Manufacturing

Processes

Chap. 27 - Advanced
Machining Processes
 Advanced Machining Processes
• When processing a component, typical material
removal methods may not always work.

• Possible reasons are:

– Material hardness, strength is too high.
– Workpiece too flexible, delicate, or thin.
– Shape/features too complex.
– Highly rigorous surface finish, dimensional tolerances.
– Undesirable temperature rise/residual stresses remaining
after processing.
 Advanced Machining Processes
• More advanced methods were developed for
such conditions.

• Typically referred to as Non-Traditional or

Unconventional Machining.

• Have major technical/economical advantages

and also limitations.
 Some Non-Traditional Machining
Processes
• Electrical Discharge Machining (EDM)
• Wire Electrical Discharge Machining (WEDM)
• Chemical Machining (CM)
– Chemical Milling
– Chemical Blanking
– Photochemical Blanking
• Electrochemical Machining (ECM)
• Laser Beam Machining (LBM)
• Waterjet Machining
– Abrasive Water Jet Machining
 Electrical Discharge Machining (EDM)
• Also known as spark erosion machining.
• Based on the erosion of metals by spark
discharges.
• When an arc is produced between two metals,
part of the metal is eroded.
• This erosion process, when controlled, can create
a desired shape.
• Only works with materials that are electrical
conductors.
 Basic EDM Operation
• Tool and the workpiece are connected to a DC power
supply.
• An electrode with the desired shape is cut and secured to
the machine ram.
• Work is secured to a table an immersed in a tank
containing a dielectric fluid typically mineral oils or
deionized water).
• If potential between tool (electrode) and work is high
enough, a spark is discharged across the fluid.
 Basic EDM Operation
• Spark removes a small amount of metal from
workpiece.
• Discharges are repeated many times.
• Gap: space between tool and workpiece - very critical.
• Downfeed (Z motion) is NC controlled to maintain
constant gap.
• No mechanical energy required: hardness, strength,
toughness don’t affect material removal rate (MRR).
 EDM Parameters
• Current
– Surface Finish is a function of current and frequency.
• If current is increased:
– more powerful sparks are generated.
– more material is removed per unit time.
– larger craters are generated.
– a rougher finish is produced.
– If current is decreased, the opposite occurs.
– However, it is more time consuming.
 EDM Parameters
• Frequency
– Increasing/decreasing frequency has little effect on the
MRR (while keeping current constant).
– MRR is directly proportional to current.
• Increasing frequency:
– means less power for each spark.
– less material is removed by each.
– a smoother surface can be achieved.
– however, it is more time consuming.
 EDM Tooling
• Electrodes are made of graphite or other alloys.
• Can make electrodes by machining, forming, casting.
• Can make very small and deep holes (dia. 0.005")
ratio as large as 400:1.
• Tool wears as it erodes; graphite electrodes have
greatest wear resistance.
• Must make multiple electrodes to cut the same cavity
to compensate for wear.
 EDM Capabilities
• Great for irregular shaped cavities.
• Can make sharp corners.
• MRR can be 2 - 400 mm3/min, depending on
material and parameters.
• Used for:
– Die and mold cavities.
– Small deep holes.
– Multiple Intricate Shapes
– Internal Cavities
EDM Machines
 Wire EDM (WEDM)
• Process is similar to cutting with a band saw.
• Moving wire travels along specified path.
• Wire cuts workpiece by discharging sparks.
• Dielectric floods the spark region, carrying away
debris.
• Can cut plates 12" thick.
• When doing inside cuts, must have previous pilot
hole to thread wire.
 WEDM Tooling
• Wire
– Made of brass, copper or tungsten.
– Can be as thin as 0.005".
– Must be strong and tough.
– Used only once, but cheap.
– Kerf: gap left by wire on material after cutting.

– Typical wire velocity: 0.15-9 m/min.

– Cutting Speed: 6 mm/min for steel.
WEDM Machine
Wire EDM Example
 Chemical Machining (CM)
• Chemicals can attach and etch metals.
• Etching removes small amounts of
material from surface.
• Reagents/etchants are typically
acid/alkaline solutions.
• Used in the past for engraving.
 Chemical Machining (CM)
• Can produce shallow cavities on sheets,
plates up to 0.5".
• Main purpose: weight reduction.
• Can selectively attack regions of the
material via:
• masking
• partial immersion
Chemical Machining Procedure (I)
• Stress-relieve the part to prevent post-CM
warping.
• Thoroughly clean/degrease part
( to ensure good mask adherence & material removal.)

