me_350_-_lect_24_-_ch_26.20091112.4afcf52b7ebd76.99407892

me_350_-_lect_24_-_ch_26.20091112.4afcf52b7ebd76.99407892 -...

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ME 350 – Lecture 24 – Chapter 26 NONTRADITIONAL MACHINING PROCESSES 1. Mechanical Energy Processes (USM, WJC, AJM) - high velocity stream of abrasives or fluid (or both) 1. Electrochemical Processes (ECM) - reverse of electroplating 1. Thermal Processes (EDM, Wire EDM, EBM, LBM, PAC) - vaporizing of a small area of work surface 1. Chemical Processes (CHM, Chemical Blanking, PCM) - chemical etching of areas unprotected by “maskant” Nontraditional machining is characterized by material removal that:
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Nontraditional Processes Used When: 1. Material is either very hard, brittle or both; or material is very ductile: 2. Part geometry is complex or geometric requirements impossible with conventional methods: 3. Need to avoid surface damage or contamination that often accompanies conventional machining:
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1. Mechanical Energy Processes Ultrasonic machining (USM) Water jet cutting (WJC) Abrasive jet machining (AJM)
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1a) Ultrasonic Machining (USM) Abrasives in a slurry are driven at high velocity against Tool oscillation is perpendicular to work surface Abrasives accomplish material removal Tool is fed slowly into work Shape of tool is formed into part
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USM Applications Used only on hard and brittle work materials: Shapes include non-round holes, holes along a curved axis “Coining operations” - pattern on tool is imparted to a flat work surface Produces virtually stress free shapes Holes as small as 0.076 mm have been made
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Uses high pressure, high velocity stream of water directed at work surface for cutting 1b) Water Jet Cutting (WJC)
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WJC Applications Usually automated using CNC or industrial robots Best used to cut narrow slits in flat stock such as: Not suitable for: When used on metals, you need to add to the water stream: Smallest kerf width about 0.4 mm for metals, and 0.1mm for plastics and non-metals. More info: http://www.waterjets.org/index.html
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WJC Advantages No crushing or burning of work surface Minimum material loss No environmental pollution Ease of automation
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High velocity gas stream containing abrasive particles (aka: sand blasting or bead blasting) Normally used as a finishing process rather than
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me_350_-_lect_24_-_ch_26.20091112.4afcf52b7ebd76.99407892 -...

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