1 Introduction of Unconventional Manufacturing Process 1.0 INTRODUCTION Since beginning of the human race, people have evolved tools and energy sources to power these tools to meet the requirements for making the life more easier and enjoyable. In the early stage of mankind, tools were made of stone for the item being made. When iron tools were invented, desirable metals and more sophisticated articles could be produced. In twentieth century products were made from the most durable and consequently, the most unmachinable materials. In an effort to meet the manufacturing challenges created by these materials, tools have now evolved to include materials such as alloy steel, carbide, diamond and ceramics. A similar evolution has taken place with the methods used to power our tools. Initially, tools were powered by muscles; either human or animal. However as the powers of water, wind, steam and electricity were harnessed, mankind was able to further extend manufacturing capabilities with new machines, greater accuracy and faster machining rates. HSTR Alloys
Ultimate tensile strength Kgf/cm
2
14000 Titanium 7000 Al alloy
3500
1400
700 350
Al
1915
1930
1945 1960 Year of development
Fig. 1.1. Trend of increase of material strength 1
Comp-1/Newage/Uncmp-1—II print/22.5.07
7.6.07
30.6.07
13.9.07
18.9.07
2
UNCONVENTIONAL MANUFACTURING PROCESSES
Every time new tools, tool materials, and power sources are utilized, the efficiency and capabilities of manufacturers are greatly enhanced. Since 1940’s, a revolution in manufacturing has been taking place that once again allows manufactuers to meet the demands imposed by increasingly sophisticated designs and durable but in many cases nearly unmachinable, materials. In the figure 1.1, Merchant had displayed the gradual increase in strength of material with year wise development of material in aerospace industry. This manufacturing revolution is now, as it has been in the past, centered on the use of new tools and new forms of energy. The result has been the introduction of new manufacturing processes used for material removal, forming and joining, known today as non-traditional manufacturing processes. The conventional manufacturing processes in use today for material removal primarily rely on electric motors and hard tool materials to perform tasks such as sawing, drilling and broaching. Conventional forming operations are performed with the energy from electric motors, hydraulics and gravity. Likewise, material joining is conventionally accomplished with thermal energy sources such as burning gases and electric arcs. In contrast, non-traditional manufacturing processes harness energy sources considered unconventional by yesterday’s standards. Material removal can now be accomplished with electrochemical reaction, high temperature plasmas and high-velocity jets of liquids and abrasives. Materials that in the past have been extremely difficult to form, are now formed with magnetic fields, explosives and the shock waves from powerful electric sparks. Material-joining capabilities have been expanded with the use of high-frequency sound waves and beams of electrons and coherent light. During the last 55 years, over 20 different non-traditional manufacturing processes have been invented and successfully implemented into production.
1.1 CLASSIFICATION OF UNCONVENTIONAL MANUFACTURING PROCESSES The non-conventional manufacturing processes are not affected by hardness, toughness or brittleness of material and can produce any intricate shape on any workpiece material by suitable control over the various physical parameters of the processes. The non-conventional manufacturing processes may be classified on the basis of type of energy namely, mechanical, electrical, chemical, thermal or magnetic, apply to the workpiece directly and have the desired shape transformation or material removal from the work surface by using different scientific mechanism. Thus, these non-conventional processes can be classified into various groups according to the basic requirements which are as follows : (i) Type of energy required, namely, mechanical, electrical, chemical etc. (ii) Basic mechanism involved in the processes, like erosion, ionic dissolution, vaporisation etc. (iii) Source of immediate energy required for material removal, namely, hydrostatic pressure, high current density, high voltage, ionised material, etc. (iv) Medium for transfer of those energies, like high velocity particles, electrolyte, electron, hot gases, etc. On the basis of above requirements, the various processes may be classified as shown in table 1.1.
