Manufacturing Process II

(Modern Machining )
Dr. A. S. M. Mojahidul Hoque
Associate Professor , Dept. of IPE, JUST
 Introduction
Four basic groups of material removal using modern machining
processes-

Chemical:
Chemical reaction between a liquid reagent and work-piece
results in etching

Electrochemical
An electrolytic reaction at workpiece surface for removal of
material

Thermal
High temperature in very localized regions evaporate
materials, for example, EDM

Mechanical
High-velocity abrasives or liquids remove materials
Introduction
 Introduction
Limitations of Conventional Machining Processes
Machining processes that involve chip formation have a number of
limitations
• Large amounts of energy
• Unwanted distortion
• Residual stresses
• Burrs
• Delicate or complex geometries may be difficult or impossible
Advantages
• Complex geometries are possible
• Extreme surface finish
• Tight tolerances
• Delicate components
• Little or no burring or residual stresses
• Brittle materials with high hardness can be machined
• Microelectronic or integrated circuits (IC) are possible to mass produce
 Electro Chemical Machining (ECM)
Electrochemical machining (ECM) also uses electrical energy to
remove material. An electrolytic cell is created in an electrolyte
medium, with the tool as the cathode and the work-piece as the
anode. A high-amperage, low-voltage current is used to dissolve the
metal and to remove it from the work-piece, which must be
electrically conductive. ECM is essentially a depleting process that
utilizes the principles of electrolysis. The ECM tool is positioned
very close to the work-piece and a low voltage, high amperage DC
current is passed between the two via an electrolyte. Material is
removed from the work-piece and the flowing electrolyte solution
washes the ions away. These ions form metal hydroxides which are
removed from the electrolyte solution by centrifugal separation.
Both the electrolyte and the metal sludge are then recycled.
Electro Chemical Machining (ECM)
 Electro Chemical Machining (ECM)
Parts Made by Electrochemical Machining
 Electro Chemical Machining (ECM)
Knee Implants

Figure (a) Two total knee replacement systems showing metal implants (top
pieces) with an ultra-high molecular-weight polyethylene insert (bottom
pieces). (b) Cross-section of the ECM process as applies to the metal implant.
 Electro Chemical Machining (ECM)
Advantages of Electrochemical Machining (ECM)
• The components are not subject to either thermal or mechanical
stress.
• There is no tool wear during Electrochemical machining.
• Non-rigid and open work pieces can be machined easily as there is
no contact between the tool and work-piece.
• Complex geometrical shapes can be machined repeatedly and
accurately
• Electrochemical machining is a time saving process when compared
with conventional machining
• During drilling, deep holes can be made or several holes at once.
• ECM deburring can debur difficult to access areas of parts.
• Fragile parts which cannot take more loads and also brittle material
which tend to develop cracks during machining can be machined easily
through Electrochemical machining
• Surface finishes of 25 µ in. can be achieved during Electrochemical
machining
 Chemical Machining (CM)
Chemical Machining aides in the manufacture of light gauge metal parts.
The photo etching process (also called chemical etching and chemical
milling) allows people to produce intricate metal components with close
tolerances that are impossible to duplicate by other production methods. It
is also known as chemical milling.

Figure Schematic illustration of the chemical-machining process. Note that

no forces or machine tools are involved in this process. (b) Stages in
producing a profiled cavity by chemical machining; note the undercut.
Applications
Chemical Machining (CM)
Chemical Machining is utilized in the manufacturing of encoders, masks,
filters, lead frames, flat springs, strain gauges, laminations, chip carriers, step
covers, fuel cell plates, heat sinks, shutter blades, electron grids, fluidic circuit
plates, reticles, drive bands, haptics, and shims.

Advantages
• Process is relatively simple
• Does not require highly skilled labor
• Induces no stress or cold working in the metal
• Can be applied to almost any metal
• Large areas
• Virtually unlimited shape
• Thin sections

Disadvantages
• Requires the handling of dangerous chemicals Disposal of potentially
harmful byproducts
• Metal removal rate is slow
 Electric Discharge Machining (EDM)
Introduction
• The removal of metal from the work-piece is obtained by means
of energy released by repetitive spark discharges
• Take place between two conductors (tool, work-piece)
History of EDM

• In1770s, discovered by Joseph Priestly.

