Non-Traditional ManufacturingProcessesChemical Machining (CM)Electrochemical Machining(ECM)Electro-Discharge Machining (EDM)Laser cuttingUltrasonic Machining (USM)Water-Jet and Abrasive Water-Jet Machining
Non-Traditional Manufacturing Processes Chemical Machining (CM) Electrochemical Machining (ECM) Electro-Discharge Machining (EDM) Water-Jet and Abrasive Water-Jet Machining Laser cutting Ultrasonic Machining (USM)
Chemical MachiningEtching:Chemical reaction between reagent (in gas, solution, or paste form)andworkpiece.Mainuses:- Shallow, wide cavities on plates, forgings, castings reduce weight-Electronicsmanufacturing (wafer fabrication)- Hydrogen Flouride, Hydrofloric acid: etching of glass
Chemical Machining Etching: Chemical reaction between reagent (in gas, solution, or paste form) and workpiece. Main uses: - Shallow, wide cavities on plates, forgings, castings → reduce weight - Electronics manufacturing (wafer fabrication) - Hydrogen Flouride, Hydrofloric acid: etching of glass
Photo-ChemicalMachining(i) Clean(ii)UVexposure(iv) Development(v) Etching(v) Stripping(ii) Apply resistMain uses:- Flat springs, metal bookmarks, encoder wheels, lead frames for IC chips,sieves for medical applications, microwave oven filters, heat-sinks for PCBs
Photo-Chemical Machining Main uses: - Flat springs, metal bookmarks, encoder wheels, lead frames for IC chips, sieves for medical applications, microwave oven filters, heat-sinks for PCBs (i) Clean (i) Clean (ii) Apply resist (ii) Apply resist (iii) UV exposure (iii) UV exposure (iv) Development (iv) Development (v) Etching (v) Etching (v) Stripping (v) Stripping
Electrochemical Machining (ECM)Reverseofelectro-plating(workpieceisanode)H,O-(OH)+H+Naci--Na+crPump forcirculatingelectrolyteDCPowerSupplyTOC/DHTankWorkpieceElectrolyteMain uses:- Dies and glass-making molds, turbine and compressor blades, Holes, DeburringDueto lowforces ontoolTurbine NozzlesECM canbeusedtomakeholes at very large angle toasurface-an exampleisshown intheturbinenozzleholes in the figure here.Turbine Blading[source:www.barber-nichols.com]
Electrochemical Machining (ECM) Reverse of electro-plating (workpiece is anode) Main uses: - Dies and glass-making molds, turbine and compressor blades, Holes, Deburring Due to low forces on tool, ECM can be used to make holes at very large angle to a surface – an example is shown in the turbine nozzle holes in the figure here. [source: www.barber-nichols.com] Due to low forces on tool, ECM can be used to make holes at very large angle to a surface – an example is shown in the turbine nozzle holes in the figure here. [source: www.barber-nichols.com]
Electro-Discharge Machining (EDM)ElectrodeEDMToolholderComplexcombinationsofvertical,orbitatandeccentricmotionsDicleetre-Sparksbetweenelectrode-workpieceElectrode- Dielectric flushes the metal powderFilterTankSparkdischargWorkpicceInexpensive,precise,complex shapesDielectric-Workpiecemust be a conductorpumpd.c.FixturepulsegeneratorWire-cutEDMWorkpiecWteeiectrocMachinnangpiatform
Electro-Discharge Machining (EDM) - Sparks between electrode-workpiece - Dielectric flushes the metal powder - Inexpensive, precise, complex shapes - Workpiece must be a conductor Electrode EDM Wire-cut EDM