UNIT V

NON CONVENTIONAL MACHINING PROCESSES

1. Define Water Jet Machining.
Water jet machining (WJM) is a precision cutting process that utilizes a high-velocity
stream of water, often with abrasive particles, to erode materials.
2. What is the role of abrasive particles in AJM?
In Abrasive Jet Machining (AJM), abrasive particles play a crucial role in removing
material from the workpiece. They are propelled by a high-pressure gas stream and impact the
workpiece surface, causing material removal through micro-cutting and erosion.
3. Name two advantages of EDM.
Ability to create complex shapes with high precision and its versatility in machining
hard, exotic, and delicate materials.
4. Mention any two limitations of ECM.
 High Energy Consumption
 Limitation to Conductive Materials
5. List two common applications of LBM.
Micro-hole drilling, Cutting complex profiles
6. What is the frequency range used in Ultrasonic Machining?
Ultrasonic Machining (USM) utilizes a vibrating tool operating at frequencies typically
ranging from 20 to 40 kHz, which is above the audible range for humans.
7. What is the function of dielectric fluid in EDM?

1. Insulation
2. Spark Generation and Control
3. Cooling
4. Debris Removal (Flushing)
5. Surface Finish Improvement

8. Differences between WJM and AWJM

Water Jet Machining (WJM) Abrasive Water Jet Machining (AWJM)

In WJM, a high velocity jet of pure water In AWJM, a high velocity jet of water-
(sometimes mixed with stabilizer) is used to abrasive mixture is used to erode the
erode material. workpiece material.

Material removal from the workpiece takes Material removal takes place due to the micro-
place only due to the erosive action of water cutting action of abrasives (water does not
jet. directly participate in cutting the material).

No mixing chamber is desired as abrasive is A mixing chamber (focused tube) is required

not mixed with water. for mixing abrasives with the pressurized
water maintaining the pre-defined mixing
ratio.

9. Write any two properties of work materials suitable for ECM.

 The viscosity must be as low as possible
 The electrolyte must be chemically stable.
 Electrolyte must be chemically active to cause the better metal or material removal rate

10. State one application each for EDM and USM.

One application for EDM (Electrical Discharge Machining) is in the manufacturing of
dies and moulds for metalworking. One application for USM (Ultrasonic Machining) is in the
production of precise, intricate holes in hard and brittle materials like ceramics.
 11. What kind of tool material is used in EDM?
In Electrical Discharge Machining (EDM), the tool material, also known as the
electrode material, is typically made of copper, graphite, or their alloys.
12. Name two parameters affecting the MRR in AJM.
Pressure and abrasive particle size
13. What is the typical pressure range used in WJM?
Although WJM machines are capable of producing pressures of up to 1400 MPa (20000
psi), these pressures are commonly employed for efficient operation. They range from 350 to
400 MPa (50000 to 60000 psi).
14. Write two advantages of using LBM for micro-machining.

o Material Versatility: Laser Beam Machining can process any type of material, including non-
metallic ones, widening its applicability across various industries.
o Precision in Small Holes: This technique excels in machining extremely small holes with
exceptional accuracy, meeting stringent requirements for precision engineering.
o Low Tool Wear: Laser Beam Machining exhibits minimal tool wear, contributing to cost-
effectiveness and longer tool life.
o Non-Mechanical Processing: The absence of mechanical force on the workpiece ensures
delicate materials like plastics and rubber can be machined with ease, avoiding deformation or
damage.
o Versatility and Automation: Laser Machining is highly flexible and easily automated,
allowing for efficient and adaptable production processes.

15. Mention two disadvantages of USM.

 Its slow material removal rate and the potential for rapid tool wear.
 Is not ideal for high-volume production or jobs requiring fast material removal.
16. Explain the principle, working, advantages and disadvantages of Water Jet Machining.
Water Jet Machining (WJM), also known as water jet cutting, is a non-conventional
machining process that utilises a high-velocity jet of water to remove materials from the surface
of the workpiece precisely.
Types of Water Jet Machining

Water Jet Machining (WJM) encompasses two fundamental types of processes:

Pure Water Jet Machining:

In Pure Water Jet Machining, the cutting medium used is solely pure water, without
any additives. This high-pressure water jet is employed to cut through materials effectively.

