reservoir, water is energies will be reservoir, and it will
supplied for the jet-jet converted into kinetic transfer the water in
machining process. energy. intensity.
Reservoir Control Valves Pump

Intensifier Accumulator
Intensifiers are used to The accumulator is used to
increase the water jet temporarily store water
pressure and to produce according to requirements. It
high-pressure liquid jets. This is connected to the
intensifier is connected to the accumulator control valve. It
accumulator. It accepts water maintains a continuous flow
under low pressure and of high-pressure water and
exhales it through an eliminates pressure
accumulator at high pressure. fluctuations.
It works through a hydraulic
reciprocating mechanism.
The flow of water
arriving from the
control valve is Catchers or drains are
regulated using a flow used to collect water
regulator. After after cutting the
regulating the flow The water which is workpiece. From here,
regulator, the water directed from the water is sent for
will pass through the nozzles will come out further purification or
nozzle from this orifice. can be reflowed.
Flow Regulator Orifice Catcher or Drain

Nozzle High-Pressure Tube

This nozzle will cover the High-pressure tubes are
pressure of the high-pressure required for high-pressure
jet in kinetic energy. The water to flow. They are about
kinetic energy increases as 6 to 14 mm in diameter. It
the field decrease at the end also allows flexible
of the nozzle. The jet of water movement of the cuttings
from the nozzle is then head.
directed towards the
workpiece.
• Process of Water Jet Machining:

1 2 3 4 5

the water is transferred High-pressure water from The flow regulator Then the water comes This pressure due to the
at an intensity using a the accumulator is controls and controls the out of the hole and is water jet will cause some
pump. The intensifier transferred to a control flow rate of the water directed towards the fractures on the part of the
accepts the water under valve that controls the and directs it towards workpiece. When the jet workpiece where the water
low pressure and then direction of the water. In the nozzle. In the nozzle, of water reaches the jet bike and some cracks will
transfers it to the the control valve, the the kinetic energy of the workpiece, the kinetic be introduced into the
accumulator at a high water pressure energy is water increases energy again changes to surface of the workpiece and
pressure of about 3800 converted to kinetic significantly, and the pressure energy, and the as the water jet continuously
bar. The accumulator energy, i.e., high-pressure nozzle produces high- workpiece will be under strikes the surface of the
temporarily stores high- water is converted to high- velocity water. full pressure. workpiece for a long period of
pressure water. velocity water, and this time, it will initially The crack
high-velocity water is sent will deepen and therefore the
to the flow regulator. material will be removed
from the workpiece.
 Advantages of water jet machining
• It has the ability to cut material without disturbing its • Thermal damage to the workpieces is negligible
original structure. due to no heat generated.

• It is capable of producing complex & intricate cuts in • It is environmentally friendly because it does not
material. create any pollution or toxic products.

• The work area remains clean and dust-free in this • It has greater machining accuracy. Inches
machining process. tolerances of 0.005-inch order can be easily
obtained.
• Its operating and maintenance costs are low because it
has no moving parts.

Disadvantages of water jet machining

• It is used to cut soft materials. But AWJM can cut rigid materials of limited thickness.

• Very thick material cannot be prepared by this process.

• Very thick material cannot be prepared by this process.

• Abrasive Jet Machining
It’s an abrasive blasting machining process that uses abrasives propelled by a high velocity gas to erode material
from the workpiece. Common uses include cutting heat-sensitive, brittle, thin, or hard materials. Specifically, it
is used to cut intricate shapes or form specific edge shapes.

• working principle of Abrasive Jet Machining:

The fundamental principle of Abrasive jet machining involves the use of a high-speed stream of abrasive
particles carried by a high-pressure gas or air on the work surface through a nozzle.

The metal is removed due to erosion caused by the abrasive particles impacting the work surface at high
speed. With repeated impacts, small bits of material get loosened, and a fresh surface is exposed to the jet.
• Abrasive Jet machining parts:
 A high-velocity jet of airlike nitrogen carbon dioxide etc and enclosed abrasive particles are aimed at the
Gas Supply
workpiece under controlled conditions. The gas is supplied under a pressure of 2 to 8 kilopascal.

The filter is used to clean the fuel supply so that dirt or other impurities do not hamper the progress of
Filter
the process.

Pressure The pressure gauge is used to control the pressure of the compressed used in the abrasive jet machining.
Gauge As the pressure decides the depth of cutting and the amount of force required for cutting.

Mixing In the mixing chamber abrasive powder is being fed and with the help of a vibrator amount of abrasives
chamber can be controlled. So that the abrasives and the gases will be mixed thoroughly in the mixing chamber.

The nozzle is used to increase the velocity of the fine abrasive jet slurry at the expense of the pressure as
Nozzle
we know if we decrease the pressure the velocity will increase.

Silicon carbide, aluminum oxide glass beads are used as abrasives in abrasive jet machining. The shape of
Abrasive
the abrasives can be regular or irregular. The size of the abrasives is around 10 to 50 microns.
• Process of Abrasive Jet Machining:

The mixing chamber, carrying the abrasive particles

The abrasive particles are held in a suitable holding
is vibrated and the amplitude of these vibrations
device, like a tank and fed into the mixing chamber.
controls the flow of abrasive particles.

A regulator is incorporated in the line to control These particles mic in the gas stream, travel further
the flow of abrasive particles compressed air or through a hose and finally pass through the nozzle
high-pressure gas is supplied to the mixing chamber at a considerably high speed causing abrasive jet
through a pipeline. which cut out the workpiece.

This pipeline carries a pressure gauge and a

regulator to control the gas flow and its pressure.
Advantages of Abrasive Jet Machining Disadvantages of Abrasive Jet Machining

• Ability to cut intricate hole shapes in • The material removal rate is slow and its
materials of any hardness and brittleness. application is therefore limited.

• Ability to cut fragile and heat-sensitive • Flaring can become large.

materials without damage as no heat is
generated due to the passing of gas or air.
• The machining accuracy is poor and the nozzle
• Normally inaccessible portions can be wear rate is high.
machined with fairly good accuracy.
• Additional cleaning of the work surface may
• Low capital cost. occur as there is a possibility of sticking abrasive
grains in softer materials.

• It is an expensive process
• Hybrid Machining systems
Hybrid Machining Systems indicates for combining two machining processes or more into one system to take
the advantages of each system.

Types of Hybrid Machining Systems

Abrasive machining Abrasive machining Abrasive machining

Machining and
and electrochemical and electrical and electrochemical
blasting.
machining. discharge machining. finishing.

Machining and
Combinations of
Electrochemical and forming processes, Abrasive machining
Water-jet cutting and various forming,
electrical discharge such as laser cutting and electrochemical
Wire EDM. machining, and
machining and punching of machining.
joining processes.
sheet metal.
• Economics of Advanced Machining Processes
The operation of the economic production of a given operation depends on the costs of tools and equip
ment, operating costs, the rate of removal of the required materials, the level of operator skill required,
as well as on secondary processes of finishing that may be necessary later.

In chemical machining (which is a slow process by nature), the important factor is the cost of reagents,
masks, and disposal with the cost of cleaning the parts. In the manufacture of electrical discharge, the
cost of electrodes and the need to periodically replace them can be significant.

The rate of material removal and the rate of production can vary greatly in these processes. The cost of
tools and equipment also varies greatly, as does the operator’s required skill. High capital investment of
machines (such as those for high-energy electric machines, especially when equipped with robotic
controls) must be justified in terms of production processes and the feasibility of manufacturing the
same part by other means if all is possible.
The End