chapter26;34 - 26.1 Why are the nontraditional material...

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26.1 Why are the nontraditional material removal processes important? Answer . Reasons for importance of are nontraditional material removal processes (1) the need to shape new metal alloys and non-metals that are difficult to machine by conventional processes; (2) the requirement of unusual and complex workpart geometries; and (3) the need to avoid surface damage which is often associated with conventional machining. 26.2 There are four categories of nontraditional machining processes, based on principal energy form. Name the four categories. Answer . The four categories are (1) mechanical, but not including conventional machining; (2) electrical; (3) thermal; and (4) chemical. 26.3 How does the ultrasonic machining process work? 1. Abrasives contained in a slurry are driven at high velocity against work by a tool vibrating at low amplitude and high frequency 2. Tool oscillation is perpendicular to work surface 3. Abrasives accomplish material removal 4. Tool is fed slowly into work 5. Shape of tool is formed into part 26.4 Describe the water jet cutting process. Uses high pressure, high velocity stream of water directed at work surface for cutting Important process parameters include standoff distance, nozzle opening diameter, water pressure, and cutting feed rate. 26.5 What is the difference between water jet cutting, abrasive water jet cutting, and abrasive jet cutting? WJC cuts with a narrow, high velocity water stream; AWJC adds abrasive grits to the water stream; and AJM cuts with abrasive particles that have been added to a high velocity air stream. 26.6 Name the three main types of electrochemical machining. 1. Electrochemical machining (ECM) 2. Electrochemical deburring (ECD) 3. Electrochemical grinding (ECG) 26.7 Identify the significant disadvantages of electrochemical machining. a) Significant cost of electrical power to drive the operation b) Problems of disposing of the electrolyte sludge 26.8 How does increasing discharge current affect metal removal rate and surface finish in electric discharge machining? As discharge current increases, metal removal rate increases and surface finish is degraded.
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26.9 What is meant by the term overcut in electric discharge machining? Overcut refers to the gap between the electrode (tool) in EDM on each side of the tool and the machined hole, cavity, or kerf (in wire EDM). 26.10 Identify two major disadvantages of plasma arc cutting. a) The cut surface is rough b) Metallurgical damage at the surface is the most severe among the nontraditional metalworking processes 26.11 What are some of the fuels used in oxyfuel cutting? C2H2; C3H4, C3H6, C3H8 26.12 Name the four principal steps in chemical machining. n Chemical milling 6 Chemical blanking 6 Chemical engraving 6 Photochemical machining 26.13 What are the three methods of performing the masking step in chemical machining? n
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chapter26;34 - 26.1 Why are the nontraditional material...

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