Abrasive Water Jet Machining:

Abrasive Water Jet Machining (AWJM) utilises abrasive particles, such as garnet abrasives,
silicon carbide, or aluminium oxide, mixed with the water jet to significantly enhance the material-
removal rate. AWJM allows precise cutting of various thicknesses of metallic, non-metallic, plastic,
and advanced composite materials, whether in single or multilayer forms. The AWJM machine employs
nozzle materials made of rubies, sapphires, and diamonds, and it enables precise control over the level
of abrasives to achieve optimal cutting results.
Parts of Water Jet Machining

Water Jet Machining comprises several essential parts that work together to facilitate the machining
process:
Hydraulic Pump:
This component circulates water from the storage tank during machining. Operating at low pressure
(about 5 bars), it supplies water to the intensifier. A booster raises the initial water pressure to 11 bars
before reaching the intensifier.
Hydraulic Intensifier:
Responsible for boosting water pressure to extremely high levels, the hydraulic intensifier receives
water from the pump at 4 bars and elevates it to a range of 3000 to 4000 bars.
Accumulator:
The accumulator temporarily stores the highly pressurised water, delivering it when substantial pressure
energy is required. It ensures a smooth and stable machining process by eliminating pressure
fluctuations.
Mixing Chamber or Tube:
The mixing chamber acts as a vacuum chamber where abrasive particles and water are combined.
Control Valve:
The control valve manages the pressure and direction of the water jet, enabling precise control over the
machining process.
Flow Regulator or Valve:
The flow regulator regulates the water flow, allowing adjustments as needed during the machining
operation.
Nozzle:
This crucial device converts the pressure energy of water into kinetic energy for the water jet. The
nozzle creates a high-velocity water jet beam, typically made of ruby or diamond, at the tip to resist
erosion.
Drain and Catcher System:
Post-machining, the drain and catcher system effectively separates debris and machined particles from
the water. It removes unwanted metal particles and other contaminants, ensuring clean water returns to
the reservoir for reuse in subsequent operations.
Working Principle of Water Jet Machining
Water Jet Machining operates on the principle of water erosion, where a high-velocity jet of water
impacts the workpiece surface, resulting in material removal. A pure water jet is employed in the
machining process for softer materials. However, the water is mixed with abrasive particles to cut harder
materials effectively, transforming it into Abrasive Water Jet Machining (AWJM). In AWJM, the
abrasive particles enhance the cutting power, enabling precise and efficient machining of tougher
materials.

17. Describe the process of Abrasive Jet Machining. Discuss its major parameters, advantages,
and limitations.

This advanced machining technique, known as Abrasive Water Jet Machining (AWJM), utilises
abrasive particles as a medium. In contrast to conventional water jet machining, AWJM addresses its
limitations by introducing abrasive particles into the water stream. Propelled at a high velocity from the
nozzle, this mixture effectively erodes material from the workpiece's surface, achieving precise shaping
and sizing with exceptional accuracy.
Construction of Abrasive Water Jet Machining
The construction of Abrasive Water Jet Machining (AWJM) centers around a high-pressure system and
precision components. It begins with a powerful water pump that generates pressures exceeding 40,000
psi, which is directed to a mixing chamber where abrasive particles are added to create a slurry.