Processes
Transfer energy medium
Source of immediate energy
Basic mechanism
Energytype
Ultrasonic machining
Mechanical contour grinding
Physical contact
Cutting tool
Shear
Pneumatic or hydraulic pressure
Erosion
Abrasive jet machining
High velocity particles
Mechanical
Electro chemical grinding
Whirling jet machining
High velocity liquid
Electro chemical machining
Chemical etching
Electrolyte
High current
Iondisplacement
Electro-chemical
Thermo-electrical
Electron
Electrical discharge machining
Electron beam machining
Fusion
Plasma arc machining
Hot gases
Ionised material
Ion beam machining
Laser beam machining
Radiation
High voltage amplified light
Vaporisation
Chemical Hot chlorine machining machining
Environment
Chemically reactive agent
Ablative action
Chemical
Non-conventional manufacturing processes
INTRODUCTION OF UNCONVENTIONAL MANUFACTURING PROCESS
3
4
UNCONVENTIONAL MANUFACTURING PROCESSES
1.2 COMPARATIVE ANALYSIS OF UNCONVENTIONAL MANUFACTURING PROCESSES A comparative analysis of the various unconventional manufacturing processes should be made so that a guide-line may be drawn to find the suitability of application of different processes. A particular manufacturing process found suitable under the given conditions may not be equally efficient under other conditions. Therefore, a careful selection of the process for a given manufacturing problem is essential. The analysis has been made from the point of view of : (i) Physical parameters involved in the processes; (ii) Capability of machining different shapes of work material; (iii) Applicability of different processes to various types of material, e.g. metals, alloys and non-metals; (iv) Operational characteristics of manufacturing and (v) Economics involved in the various processes.
Physical parameters The physical parameters of non-conventional machining processes have a direct impact on the metal removal as well as on the energy consumed in different processes. (Table 1.2) TABLE 1.2. Physical Parameters of the Non-conventional Processes Parameters
USM
AJM
ECM
CHM
EDM
EBM
LBM
PAM
220
220
10
—
45
150000
4500
100
12 (A.C.)
1.0
10000 (D.C.)
—
50 (Pulsed D.C.)
0.001 (Pulsed D.C.)
2 (Average 200 Peak)
500 (D.C.)
Power (W)
2400
220
100000
—
2700
150
—
50000
Gap (m.m.)
0.25
0.75
0.20
—
0.025
100
150
7.5
Vaccum
Air
Argon or hydrogen
Potential (V) Current (Amp)
Medium
Abrasive Abrasive Electrolyte in water in gas
Liquid Liquid chemical dielectric
5
INTRODUCTION OF UNCONVENTIONAL MANUFACTURING PROCESS
From a comparative study of the effect of metal removal rate on the power consumed by various non-conventional machining processes shown in fig. 1.2.
Power consumption, watts
10
ECM
5
PAM 10
10
10
10 10 10
4
3
USM
EDM
MCG
3
4
AJM
2
EB
M
1 0
LBM
–1
10
–1
10
0
1
2
10 10 10 10 3 Metal removal rate mm /min
10
5
Fig. 1.2. Effect of metal removal rate on power consumption.
It is found that some of the processes (e.g. EBM, ECM) above the mean power consumption line consume a greater amount of power than the processes (e.g. EDM, PAM, ECG) below the mean power consumption line. Thus, the capital cost involved in the processes (EBM, ECM etc.) lying above the mean line is high whereas for the processes below that line (e.g., EDM, PAM, MCG) is comparatively low.
Capability to shape The capability of different processes can be analysed on the basis of various machining operation point of view such as micro-drilling, drilling, cavity sinking, pocketing (shallow and deep), contouring a surface, through cutting (shallow and deep) etc. TABLE 1.3. Shape Application of Non-conventional Processes Holes Process
Precision small holes
Trough cavities Standard
Precision standard
Surfacing
Trough cutting
Double contouring
Surface of revolution
Shallow
deep
Dia Dia Length Length < .025 > .025 < 20 mm > 20 mm mm mm USM AJM ECM
— — —
— — —
good fair good
poor poor good
good poor fair
good fair good
poor — good
— — fair
poor good good
— — good
CHM EDM
fair —
fair —
— good
— fair
poor good
fair good
— fair
— —
good poor
— —
LBM PAM
good —
good —
fair fair
poor —
poor poor
poor poor
— —
— poor
good good
fair good
6
UNCONVENTIONAL MANUFACTURING PROCESSES
For micro-drilling operation, the only process which has good capability to microl < 20, drill is laser beam machining while for drilling shapes having slenderness ratio, D the process USM, ECM and EDM will be most suitable. EDM and ECM processes have good capability to make pocketing operation (shallow or deep). For surface contouring operation, ECM process is most suitable but other processes except EDM have no application for contouring operation.
