Manufacturing Processes
(ME361) Lecture 13
Instructor: Shantanu Bhattacharya
Numerical Problems
• Find out the approximate value of the time
required to machine a square hole (5mm X5mm)
in a tungsten carbide plate of 4mm. The abrasive
grains are of 0.01mm diameter. The feeding is
done with a constant force of 3.5N. The
amplitude of tool oscillation is about 25 microns,
the frequency being 25 KHz. The fracture
hardness of WC is approximately 6900 N/ mm2.
The slurry contains 1 part of abrasive to about 1
part of water. Assume μ = 1. Assume and a
hemispherical indentation.
Numerical Problem
Numerical Problem
Numerical Problem
Numerical Problem
Numerical Problem
Numerical Problem
Determine the percentage change in the machining
time for an USM operation cutting WC plates when the
tool material is changed from copper to stainless steel.
Numerical Problem
Numerical Problem
Ultrasonic Machining Unit
The main units of an Ultrasonic
Machining unit are shown in the
figure below. It consists of the
following machine components:
(1) The acoustic head.
(2) The feeding unit.
(3) The tool.
(4) The abrasive slurry and pump
unit.
(5) The body with work table.
Acoustic Head
1. The Acoustic head’s function is to produce a
vibration in the tool.
2. It consists of a generator for supplying a high
frequency electric current, a transducer to
convert this into a mechanical motion (in form of
a high frequency vibration).
3. A holder to hold the head.
4. A concentrator to mechanically amplify the
vibration while transmitting it to the tool.
5. Most transducers work on the magneto-strictive
principle because of high efficiency, high
reliability in the 15-30 KHz range, low supply
voltage, and simple cooling arrangement.
6. Stampings are used to reduce loss as in
transformers. The dimensions are so chosen that
the natural frequency coincides with the electric
supply frequency.
Acoustic Head
•The main purpose of the concentrator is to increase the amplitude to the level
needed for cutting.
•Various types of concentrator are used.
•The figure below shows how the amplitude of longitudinal vibration of the
transducer-concentrator assembly is amplified. It should be noted that the system has
to be held to the main body at a nodal point.
Feed Mechanism
•The objective of the feed
mechanism is to apply the
working force during the
machining operation.
•An instrument showing
the movement of the tool
indicates the depth of
machining.
•The basic type of feed
mechanisms are the
following:
1. Counterweight type
2. Spring type
3. Pneumatic and
hydraulic type
4. Motor type.
Design consideration for theTool
•The tool is made up of a strong but ductile metal.
•Stainless steels and low carbon steels are used for making the tools.
•Aluminum and brass tools wear ten and five times faster than steel tools.
•The geometrical features are decided by the process.
•The diameter of the circle circumscribed about the tool should not be more than
1.5-2.0 times the diameter of the end of the concentrator.
• The tool should be as short and rigid as possible.
•When the tool is made hollow the internal contour should be parallel to the
external one to ensure uniform wear.
•The thickness of any wall or projection should be atleast five times the grain size of
the abrasive.
•In the hollow tool the wall should not be made thinner than 0.5-0.8 mm.
•When designing the tool consideration should be given to the side clearance which
is normally of the order of 0.06-0.36mm, depending on the grain size of the
abrasive.
Abrasive Slurry
•The most common abrasives are Boron Carbide (B4C), Silicon
Carbide (SiC), Corrundum (Al2O3), Diamond and Boron silicarbide.
•B4C is the best and most efficient among the rest but it is
expensive.
•SiC is used on glass, germanium and most ceramics.
•Cutting time with SiC is about 20-40% more than that with B4C.
•Diamond dust is used only for cutting daimond and rubies.
•Water is the most commonly used fluid although other liquids
such as benzene, glycerol and oils are also used.
Summary
Electrochemical Machining (ECM)
•Electrochemical machining is one of the most unconventional machining
processes.
•The process is actually the reverse of electroplating with some modifications.
•It is based on the principle of electrolysis.
•In a metal, electricity is conducted by free electrons but in a solution the
conduction of electricity is achieved through the movement of ions.
•Thus the flow of current through an electrolyte is always accompanied by the
movement of matter.
•In the ECM process the work-piece is connected to a positive electrode and the
tool to the negative terminal for metal removal.
•The figure below shows a suitable work-piece and a suitably shaped tool, the gap
between the tool and the work being full of a suitable electrolyte.
Electrochemical
Machining
•The dissolution rate is more where the gap is less and vice versa.
•This is because the current density is inversely proportional to the gap.
Electrochemical Machining
• The dissolution rate is more where the gap is less and vice versa (as the current density is
proportional to the gap.
•Now, if the tool is given a downward motion, the work surface tends to take the same shape as that of
the tool, and at a steady state the gap is uniform.
•Thus the shape of the tool is represented in the job.
•In an electrochemical machining process, the tool is provided with a constant feed motion.
•The electrolyte is pumped at a high pressure through the tool and the small gap between the tool and
the work-piece.
•The electrolyte is so chosen that the anode is dissolved but there is no deposition on the cathode.
•The order of the current and voltage are a few 1000 amps and 8-20 volts. The gap is of the order of
0.1-0.2mm .
•The metal removal rate is typically 1600 mm3/sec for each 1000 Amp.
•Approximately 3 KW-hr. are needed to remove 16000 mm3 of metal which is almost 30 times the
energy required in a conventional process.
Electrochemical Machining
• With ECM the rate of metal
removal is independent of the
work-piece hardness.
•ECM becomes advantageous
when either the work material
possesses a very low
machinability or the shape to
be machined is complex.
•Unlike most other conventional and unconventional processes, here there is practically no
tool wear.
•Though it appears that, since machining is done electrochemically, the tool experiences
no force, the fact is that the tool and work is subjected to large forces exerted by the high
pressure fluid in the gap.
Electrochemistry of ECM process
•The electrolysis process is governed by the following two laws proposed by Faraday.
(1) The amount of chemical change produced by an electric current, that is, the amount of
any material dissolved or deposited, is proportional to the quantity of electricity passed.
(2) The amounts of different substances dissolved or deposited by the same quantity of
electricity are proportional to their chemical equivalent weights.
• In the quantitative form, Faraday’s two laws state that
mαItε
Where, m = weight (in grams) of a material dissolved or deposited,
I = Current (in amperes)
t = time (in seconds)
ε = gram equivalent weight of the material.
Ion-Ion and ion-solvent interaction
• Although strong electrolytes are completely ionized, their ions are not
entirely free to move independently of one another through the body of a
solution, except when this is infinitely dilute.
• The following things happen in such a situation:
1. Ions will move randomly wrt each other due to fairly violent thermal
motion.
2. Coulombic forces between ions of same and opposite kinds will be
present which leads to a time averaged ion atmosphere of one kind wrt.
To a central ion of the opposite kind.
3. Movement of such ions under an external electric field will be very slow.
So the atmosphere moves to the opposite direction as the primary
central ion resulting in a continouous disruption and reformation of the
atmosphere. (atmosphere assymetrically distributed around the central
ion) and electrophoretic effect(viscous drag of the atmosphere)