The various parts of Abrasive Water Jet Machining are:

Reservoir
The reservoir serves as the fundamental component for storing water, ensuring a consistent supply to
all other parts of the system for proper operation.
Hydraulic Pump
In the AWJM setup, the hydraulic pump assumes a crucial role as it facilitates the transfer of fluid from
one location to another. It acts as an intermediary, drawing water from the reservoir and conveying it
to the hydraulic intensifier.
Hydraulic Intensifier
Positioned after the hydraulic pump, the hydraulic intensifier is responsible for elevating the water's
pressure to the required level for effective operation.
Accumulator
The accumulator functions as a temporary water storage unit, providing water to the system in instances
of pressure drops or when high-pressure water is needed.
Control Valves
The pressure control valve within the system plays a dual role, regulating both water pressure and its
direction. A flow regulator valve is also incorporated to control the flow of water into the system.
Flow Regulator
As its name suggests, the flow regulator governs the water flow originating from the control valve,
directing it toward the nozzle.
Abrasive Tank
Abrasive particles are pivotal in the AWJM process, especially for cutting hard materials. Commonly
used abrasives include aluminum oxides, sand, garnet, and glass particles, among others.
Mixing Chamber
In contrast to traditional water jet machining, AWJM employs a mixture comprising 70% water and
30% abrasive particles blended in the mixing chamber.
Nozzle
The nozzle's primary role is to convert high-pressure water into kinetic energy (K.E), which is
intensified as the nozzle area decreases. This high kinetic energy of water, combined with abrasive
particles, is directed onto the workpiece's surface, rapidly achieving the desired shape and size.
Drain System
The drain system's primary function is to collect water discharged from the work region and return it to
the reservoir through the pump and filter, ensuring a continuous water supply for the process.
Working of Abrasive Water Jet Machining

The working of Abrasive water jet machining can be understood by going through the pointers given
below:
 o Water is sourced from the reservoir and distributed throughout the system, beginning with its
journey from the reservoir to the drainage system. Initially, the water undergoes pressurisation
in the hydraulic intensifier before being directed to the accumulator for temporary storage.
o Control valves within the system manage water pressure and control its directional flow.
Subsequently, abrasive particles are introduced into the mixing chamber, forming a mixture
with water in a ratio of 30% abrasive particles to 70% water.
o When these high-velocity abrasive particles impact hard workpieces, they can induce plastic
deformation and fracture in the hard materials.
o Increasing the percentage of abrasives enhances material removal but diminishes the flow
characteristics of the liquid mixture. Consequently, the optimal abrasive percentage typically
falls within the range of 40% to 60%.
o This technology primarily finds its application in the intricate cutting of complex shapes in
materials like granite and marble.

Abrasive Water Jet Machining Parameters

Abrasive Water Jet Machining (AWJM) parameters are critical factors that influence the machining
process's precision and efficiency. The parameters of the Abrasive Water Jet Machining process are as
follows.

o Water flow rate

o Water Pressure
o Abrasive Flow rate
o Abrasive particle size
o Abrasive materials
o Nozzle diameter
o Traverse rate
o Stand-off distance
o Depth of cut
o Material properties.

Abrasive Particle Size

In the Abrasive Water Jet Machining (AWJM) process, abrasive particles are typically employed within
the 100 to 150 grit range.

Abrasive Materials
Commonly used abrasive materials include Garnet (which offers 30% greater efficiency than sand),
silicon carbide, and silica.

Traverse Rate
Increasing the traverse rate results in a reduction in the depth of cut, with typical traverse speeds ranging
from 100 mm/min to 5 m/min.

Stand-off Distance
An increased stand-off distance leads to a shallower depth of cut, with the standard maintained within
the range of 1-2mm.

Depth of Cut
The depth of cut in AWJM typically falls within the range of 1 mm to 250 mm.

18. With a neat diagram, explain the working principle of Electro Discharge Machining. Compare
it with conventional machining.
Electrical discharge machining, also known as spark erosion or metal sparking machining, is a
non-conventional machining technique that relies on erosion as its fundamental principle. In electrical
discharge machining, or EDM for short, an electro thermal non-traditional machining process is
employed, utilising electrical energy to create sparks for material erosion. EDM is particularly valuable
for machining challenging-to-work-with materials.
Components of EDM Machining

EDM machining primarily consists of two essential components: the workpiece, typically made
of conductive material, and the electrode (tool), which generates electrical discharges to remove
material from the workpiece through controlled sparks.