• Apply masking material to entire part.

• Remove masking material from regions to be
etched.
Chemical Machining Procedure (II)
• Expose material to etchants (i.e. NaOH,
HNO3) while controlling temperature,
stirring and time.
• Wash part thoroughly.
• Remove masking material, clean part,
inspect.
 Chemical Blanking (CB)
• Blanking consists in producing shapes that fully
penetrate the thickness of the material.
• Chemical blanking is done via chemical dissolution
rather than shearing.
• No burrs are left.
• Can blank complex, small or decorative shapes on
thin metal.
Photo Chemical Blanking (PCB)

• A variation of chemical milling.

• Material is removed via photographic

techniques.

• Can create shapes on metal as thin as

0.0001".
 PCB Procedure (I)
• Prepare a design to be blanked, magnified up to
100X.
• Make a negative and reduce to part scale (the
artwork).
• Coat sheet blank with photoresist (dip, spray, coat
and oven dry).
– Coat is called emulsion.
 PCB Procedure (II)
• Place negative over coated blank and expose
to UV light, hardening exposed areas.
• Develop blank to dissolve unexposed areas.
• Immerse blank in reagent to etch away
exposed areas.
• Remove masking and wash thoroughly.
 PCB Considerations
• Etchant attacks material in horizontal and vertical
direction.
• Undercuts develop and must be taken into
account.
• Must control environment to control size changes.
• Avoid designs with sharp corners, deep narrow
cavities, seams tapers.
Electrochemical Machining (ECM)
• Process similar to EDM.
• Reverse process of electroplating.
• Shaped tool is made of brass, copper, bronze or
SS.
• Electrolyte is an inorganic salt, circulating at high
rate.
• Creates complex cavities in hard materials.
Electrochemical Machining (ECM)
• Leaves burr-free surface, no thermal damage
to part.
• No tool wear.
• Not suited for sharp corners or flat bottomed
features.
• Difficulty controlling the electrolyte solution
can produce irregular shapes/accuracies.
 Laser Beam Machining (LBM)
• Source of energy is laser: highly focused, high
density energy beam.
• Most common Laser types:
– CO2

– Nd:YAG

• Can be pulsed or continuous wave.

 Laser Beam Machining (LBM)
• Important Physical parameters of workpiece:
(the lower the better)

• Reflectivity

• Thermal conductivity

• Specific Heat

• Latent heats of melting/evaporation

Laser Beam Machining (LBM)
 Laser Beam Machining (LBM)
• Process Capabilities
– Drilling (as small as 0.0002")
– Cutting of Metals, non-metals, ceramics,
composites (as thick as 1.25")
– Very flexible: can compete with sheet metal
cutting with traditional punching processes.
Laser Beam Machining (LBM)
 Laser Beam Machining (LBM)
• Other Uses:
Welding
Localized Heat Treating
Marking,engraving of parts.
• Design Considerations
Use on dull, unpolished surfaces.
Avoid sharp corners. Deep cuts produce
tapers.
 Waterjet Machining (WJM)
• Force of water is used to cut.
• Recall continuity equation for incompressible fluids:
A1V1 = A2V2
– Let A2 << A1;
• A jet of water concentrated on a small area can have
very high velocity.
• Water acts like saw cutting narrow grove in material.
Waterjet Machining (WJM)
 Waterjet Machining (WJM)
• Typical pressures 60-200 kips/square inch.
• Nozzle diameters (0.0002" - 0.040").
• Can cut variety of materials, 1" thick and more.
• Excellent for foam, vinyl parts using multi-axis
machines.
• Also used in food industry for food cutting.
 Waterjet Machining (WJM)
• Advantages:
- No need for pilot holes.
- No heat generated.
- Suitable for flexible parts.
- Little wetting of work area.
- Very little burrs.
- Environmentally safe process.
Abrasive Waterjet Machining (AWJM)
• Water is mixed with abrasive particles (silicon
carbide, aluminum oxide).
• Better Material Removal Rate than regular WJM.
• Cutting Speeds: 25 ft/min for plastics, lower for
harder materials.
• Min hole diam. 0.12”; max. depth: 1”