• Developed in the mid 1970s
• In the mid 1980s, the EDM techniques were transferred to a
machine tool
• Today,it is a viable technique that helped shape
the metal working industry.
 Electric Discharge Machining (EDM)
Principle of EDM

• The tool (electrode) usually acts as a cathode and is immersed

in a dielectric fluid.
• DC voltage (~300V) is applied in modulated pulses (200-500K
Hz).
• The dielectric breaks down (sparking at around 12,000 deg F)
when gap is small.
• The sparks erodes the work-piece in the shape of the tool.
• The tool is progressively lowered as the work-piece erodes.
• Material removal rate is typically 300 mm3/min
• Tool wear ratio 3:1 with metallic electrodes, 3:1-100:1 with
graphite electrodes
Electric Discharge Machining (EDM)
 Electric Discharge Machining (EDM)

• Pulsed power supply (Pulsed generator)

• Electrode (tool, workpiece) shape must match
• Electric discharge (spark)
• Dielectric
• Gap
 Electric Discharge Machining (EDM)
Physical Principle of EDM

• Charge up an electrode
• Bring the electrode near a metal work-piece (oppositely
charged).
• As the two conductors get close enough a spark will arc across a
dielectric fluid. This spark will "burn" a small hole in the electrode
and work-piece.
• Continue steps 1-3 until a hole the shape of the electrode is
formed.
Work-piece

• Electrical conductor
• To require to erode cavity or hole
• Connected to power supply
Electrode Materials
Copper, tungsten, graphite
 Electric Discharge Machining (EDM)
Tool
• An electrically conductive electrode
• Shaped to match the dimensions of the desired cavity or hole
• Connected to the pole of the supply
Dielectric and gap
• Dielectric---insulating fluid
• Gap --- work-piece and tool are separated by a
small gap flooded by dielectric to provide
a controlled electrical resistant
 Electric Discharge Machining (EDM)
Process of EDM

Step 1
An increasing voltage is
applied to the electrodes,
resulting in an increasing stress
on the fluid between them until
it is ionized, and the gap
becomes conductive, allowing
current to flow from one
electrode to the other in the
form of a spark discharge.
 Electric Discharge Machining (EDM)
Process of EDM
Step 2
The spark channel in
the first few
microseconds has a
very small cross-
sectional area
resulting in a
correspondingly high
current density
calculated to be on
the order of l04~l06
A /cm2.
 Electric Discharge Machining (EDM)
Process of EDM
Step 3
Because of these extreme
densities, the temperature in the
channel is very high, (5,000
l0,000℃), resulting in the
melting and vaporization of a
small amount of material from
the surfaces of both the electrode
and the work-piece at the points
of spark contact, a rapidly
expanding bubble is created in
the dielectric fluid around the
spark channel.
 Electric Discharge Machining (EDM)
Process of EDM
Step 4

When the electrical pulse is

terminated, both the spark channel
and the vapor bubble collapse.
The violent inrush of cool
dielectric fluid results in an
explosive expulsion of molten
metal from both the electrode and
work-piece surfaces, resulting in
the formation of a small crater in
the surfaces of the two conductors,
solidifying hollow balls of material,
which are removed from the gap by
the fluid.
 Electric Discharge Machining (EDM)
Equipment of EDM
Cathode and anode

• In EDM, therefore, the cathode-electrode is made the work-

piece
• The anode becomes the tool
• The erosion of metal from the cathode can be as high as 99.5%
• The wear of the anode being kept as low as 0.5%.
Fluid
• Fluid is used to act as a dielectric, and to help carry away debris.
• If the fluid is pumped through and out the end of the electrode,
particles will push out, and mainly collect at the edges. They will
lower the dielectric resistance, resulting in more arcs. As a result
the holes will be conical.
• If fluid is vacuum pumped into the electrode tip,straight holes
will result.
 Electric Discharge Machining (EDM)
Equipment of EDM

Fluid
 Electric Discharge Machining (EDM)
Equipment of EDM
Dielectric type and recycle

• Quite often kerosene-based oil.

• Paraffin and light oils, (cheap, low viscosity, and a flash point high enough to
make them safe to work
• The fluid must be cleaned, recycled, and returned to the cutting
gap by means of pumps and filters.