An EDM machine consists of the following parts:

o DC pulse Generator
o Voltmeter
o Ammeter
o Tool
o Die electric fluid
o Pump
o Filter
o Servo Controlled Feed
o Fixtures
o Table

Working Principle of Electrical Discharge Machining

Electrical discharge machining operates based on the concept of material removal through the
combination of electrical and thermal energy. Electrical energy is harnessed to generate an electric
spark, and heat is generated as a result of metal erosion.

In electrical discharge machining, there is no physical contact between the tool and the
workpiece, making it a non-conventional machining process. In this process, the tool electrode is
connected to the negative (-) terminal of the DC power supply, while the workpiece is connected to the
positive (+) terminal of the DC power supply. Therefore, the tool functions as the cathode, and the
workpiece functions as the anode.

A spark gap of approximately 0.05 to 0.25 mm exists between the tool and the workpiece within
the flow of dielectric fluid. This dielectric fluid serves both as an insulator and a conductor. When the
DC power supply is activated, the tool electrode generates a spark, and this spark travels to the
workpiece through the dielectric fluid, enabling the machining process.
Comparison: EDM vs. Conventional Machining
Feature EDM Conventional Machining

Spark erosion (melting and

Material Removal Shear deformation using cutting tools
vaporizing)
 Feature EDM Conventional Machining

No direct contact (non-contact Direct contact between tool and

Tool Contact
process) workpiece

Tool Material Must be conductive Can be harder than the workpiece

Only conductive materials can be Both conductive and non-conductive

Material Type
machined materials

Depends on tool sharpness and cutting

Surface Finish Excellent (micro-level)
speed

Moderate (wears due to spark Depends on material and cutting

Tool Wear
erosion) conditions

Complex Shapes Easily machinable Difficult or costly to achieve

Heat Affected Zone

Present Less prominent
(HAZ)

Productivity Lower than conventional methods Generally higher

Burr Formation None Burrs may form

19. Illustrate with the help of a simple diagram, explain the working of Electro-chemical
machining process.
Electrochemical Machining (ECM) is a precise metal removal process utilizing electrolysis. It
dissolves material from a workpiece through controlled electrically-assisted chemical reactions. ECM
is adept at intricate shapes, hard materials, and avoids mechanical stress. Industries like aerospace and
medical devices benefit from its high precision and material preservation.

Workpiece:
The workpiece serves as the anode in ECM and is the object to be machined, with the material removal
rate dependent on the atomic weight and valency of the work material. It can be any electrically
conducting material and is insulated from the system to prevent current leakage.

Tool:

The tool, serving as the cathode, is used to remove material from the workpiece. It is connected to the
negative terminal of the power supply and must meet specific criteria, including being a good conductor
of electricity, rigid enough to handle load and fluid pressure, chemically inert with respect to the
electrolyte, and easily formable and machinable to the desired shape. The tool's accuracy directly affects
the precision of the machined workpiece.

Feed Unit:
A servo motor-driven feed unit provides controlled material removal from the workpiece. It ensures a
feed rate ranging from 0.5 mm/min to 15 mm/min.
Tank:
The tank holds the electrolyte in which both the tool and workpiece are immersed during the machining
process.
Workpiece Holding Table:
The workpiece holding table securely holds the workpiece in place during machining.

20. Describe the construction and working of Laser Beam Machining. What are its typical
applications and hazards?
Laser Beam Machining (LBM) is a precise non-contact manufacturing process that utilizes a focused
laser beam to remove material from a workpiece. Widely used in industries such as aerospace and
electronics, LBM offers high accuracy and minimal heat-affected zones. It's ideal for intricate designs
and delicate materials, enhancing manufacturing versatility.

