IE 204 Manufacturing Processes

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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
NONTRADITIONAL MACHINING PROCESSES
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
CHEMICAL MACHINING
Material is removed from a surface by chemical
dissolution, using chemical reagents or etchants
(e.g. acids and alkaline solutions) Applications
? printed-circuit boards and microprocessor chips
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Chemical Milling

• Shallow cavities on plates, sheets, forgings and
  extrusions
• Maximum depth of removal ? 12 mm
• Chemical attack by the reagent on different areas
  of the w/p
• is controlled by removable layers of material
  (masking) or by
• partial immersion in the reagent
• May result in some surface damage
• Mainly used in aerospace industry, also in the
  fabrication of
• microelectronic devices

Atilim University / Dept. of Industrial
Engineering
4
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Chemical Blanking

• Production of features which penetrate through
  the thickness
• of the material by chemical dissolution
• Applications ? Burr-free etching of
  printed-circuit boards,
• decorative panels, thin-sheet
  metal stamping

Atilim University / Dept. of Industrial
Engineering
7
IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Photochemical Blanking

• Photochemical blanking ? Material is removed from
  flat thin-sheet by photographic techniques
• Applications ? printed-circuit cards,
  electric-motor laminations, masks for color TV
• Skilled labor is required
• Low tooling costs, economical for medium to high
  production volume
• Safety for handling chemical reagents
• Disposal of chemical by-products

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
ELECTROCHEMICAL MACHINING
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Applications ? Complex cavities in high-strength
  materials,
• in the aerospace industry turbine blades,
  jet-engine parts,
• nozzles, also for machining forging-die cavities
• Burr-free surface, no thermal damage, no tool
  wear
• Capable of producing complex shapes as well as
  machining hard
• materials
• Not suitable for producing sharp square corners
  or flat bottoms,
• due to the tendency for the electrolyte to erode
• Irregular cavities may not be produced to the
  desired shape,
• since controlling electrolyte flow is difficult

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
ELECTROCHEMICAL GRINDING
Electrochemical machining conventional grinding
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Not suitable for cavity-sinking operations, such
  as die making
• Successfully applied to carbides and
  high-strength alloys
• Advantageous when processing very hard materials
  where
• traditional grinding wheel wear is high

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
ELECTRICAL-DISCHARGE MACHINING (EDM)
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Dielectric fluids mineral oil, kerosene,
  distilled and deionized water
• Can be used to machine any material which is
  electrically conductive
• Tool wear is related to the melting point of the
  material the lower the melting point, the higher
  the wear rate
• Applications ? die cavities for large automotive
  body components, small-diameter deep holes,
  narrow slots, turbine blades and various
  intricate shapes

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
WIRE EDM
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Used to cut plates as thick as 300 mm for making
  punches, tools and dies from hard metals, for
  cutting intricate components for electronics
  industry
• Wire material brass, copper, tungsten (0.25 mm
  in diameter)

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
LASER BEAM MACHINING
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
Important parameters Reflectivity and thermal
conduction of the workpiece surface Used in
drilling and cutting metals, nonmetals and
composite materials in electronics and automative
industries
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
ELECTRON BEAM MACHINING AND PLASMA ARC CUTTING

• Source of energy is high-velocity electrons in
  EBM and plasma beams (ionized gas) in PAC
• Applications are similar to those for LBM,
  generally used for very accurate cutting of metals

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
WATER-JET MACHINING (WJM)
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Various materials can be cut such as plastics,
  fabrics, rubber, wood, paper, leather,composite
  materials
• Efficient and clean, used for cutting and slicing
  food products
• Cut can be started at any location
• No heat is produced
• No deflection of the rest of the w/p
• Environmentally safe

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
ABRASIVE-JET MACHINING (AJM)

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Cutting small holes and slots in hard and brittle
  materials
• Deburring and removing small flash from parts
• Removing oxides and other surface films
• Trimming and beveling
• General cleaning of components with irregular
  surfaces

Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN
ULTRASONIC MACHINING (USM)
Atilim University / Dept. of Industrial
Engineering
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IE 204 Manufacturing Processes
Dr. Zühal ERDEN

• Material is removed from a surface by
  microchipping or erosion with fine abrasive
  grains
• Suitable for hard and brittle materials such as
  ceramics, carbides

Atilim University / Dept. of Industrial
Engineering