Power
the power is given by P=V I t

Parameter Typical Value

Power(KW) 0.5-1.5
In.**3/hr .18-1.1
Electrode wear(%) 1-10
Surface(micro [Link]) 12
 Electric Discharge Machining (EDM)
Wire EDM
• A thin wire of brass, tungsten, or copper is used as an electrode.
• Deionized water is used as the dielectric.
• Slowly cuts groove in shape of wire
• Wire is consumed and is slowly fed.
• The process is similar to standard EDM.
 Electric Discharge Machining (EDM)
Wire EDM
 Electric Discharge Machining (EDM)
Benefits of Wire EDM
• Precision cuts; Wire EDM accuracy can be within +/- .0003”
• Internal corner cuts with nearly square edges
• Ability to cut long tapers that would otherwise be impossible
• More accurate production & prototype runs with shorter lead
times
• Capability to accurately and repeatedly machine delicate &
intricate parts with no deflection
• Wire EDM does not generate burrs
• Does not require tooling
• Ability to machine pieces up to 12″
• Machining takes place after heat treatment so dimensional
accuracy is not affected by heat treat distortion
 Electric Discharge Machining (EDM)

Ram EDM
A process using a shaped electrode made from graphite or copper.
The electrode is separated by a nonconductive liquid and
maintained at a close distance (about 0.001"). A high DC voltage
is pulsed to the electrode and jumps to the conductive work-piece.
The resulting sparks erode the work-piece and generate a cavity in
the reverse shape of the electrode, or a through hole in the case of
a plain electrode. Permits machining shapes to tight accuracies
without the internal stresses conventional machining often
generates. Also known as “die-sinker” or “sinker” or RAM
electrical-discharge machining.
 Electric Discharge Machining (EDM)

Ram EDM
 Electric Discharge Machining (EDM)
Benefits of RAM EDM
• A variety of shapes and sizes inside blind cavities
• Remarkable accuracy and fine finish control with no compromise to
structural integrity
• Shapes are burned into hardened materials eliminating the chance of size
change caused by heat treating
• Production with greater consistency, repeatability, and efficiency
• Little required tooling means reduction in set-up time
• Internal splines, blind keyways, moulds
• Hexes for special bolts and parts & helical cut gears and shapes
• Complex shapes that would otherwise be difficult or impossible to produce
with conventional cutting tools
• Extremely hard material machined to very close tolerances
• Very small work pieces where conventional cutting tools may damage the
part from excess cutting tool pressure
• There is no direct contact between tool and work piece. Therefore delicate
sections and weak materials can be machined without any distortion.
 Electric Discharge Machining (EDM)
Small Hole Drill EDM (Hole Popping)
Small hole drilling EDM machining allows a 0.3mm-6.1mm
diameter hole to be drilled through a 100mm piece of soft or
hardened steel in about 10 seconds with an average wear rate of
50% to 80%. This process uses a long brass or copper electrode in
the form of a tube. The electrode is held in a chuck and rotated as a
flow of distilled water flows through the electrode and flushes
away the eroded material.
 Electric Discharge Machining (EDM)
Benefits of Small Hole Drill EDM (Hole Popping)
• Less time spent means shorter lead times
• Drilling is done into hardened materials eliminating the chance
of size change caused by heat treating
• Little required tooling means reduction in set-up time

Applications of EDM

• Slots, keyways, square & hex drives

• Gears, splines
• Small or deep holes, especially in hardened
• Removal of broken taps and drills
• Hard tapping
• Machining of carbide
• Application of textured surface finish
 Plasma Arc Cutting (PAC)

• Uses a superheated
stream of electrically
ionized gas to melt and
remove material
• The process can be used
on almost any
conductive material
• PAC can be used on
exotic materials at high
rates