Working Principle of Laser Beam Machining

o Laser Machining is a sophisticated process that relies on the principles of LASER technology,
involving the conversion of electric energy into light energy and subsequently into thermal
energy. At the atomic level, electrons orbit around the nucleus in specific energy levels, with
each orbital associated with distinct energy states. At absolute zero temperature, electrons
occupy their lowest potential energy, known as the ground state. However, as the temperature
rises, electrons can absorb energy and transition to higher energy states through electronic
vibration.
o The working principle of Laser Beam Machining involves the application of high voltage,
leading to the formation of gas plasma through discharge. This creates a condition called
population inversion, triggering lasing action as energy transforms within the system. The laser
setup typically consists of one 100% reflector and one partial reflector. The 100% reflector
guides photons inside the gas tube, while the partial reflector allows only a specific portion of
the laser beam for material processing.
o During the machining process, the focused laser beam interacts with the workpiece, delivering
thermal energy to the target area. Consequently, the material undergoes heating, melting,
 vaporisation, and removal. As a result, Laser Machining offers exceptional precision for
material removal, utilising a coherent beam of light to carry out intricate machining tasks.
o In this process, the Material Removal Rate (MRR) is influenced by the wavelength of the laser
used, as it determines the amount of energy impinging on the workpiece. By understanding and
controlling these principles, Laser Machining enables the precise and efficient shaping of
materials for a wide range of applications.

Application of Laser Beam Machining

Laser Beam Machining finds diverse applications in various industries, owing to its precision and
versatility:

o Micro Hole Machining: Laser Machining is ideal for creating very small holes, making it
invaluable in industries requiring intricate and precise micro-drilling operations.
o Welding Non-Conductive and Refractory Materials: Laser Machining is employed for
welding non-conductive and refractory materials, expanding its utility in specialised
manufacturing processes.
o Brittle and Low Conductivity Materials: It excels in machining brittle materials with low
conductivity, such as ceramics, cloth, and wood, where traditional methods may be less
effective.
o Surgical Procedures: In medical science, Laser Machining plays a vital role in surgical
applications, enabling precise and minimally invasive procedures.
o Spectroscopic Science and Photography: The laser's coherent light is utilised in spectroscopic
science and medical photography, enhancing analytical capabilities and diagnostic imaging.
o Mass Macro Machining Production: Laser Machining is employed in mass production
processes, where it offers efficient and consistent machining of large-scale components.
o Cutting Complex Profiles: The technology's ability to cut complex profiles makes it valuable
in various industries, especially for thin and hard materials requiring intricate designs.
o Tiny Hole Fabrication: Laser Machining is used to create tiny holes with exceptional
precision, exemplified by applications like manufacturing nipples for baby feeders.

21. Explain the working of Ultrasonic Machining with a neat sketch. Discuss the effect of
frequency and amplitude on MRR.
Ultrasonic Machining (USM) employs ultrasonic vibrations and abrasive slurry to erode
material from a workpiece. This non-thermal process excels in intricate and fragile materials,
maintaining structural integrity. USM finds applications in creating complex shapes for
semiconductors, ceramics, and jewelry, where traditional methods might fall short.
Working of Ultrasonic Machining

o The working principle of Ultrasonic Machining involves maintaining a 0.25 mm gap between
the ductile tool and the workpiece, with a slurry of abrasive particles in between. As the tool
moves downward, the embedded abrasives hammer the workpiece, effectively removing
material. The slurry facilitates material flushing from the machining area, ensuring clean results
and allowing for the creation of straight holes with a slightly tapered tool.
o In Ultrasonic Machining, varying certain parameters affects the material removal rate (MRR).
Increasing the viscosity of the carrier fluid leads to a decrease in MRR due to reduced flushing
efficiency. Elevating the frequency results in increased MRR as more impacts occur per unit
time. Similarly, raising the amplitude boosts MRR by enhancing the momentum of the
abrasives. The amplitude of vibration can vary between 5 to 75 µm, while the frequency ranges
from 19 to 25 kHz.
o Moreover, MRR can be influenced by adjusting the concentration and size of the abrasives.
Higher abrasive concentration leads to more impacts and increases MRR until a point where
collisions between the abrasive particles cause momentum loss, subsequently reducing MRR.
Similarly, increasing the size of the abrasive results in a larger impact area, but exceeding a
certain size diminishes the momentum of the abrasives.
o In terms of material removal rate, it is essential to note that Ultrasonic Machining (USM) ranks
between Electrochemical Machining (ECM) and Electrical Discharge Machining (EDM)
22. Discuss the advantages and disadvantages of non-traditional machining processes in
comparison to conventional methods.
Advantages of Non-Traditional Machining (NTM) Processes:

1. Machining of Hard and Brittle Materials:

o NTM processes can machine hard-to-cut materials such as ceramics, hardened steels,
composites, and super alloys, which are challenging for conventional methods.
2. No Tool Wear (in some processes):
o Processes like Electro Chemical Machining (ECM) and Laser Beam Machining (LBM)
involve no direct contact, hence no tool wear.
3. Complex Shapes and Fine Features:
o Capable of producing intricate geometries, micro-holes, and high-aspect-ratio features,
which are difficult or impossible with conventional machining.
4. Minimal Residual Stresses and Burrs:
o Since many NTM methods are non-contact or low-force, they produce parts with
minimal mechanical distortion or burr formation.
5. Suitable for Thin or Fragile Components:
o Low-force techniques like Ultrasonic Machining (USM) or Water Jet Machining
(WJM) can machine fragile components without deformation.
6. No Heat-Affected Zones (for some):
o AJM and WJM generate little or no heat, avoiding thermal damage to the workpiece.

Disadvantages of Non-Traditional Machining Processes:

1. High Initial and Operating Costs:

o Machines and maintenance for NTM methods (e.g., laser systems, EDM setups) are
expensive compared to traditional tools.
2. Lower Material Removal Rates (in some):
o Processes like ECM, AJM, and USM may have lower productivity for bulk material
removal than conventional machining.
3. Limited Material Compatibility:
o Some methods are restricted to electrically conductive materials (e.g., EDM, ECM),
while others may not work well with ductile materials (e.g., USM).
4. Complex Setup and Skilled Operation:
o Requires skilled operators and specialized knowledge for setup, parameter selection,
and maintenance.
5. Environmental and Safety Issues:
o Certain processes (e.g., WJM, EDM) involve hazardous waste, noise, or fumes,
requiring special handling and safety precautions.
6. Surface Finish and Tolerance Control:
 o May not always achieve tight tolerances or desired surface finish without secondary
operations.

23. Explain the various factors affecting the performance of AJM and how they influence the
machining rate.

In Abrasive Jet Machining (AJM), the performance and Material Removal Rate (MRR) are
influenced by several factors related to the abrasive jet stream and operating conditions. These factors
affect how efficiently material is removed from the work surface. Below are the key factors and their
influence:

1. Abrasive Type
 Description: Common abrasives include aluminum oxide, silicon carbide, glass beads, and
crushed glass.
 Influence: Harder abrasives (e.g., silicon carbide) produce a higher machining rate and can cut
harder materials more effectively. However, very hard abrasives may cause nozzle wear.

2. Abrasive Grain Size

 Description: Typically ranges from 10 to 50 microns.
 Influence:
o Smaller grains → Finer surface finish but lower MRR.
o Larger grains → Higher MRR but rougher surface finish.
There is an optimal grain size that balances MRR and surface quality.

3. Abrasive Flow Rate

 Description: Mass of abrasive particles delivered per unit time.
 Influence:
o Initially, MRR increases with abrasive flow rate because more particles impact the
surface.
o Beyond a certain point, MRR decreases due to particle interference and energy
sharing.

4. Gas Pressure
 Description: Pressure of the carrier gas (typically air, nitrogen, or CO₂), often between 2–8
bars.
 Influence:
o Higher pressure increases particle velocity → higher kinetic energy → higher MRR.
o But excessive pressure can cause excessive wear on the nozzle and affect accuracy.

5. Nozzle Design and Material

 Description: Shape (cylindrical or converging), diameter, and material (e.g., tungsten carbide
or sapphire).
 Influence:
o Smaller diameter → concentrated jet, higher precision, but lower MRR.
o Worn nozzles cause jet dispersion, reducing MRR and accuracy.
o Nozzle shape affects focus and directionality of the jet.

6. Stand-off Distance (SoD)

 Description: Distance between the nozzle tip and the work surface.
 Influence:
o Shorter SoD → more focused jet, higher MRR, better accuracy.
o Longer SoD → dispersed jet, reduced MRR and poor precision.
An optimal SoD is necessary for best performance.

