Advanced Machining Process

Advanced Machining ProcessesParts Made by Advanced Machining Processes (a) (b) Examples of parts produced by advanced machining processes. (a) Samples of parts produced from waterjet cutting. (b) Turbine blade, produced by plunge EDM, in a fixture to produce the holes by EDM. Source: (a) Courtesy of Omax Corporation. (b) Courtesy of Hi-TEK Mfg., Inc. General Characteristics of Advanced Machining Processes . (b) Weight reduction of space-launch vehicles by the chemical milling of aluminum-alloy plates.Chemical Milling (a) Missile skin-panel section contoured by chemical milling to improve the stiffness-toweight ratio of the part. . These panels are chemically milled after the plates first have been formed into shape by a process such as roll forming or stretch forming. The design of the chemically machined rib patterns can be modified readily at minimal cost. Chemical-Machining (a) Schematic illustration of the chemical-machining process. note the undercut. . (b) Stages in producing a profiled cavity by chemical machining. Note that no forces or machine tools are involved in this process. Used by permission of Metcut Research Associates. Copyright © 1980. . 3rd ed. Inc. 23.13). Note the wide range within each process (see also Fig. Source: Machining Data Handbook.Surface Roughness and Tolerances in Machining Surface roughness and tolerances obtained in various machining processes. Source: Courtesy of Buckbee-Mears. St. .Parts Made by Chemical Blanking Various parts made by chemical blanking. Paul. Note the fine detail. Electrochemical Machining Schematic illustration of the electrochemical machining process. . Parts Made by Electrochemical Machining Typical parts made by electrochemical machining. . Note the shape of the electrode on the right. (c) Integral airfoils on a compressor disk. (a) Turbine blade made of nickel alloy of 360 HB. (b) Thin slots on a 4340steel roller-bearing cage. Source: Courtesy of Biomet.Knee Implants (a) Two total knee replacement systems showing metal implants (top pieces) with an ultra-high molecular-weight polyethylene insert (bottom pieces). Inc. . (b) Cross-section of the ECM process as applies to the metal implant. (b) Thin slot produced on a round nickel-alloy tube by this process. .Electrochemical-Grinding Process (a) Schematic illustration of the electrochemical-grinding process. particularly for die-sinking applications. (c) A spiral cavity produced by EDM using a slowly rotating electrode similar to a screw thread. (b) Examples of cavities produced by the electrical-discharge machining process. . (d) Holes in a fuel-injection nozzle made by EDM. the material is heat-treated steel. using shaped electrodes. 19. Two round parts (rear) are the set of dies for extruding the aluminum piece shown in front (see also Fig. Source: (b) Courtesy of AGIE USA Ltd.9b). This is one of the most widely used machining processes.Electrical-Discharge Machining Process (a) Schematic illustration of the electrical-discharge machining process. Stepped Cavities Produced by EDM Process Stepped cavities produced with a square electrode by the EDM process. . The workpiece moves in the two principle horizontal directions (x – y). and its motion is synchronized with the downward movement of the electrode to produce these cavities. Source: Courtesy of AGIE USA Ltd. Also shown is a round electrode capable of producing round or elliptical cavities. which is then discarded. C Schematic illustration of the wire EDM  process.The Wire EDM Process Metal removal rate : 1. As many as 50 hours of machining can be performed with one reel of wire. .23 MRR  4  10 4 ITw where I  current in amperes Tw  melting temperature of workpiece. Source: Courtesy of AGIE USA Ltd. .Wire EDM (a) (b) (a) Cutting a thick plate with wire EDM. (b) A computer-controlled wire EDM machine. Source: (d) Courtesy of Rofin-Sinar. (d) Cutting sheet metal with a laser beam.Laser-Beam Machining (LBM) (a) Schematic illustration of the laser-beam machining process. (b) and (c) Examples of holes produced in nonmetallic parts by LBM. Inc. . General Applications of Lasers in Manufacturing . Unlike LBM. this process requires a vacuum.Electron-Beam Machining Process Schematic illustration of the electron-beam machining process. . so workpiece size is limited to the size of the vacuum chamber. (b) A computer-controlled water-jet cutting machine cutting a granite plate. Source: Courtesy of Possis Corporation . (c) Examples of various nonmetallic parts produced by the water-jet cutting process. (Enlarged on next slide).Water-Jet Cutting Process (a) Schematic illustration of the water-jet machining process. Nonmetallic Parts Made by Water-Jet Cutting Examples of various nonmetallic parts produced by the water-jet cutting process. Source: Courtesy of Possis Corporation . (b) Examples of parts produced through abrasive-jet machining. .Abrasive-Jet Machining (b) (a) Schematic illustration of the abrasive-jet machining process.) thick 304 stainless steel. Source: Courtesy of OMAX Corporation. produced in 50-mm (2-in. Evolution of the stent surface. Note that a metal slug is still attached. (b) After removal of slag. Detail of the 3-3-3 MULTI-LINK TETRATM pattern. .Case Study: Stent Manufacture The Guidant MULTI-LINK TETRATM coronary stent system. (a) MULTI-LINK TETRATM after lasing. (c) After electropolishing.