Figure Plasma arc machining or

cutting.
 Thermal Deburring

• Used to remove burrs

and fins by exposing
the workpiece to hot
corrosive gases for a
short period of time
• Thermal deburring can
remove burrs or fins
from almost any
material but is
especially effective
with materials of low
thermal conductivity
Figure Thermochemical
machining process for the
removal of burrs and fins.
 Laser Beam Machining (LBM)
Introduction
Laser Beam Machining or more
broadly laser material processing
deals with machining and
material processing like heat
treatment, alloying, cladding,
sheet metal bending etc. Such
processing is carried out utilizing
the energy of coherent photons or
laser beam, which is mostly
converted into thermal energy
upon interaction with most of the
materials.
Fig. (a) Schematic illustration of
the laser-beam machining
process. (b) and (c) Examples of
holes produced in nonmetallic
parts by LBM. (d) Cutting sheet
metal with a laser beam.
 Laser Beam Machining (LBM)
General Applications of Lasers in Manufacturing
 Electron Beam Machining (EBM)
Introduction
• Electrons generated in a vacuum chamber
• Similar to cathode ray tube
Main Elements of m/c
 Electron Beam Machining (EBM)
Main Elements
• 10-4 torr
• Electron gun
• Cathode - tungsten filament at 2500 – 3000 degC
• Emission current – between 25 and 100mA (a measure of electron
beam density)
Electron beam
• Emmision current increases with increases in temperature and
accelerating voltage (kV). It is also dependent on cathode material.
• Electrons are focused by the field formed by the grid cup and by a
magnetic or electrostatic lens system.
Material removal
• Electrons therefore hit workpiece in a well defined manner, over a
circular area typically 0.025 mm in diameter.
• Kinetic energy of the electrons is rapidly translated into heat, causing a
correspondingly rapid increase in the temperature of the workpiece, to
well above its boiling point. Material removal by evaporation then occurs.
Power densities of 1.55 MW/mm2.
 Electron Beam Machining (EBM)
Material removal
• In the region where the beam of electrons meet the workpiece,
their energy is converted into heat
• Workpiece surface is melted by a combination of electron
pressure and surface tension
• Melted liquid is rapidly ejected and vaporized to effect
material removal
• Temperature of the workpiece specimen outside the region
being machined is reduced by pulsing the electron beam
(10kHz or less)
Advantages
• Large depth-to-width ratio of material penetrated by the beam
with applications of very fine hole drilling becoming feasible
• There is a minimum number of pulses ne associated with an
optimum accelerating voltage. In practice the number of pulses
to produce a given hole depth is usually found to decrease with
increase in accelerating voltage.
 Electron Beam Machining (EBM)
Limit of accelerating voltage
• Increasing the hole depth requires a much greater rise in the
number of pulses at low voltage, due mainly to a relative rise
in heat losses resulting from conduction and melting of the
adjacent metal layers.
• For a given number of pulses little improvement in material
removal rate is obtained from increasing the accelerating
voltage above 120 kV.

Surface roughness
• Depends on material being machined
• Pitting is common – depends on thermal properties of material
and pulse energy
• Ra increases from 5-10m to 8-15m have been reported in
nickel, tungsten and gold for an increase in pulse charge from
10E-9 to 200E-9 As.
 Electron Beam Machining (EBM)
Heat affected zone
• Microstructure of the surface layer around the hole can be
severly altered by the EBM process (e.g. the formation of an
amorphous white layer in steels)
• This layer increases with pulse duration and hole diameter.
• Can be as much as 0.25 mm