7. Work Material Properties

 Description: Includes hardness, brittleness, and toughness.
  Influence:
o Brittle materials (glass, ceramics) are more easily fractured by abrasive particles →
higher MRR.
o Ductile materials (aluminum, copper) resist micro-chipping → lower MRR.

8. Nozzle Angle (Impact Angle)

 Description: Angle at which abrasive particles strike the surface (typically 60°–90°).
 Influence:
o 90° (normal) → effective for brittle materials.
o 60°–70° (oblique) → better for ductile materials due to shearing action.
o Optimal angle varies with material type.

24. With a neat sketch, explain the working of Abrasive Water Jet Machining. How is it different
from pure WJM?
Abrasive Water Jet Machining (AWJM) is a cutting-edge manufacturing process that uses a
high-velocity stream of water mixed with abrasive particles to precisely cut, shape, and machine a wide
range of materials, including metals, ceramics, and composites. It offers advantages such as minimal
heat-affected zones and intricate, burr-free cuts, making it ideal for applications in aerospace,
automotive, and architectural industries.
Construction of Abrasive Water Jet Machining

The construction of Abrasive Water Jet Machining (AWJM) centers around a high-pressure system and
precision components. It begins with a powerful water pump that generates pressures exceeding 40,000
psi, which is directed to a mixing chamber where abrasive particles are added to create a slurry.

The various parts of Abrasive Water Jet Machining are:

Reservoir
The reservoir serves as the fundamental component for storing water, ensuring a consistent supply to
all other parts of the system for proper operation.
Hydraulic Pump
In the AWJM setup, the hydraulic pump assumes a crucial role as it facilitates the transfer of fluid from
one location to another. It acts as an intermediary, drawing water from the reservoir and conveying it
to the hydraulic intensifier.
Hydraulic Intensifier
Positioned after the hydraulic pump, the hydraulic intensifier is responsible for elevating the water's
pressure to the required level for effective operation.
Accumulator
The accumulator functions as a temporary water storage unit, providing water to the system in instances
of pressure drops or when high-pressure water is needed.
Control Valves
The pressure control valve within the system plays a dual role, regulating both water pressure and its
direction. A flow regulator valve is also incorporated to control the flow of water into the system.
Flow Regulator
As its name suggests, the flow regulator governs the water flow originating from the control valve,
directing it toward the nozzle.
Abrasive Tank
Abrasive particles are pivotal in the AWJM process, especially for cutting hard materials. Commonly
used abrasives include aluminum oxides, sand, garnet, and glass particles, among others.
Mixing Chamber
In contrast to traditional water jet machining, AWJM employs a mixture comprising 70% water and
30% abrasive particles blended in the mixing chamber.
Nozzle
The nozzle's primary role is to convert high-pressure water
into kinetic energy (K.E), which is intensified as the nozzle
area decreases. This high kinetic energy of water, combined
with abrasive particles, is directed onto the workpiece's
surface, rapidly achieving the desired shape and size.
Drain System
The drain system's primary function is to collect water
discharged from the work region and return it to the reservoir
through the pump and filter, ensuring a continuous water
supply for the process.
Working of Abrasive Water Jet Machining
The working of Abrasive water jet machining can be
understood by going through the pointers given below:
o Water is sourced from the reservoir and distributed throughout the system, beginning with its
journey from the reservoir to the drainage system. Initially, the water undergoes pressurisation
in the hydraulic intensifier before being directed to the accumulator for temporary storage.
o Control valves within the system manage water pressure and control its directional flow.
Subsequently, abrasive particles are introduced into the mixing chamber, forming a mixture
with water in a ratio of 30% abrasive particles to 70% water.
o When these high-velocity abrasive particles impact hard workpieces, they can induce plastic
deformation and fracture in the hard materials.
o Increasing the percentage of abrasives enhances material removal but diminishes the flow
characteristics of the liquid mixture. Consequently, the optimal abrasive percentage typically
falls within the range of 40% to 60%.
o This technology primarily finds its application in the intricate cutting of complex shapes in
materials like granite and marble.
25. Explain the working of ECM with a neat diagram. Discuss the role of electrolyte and the tool
in the process.
Electrochemical Machining (ECM) is a precise metal removal process utilizing electrolysis. It
dissolves material from a workpiece through controlled electrically-assisted chemical reactions. ECM
is adept at intricate shapes, hard materials, and avoids mechanical stress. Industries like aerospace and
medical devices benefit from its high precision and material preservation.