Applicability to materials Materials applications of the various machining methods are summarised in the table 1.4 and table 1.5. For the machining of electrically non-conducting materials, both ECM and EDM are unsuitable, whereas the mechanical methods can achieve the desired results. TABLE 1.4 Metals Alloys Process USM AJM ECM CHM EDM EBM LBM PAM
Aluminium
Steel
Super alloy
Titanium
Refractory material
Poor Fair Fair Good Fair Fair Fair Good
Fair Fair Good Good Good Fair Fair Good
Poor Good Good Fair Good Fair Fair Good
Fair Fair Fair Fair Good Fair Fair Fair
Good Good Fair Poor Good Good Poor Poor
USM is suitable for machining of refractory type of material while AJM are for super alloys and refractory materials. TABLE 1.5 Non-Metals Process
Ceramics
Plastic
Glass
USM AJM ECM CHM EDM EBM LBM
Good Good — Poor — Good Good
Fair Fair — Poor — Fair Fair
Good Good — Fair — Fair Fair
PAM
—
Poor
—
7
INTRODUCTION OF UNCONVENTIONAL MANUFACTURING PROCESS
Machining characteristics The machining characteristics of different non-conventional processes can be analysed with respect to : (i) Metal removal rate (ii) Tolerance maintained (iii) Surface finish obtained (iv) Depth of surface damage (v) Power required for machining The process capabilities of non-conventional manufacturing processes have been compared in table 1.6. The metal removal rates by ECM and PAM are respectively one-fourth and 1.25 times that of conventional whereas others are only a small fractions of it. Power requirement of ECM and PAM is also very high when compared with other non-conventional machining processes. This involves higher capital cost for those processes. ECM has very low tool wear rate but it has certain fairly serious problems regarding the contamination of the electrolyte used and the corrosion of machine parts. The surface finish and tolerance obtained by various processes except PAM is satisfactory. TABLE 1.6 Process
MRR (mm3/min)
Tolerance (µ)
Surface (µ) CLA
Depth of surface damage (µ)
Power (watts)
USM AJM ECM CHM EDM EBM
300 0.8 15000 15 800 1.6
7.5 50 50 50 15 25
0.2–0.5 0.5–1.2 0.1–2.5 0.5–2.5 0.2–1.2 0.5–2.5
25 2.5 5.0 50 125 250
LBM PAM Conventional machining
0.1 75000 50000
25 125 50
0.5–1.2 Rough 0.5–5.0
125 500 25
2400 250 100000 — 2700 150 (average) 2000 (peak) 2 (average) 50000 3000
Economics of the processes The economics of the various processes are analysed on the basis of following factors and given in Table 1.7. (i) Capital cost (ii) Tooling cost (iii) Consumed power cost (iv) Metal removal rate efficiency (v) Tool wear.
8
UNCONVENTIONAL MANUFACTURING PROCESSES
TABLE 1.7 Process
Capital cost
Tooling cost
Power consumption cost
Material removal rate efficiency
Tool wear
USM AJM ECM CHM EDM EBM LBM PAM MCG
L VL VH M M H L VL L
L L M L H L L L L
L L M H* L L VL VL L
H H L M H VH VH VL VL
M L VL VL H VL VL VL L
* indicates cost of chemicals.
The capital cost of ECM is very high when compared with traditional mechanical contour grinding and other non-conventional machining processes whereas capital costs for AJM and PAM are comparatively low. EDM has got higher tooling cost than other machining processes. Power consumption is very low for PAM and LBM processes whereas it is greater in case of ECM. The metal removal efficiency is very high for EBM and LBM than for other processes. In conclusion, the suitability of application of any of the processes is dependent upon various factors and must be considered all or some of them before applying nonconventional processes.
REVIEW QUESTIONS 1. Justify the need of unconventional manufacturing process in today’s industries. 2. What are the basic limitations of conventional manufacturing process ? Explain. 3. What are the basic factors upon which the unconventional manufacturing processes are classified ? Explain. 4. List five conventional and five related unconventional manufacturing processes used in industries. 5. Distinguish between conventional and unconventional manufacturing processes. 6. Why are the unconventional manufacturing processes not completely taking over the conventional manufacturing processes ? Explain. 7. Unconventional machining processes yield low rates of material removal compared to conventional processes even then they have gained wide popularity. Discuss why ? 8. Enumerate the limitations of conventional manufacturing processes particularly in the light of present day manufacturing environment. 9. ECM, EDM, USM etc. are commonly referred to as unconventional machining processes, what is unconventional in these processes ? Explain.
HHH