Introduction to
Manufacturing Technology
Lecture 2
Instructors:
(1)Shantanu Bhattacharya, ME, IITK,
email: [email protected]
(2)Prof. Arvind Kumar, ME, IITK email:
[email protected]
Review of Last Lecture
Manufacturing systems approaches.
Basic manufacturing processes.
(Casting, Forming process, Fabrication
process, Material removal process)
Advanced Machining processes (ECM,
EDM, EBM, LBM, AJM, USM processes)
Classification of Non Traditional
Machining
Single action non traditional Machining processes:
For these processes only one machining action is used for material removal. These
can be classified according to the source of energy used to generate such a
machining action: mechanical, thermal, chemical and electrochemical.
Mechanical Machining
Ultrasonic Machining (USM) and Waterjet Machining (WJM) are
typical examples of single action, mechanical non traditional
machining processes.
The machining medium is solid grains suspended in an abrasive
slurry in the former, while a fluid is employed in the WJM process.
The introduction of abrasives to the fluid jet enhances the
machining efficiency and is known as abrasive water jet
machining. Similar case happens when ice particles are introduced
as in Ice Jet Machining.
Basics of the USM process
The basic USM process involves a tool ( made of a ductile
and tough material) vibrating with a very high frequency
and a continuous flow of an abrasive slurry in the small gap
between the tool and the work piece.
The tool is gradually fed with a uniform force.
The impact of the hard abrasive grains fractures the hard
and brittle work surface, resulting in the removal of the
work material in the form of small wear particles.
The tool material being tough and ductile wears out at a
much slower rate.
Mechanics of USM
The reasons for material removal in an USM process are
believed to be:
1. The hammering of the abrasive particles on the work surface
by the tool.
2. The impact of free abrasive particles on the work surface.
3. The erosion due to cavitation.
4. The chemical action associated with the fluid used.
A no. of researchers have tried to develop the theories to
predict the characteristics of ultrasonic machining. The model
proposed by M.C. Shaw is generally well accepted and explains
the material removal process well.
1.
2.
3.
4.
5.
M.C. Shaws model of USM
mechanics
In this model the direct impact of the tool on the
grains in contact with the work piece is taken into
consideration. Also, the assumptions made are:
The rate of work material removal is proportional
to the volume of the work material per impact.
The rate of work material removal is proportional
to the no. of particles making impact per cycle.
The rate of work material removal is proportional
to the frequency (no. of cycles per unit time).
All impacts are identical.
All abrasive grains are identical and spherical in
shape.
USM process
Thus, volume of work material removal
rate (Q)
Q vZ
where, v = volume of the work material
removal
per impact
Z = number of particles making
impact
per cycle
= frequency
Mechanics of USM
Let us now consider the impact of a
rigid, spherical abrasive grain of
diameter d on the work surface.
Calculation of Crater Volume
Calculation of the Crater
Volume
Mechanics of USM
Mechanics of USM
Various Tool Position
during a USM cycle.
The position A indicates the instant the tool face touches the
abrasive grain.
The period of movement from A to B represents the impact.
The indentations, caused by the grain on the tool and the work
surface at the extreme bottom position of the tool from the position
A to position B is h (the total indentation).
Indentations on tool and work
surface at bottom position of
the tool