Workpiece:
The workpiece serves as the anode in ECM and is the object to be machined, with the material removal
rate dependent on the atomic weight and valency of the work material. It can be any electrically
conducting material and is insulated from the system to prevent current leakage.
Tool:
The tool, serving as the cathode, is used to remove material from the workpiece. It is connected to the
negative terminal of the power supply and must meet specific criteria, including being a good conductor
of electricity, rigid enough to handle load and fluid pressure, chemically inert with respect to the
electrolyte, and easily formable and machinable to the desired shape. The tool's accuracy directly affects
the precision of the machined workpiece.
Feed Unit:
A servo motor-driven feed unit provides controlled material removal from the workpiece. It ensures a
feed rate ranging from 0.5 mm/min to 15 mm/min.
Tank:
The tank holds the electrolyte in which both the tool and workpiece are immersed during the machining
process.
Workpiece Holding Table:
The workpiece holding table securely holds the workpiece in place during machining.
Role of Electrolyte in ECM
The electrolyte plays multiple essential roles:
Function Description

Ion Conduction Completes the electric circuit between tool and workpiece

Metal Dissolution Carries away dissolved metal ions from the workpiece

Cooling Removes heat generated during machining

Gas Removal Flushes out hydrogen and oxygen gases formed by electrolysis

Preventing Passivation Prevents formation of oxide films on the work surface

27. Explain the following in LBM process. (i)Advantages (ii)Disadvantages (iii)Application

In the Laser Beam Machining (LBM) process, a high-energy laser beam is focused on the
workpiece surface to remove material by melting and vaporization. It is a non-contact, thermal-
based non-traditional machining process.

Here is a breakdown of the requested points:

(i) Advantages of LBM:

1. Non-contact Process: No tool wear as there is no physical contact between tool and workpiece.
2. Precision and Accuracy: Capable of producing very fine and intricate features with tight
tolerances.
3. Can Machine Hard Materials: Easily machines hard, brittle, and difficult-to-machine
materials like ceramics, diamonds, and superalloys.
4. Minimal Heat-Affected Zone (HAZ): Especially with pulsed lasers, the localized heating
minimizes thermal damage to surrounding material.
5. No Mechanical Force: Ideal for delicate and thin materials since there is no mechanical stress
involved.
6. Micro-Machining Capabilities: Effective for micro-drilling, engraving, and cutting very small
and precise features.
7. Automation Friendly: Easily integrated into CNC systems and automated setups.

(ii) Disadvantages of LBM:

1. High Initial Cost: Laser systems are expensive to set up and maintain.
2. Low Material Removal Rate (MRR): Not suitable for high-volume material removal or bulk
cutting.
 3. Heat-Affected Zone (HAZ): Though minimal, it can still cause micro-cracks or thermal
damage in some materials.
4. Limited to Thin Materials: Thick materials are difficult to cut or drill due to limited
penetration depth.
5. Requires Skilled Operation: Proper focusing and control of the laser requires technical
expertise.
6. Reflective Materials: Difficult to machine highly reflective surfaces like copper or aluminum
without special lasers.

(iii) Applications of LBM:

1. Micro-drilling of holes in aerospace and medical components.

2. Cutting and shaping of intricate parts in the electronics industry (e.g., PCB fabrication).
3. Engraving and marking on metals, plastics, and ceramics.
4. Welding and cladding in automotive and aerospace industries.
5. Surgical tools manufacturing and other biomedical applications.
6. Texturing and surface modification in tool and die industries.