Applications of EBM
 Drilling
 Perforating of sheet
 Pattern generation (associated with integrated circuit
fabrication)
 Electron Beam Machining (EBM)
Drilling
• Electron beam machines are fitted with systems for numerically
controlling the beam power, focus and pulse duration, and
mechanical motion
• Cylindrical and other configurations, such as conical and barrel
shaped holes, of various diameters can now be drilled with
consistent accuracy at rates of several thousand holes per second.
Perforation
• Usually lined with an auxiliary material
• The electron beam first penetrates through the sheet forming a vapor
channel within the fused material, and then enters the auxiliary
lining.
• An eruption of vapor occurs, causing ejection of molten material.
• 104 to 105 holes per second have to be produced (s pules needed)
• Ceramic and syntethic filter material applications (e.g 620
holes/mm2)
 Electron Beam Machining (EBM)
Pattern generation
• The beam is positioned accurately by means of deflection coils
at the location where a pattern is to be written, by exposing a
film of electron resist coated on either a chrome mask blank or a
wafer, for the production of the lithographic definition required.
• Resist film is immersed in the developer, usually a solvent. Due
to the difference in solubility between the original and exposed
resist polymers, differential material removal occurs.
• A fine pattern of polymer is thus obtained. This pattern is then
used as an active mask to avoid unwanted etching of the
integrated circuit mask or wafer.
• Line widths of a few hundred Ǻ
• Writing speed 20 MHz
• Across a 125mm mask an accuracy of 0.125m can be achieved
in about 60 minutes.
 Ultrasonic Machining (UM)
History
• The roots of ultrasonic technology can be traced back to
research on the piezoelectric effect conducted by Pierre Curie
around 1880.
• He found that asymmetrical crystals such as quartz and
Rochelle salt (potassium sodium titrate) generate an electric
charge when mechanical pressure is applied.
• Conversely, mechanical vibrations are obtained by applying
electrical oscillations to the same crystals.
• One of the first applications for Ultrasonic was sonar (an
acronym for sound navigation ranging). It was employed on a
large scale by the U.S. Navy during World War II to detect
enemy submarines.
• Frequency values of up to 1Ghz (1 billion cycles per second)
have been used in the ultrasonic industry.
• Today's Ultrasonic applications include medical imaging
(scanning the unborn fetus) and testing for cracks in airplane
construction.
 Ultrasonic Machining (UM)
Ultrasonic waves
• The Ultrasonic waves are sound waves of frequency higher
than 20,000 Hz.
• Ultrasonic waves can be generated using mechanical,
electromagnetic and thermal energy sources.
• They can be produced in gasses (including air), liquids and
solids.
Magnetostrictive transducers
• Magnetostrictive transducers use the inverse magnetostrictive
effect to convert magnetic energy into ultrasonic energy.
• This is accomplished by applying a strong alternating
magnetic field to certain metals, alloys and ferrites.
Piezoelectric Transducers
• Piezoelectric transducers employ the inverse piezoelectric
effect using natural or synthetic single crystals (such as
quartz) or ceramics (such as barium titanate) which have
strong piezoelectric behavior.
• Ceramics have the advantage over crystals in that they are
easier to shape by casting, pressing and extruding.
 Ultrasonic Machining (UM)
Principle of Ultrasonic Machining
• In the process of Ultrasonic
Machining, material is removed by
micro-chipping or erosion with
abrasive particles.
• In USM process, the tool, made of
softer material than that of the
workpiece, is oscillated by the
Booster and Sonotrode at a
frequency of about 20 kHz with an
amplitude of about 25.4 um (0.001
in).
• The tool forces the abrasive grits, in
the gap between the tool and the
workpiece, to impact normally and
successively on the work surface,
thereby machining the work surface.
 Ultrasonic Machining (UM)

1- This is the standard mechanism used in most of the universal Ultrasonic machines
 Ultrasonic Machining (UM)
Principle of Ultrasonic Machining

• During one strike, the tool moves down from its most upper
remote position with a starting speed at zero, then it speeds up
to finally reach the maximum speed at the mean position.

• Then the tool slows down its speed and eventually reaches
zero again at the lowest position.

• When the grit size is close to the mean position, the tool hits
the grit with its full speed.

• The smaller the grit size, the lesser the momentum it receives
from the tool.

• Therefore, there is an effective speed zone for the tool and,

correspondingly there is an effective size range for the grits.
 Ultrasonic Machining (UM)
• In the machining process, the tool, at some point, impacts on the
largest grits, which are forced into the tool and workpiece.

• As the tool continues to move downwards, the force acting on

these grits increases rapidly, therefore some of the grits may be
fractured.

• As the tool moves further down, more grits with smaller sizes
come in contact with the tool, the force acting on each grit
becomes less.

• Eventually, the tool comes to the end of its strike, the number of
grits under impact force from both the tool and the workpiece
becomes maximum.

• Grits with size larger than the minimum gap will penetrate into
the tool and work surface to different extents according to their
diameters and the hardness of both surfaces.
 Ultrasonic Machining (UM)
Various work samples machined by USM

1- The first picture on the left is a plastic sample that has inner grooves that are machined
using USM.
2- The Second picture (in the middle is a plastic sample that has complex details on the
surface
3- The third picture is a coin with the grooving done by USM
 Ultrasonic Machining (UM)
Piezoelectric Transducer
• Piezoelectric transducers utilize crystals like quartz whose dimensions alter
when being subjected to electrostatic fields.
• The charge is directionally proportional to the applied voltage.
• To obtain high amplitude vibrations the length of the crystal must be
matched to the frequency of the generator which produces resonant
conditions.
 Ultrasonic Machining (UM)
Magnetostictive transducer
• Magnetostictive transducers work on the principle that if a
piece of Ferro-magnetic material (like nickel) is magnetized,
then a change in dimension occurs.

• The transducer has solenoid type winding of wire over a stack

of nickel laminations (which has rapid dimensional change
when placed in magnetic fields) and is fed with an A.C supply
with frequencies up to 25,000 c/s.
Abrasive Slurry
• The abrasive slurry contains fine abrasive grains. The grains
are usually boron carbide, aluminum oxide, or silicon carbide
ranging in grain size from 100 for roughing to 1000 for
finishing.

• It is used to microchip or erode the work piece surface and it is

also used to carry debris away from the cutting area.
 Ultrasonic Machining (UM)
Tool holder
• The shape of the tool holder is cylindrical or conical, or a
modified cone which helps in magnifying the tool tip
vibrations.

• In order to reduce the fatigue failures, it should be free from

nicks, scratches and tool marks and polished smooth.

Tool
• Tool material should be tough and ductile. Low carbon steels
and stainless steels give good performance.

• Tools are usually 25 mm long ; its size is equal to the hole size
minus twice the size of abrasives.

• Mass of tool should be minimum possible so that it does not

absorb the ultrasonic energy.
 Ultrasonic Machining (UM)
Materials that can be UM
• Hard materials like stainless steel, glass, ceramics, carbide,
quatz and semi-conductors are machined by this process.
• It has been efficiently applied to machine glass, ceramics,
precision minerals stones, tungsten.
• Brittle materials
Applications
It is mainly used for
(1) drilling
(2) grinding,
(3) Profiling
(4) coining
(5) piercing of dies
(6) welding operations on all materials which can be treated
suitably by abrasives.
 CNC Ultrasonic Machining (UM)
• 4-axis CNC drills holes as
small as 0.010", multi-sided
holes, multiple hole and slot
patterns, and many other
complicated, irregular
shapes.

• Works on hard, brittle

materials such as ceramic
and glass with precision to
0.0005".

900 watt Sonic-mill, Ultrasonic Mill

 Ultrasonic Machining (UM)
Limitations
• Under ideal conditions, penetration rates of 5 mm/min can be
obtained.
• Power units are usually 500-1000 watt output.
• Specific material removal rate on brittle materials is 0.018
mm cubic/Joule.
• Normal hole tolerances are 0.007 mm and a surface finish of
0.02 to 0.7 micro meters.
Advantages
• Machining any materials regardless of their conductivity
• USM apply to machining semi-conductor such as silicon,
germanium etc.
• USM is suitable to precise machining brittle material.
• USM does not produce electric, thermal, chemical abnormal
surface.
• Can drill circular or non-circular holes in very hard materials
• Less stress because of its non-thermal characteristics
 Ultrasonic Machining (UM)
Disadvantages
• UM has low material removal rate.
• Tool wears fast in UM.
• Machining area and depth is restraint in UM.
Safety Considerations
The worker must be wearing eye goggles to prevent the abrasive
particles or the microchips from getting into his eye.
 Waterjet Machining (WJM)
Introduction to Waterjet
• Fastest growing machining process
• One of the most versatile machining processes
• Compliments other technologies such as milling, laser, EDM, plasma and
routers
• True cold cutting process – no HAZ, mechanical stresses or operator and
environmental hazards
• Not limited to machining – food industry applications
History
• Dr. Franz in 1950’s first studied UHP water cutting for forestry and wood
cutting (pure WJ)
• 1979 Dr. Mohamed Hashish added abrasive particles to increase cutting
force and ability to cut hard materials including steel, glass and concrete
(abrasive WJ)
• First commercial use was in automotive industry to cut glass in 1983
• Soon after, adopted by aerospace industry for cutting high-strength
materials like Inconel, stainless steel and titanium as well as composites like
carbon fiber
 Waterjet Machining (WJM)

Pure WJ Cutting
• Pure cuts soft materials – corrugated cardboard, disposable
diapers, tissue papers, automotive interiors
• Very thin stream (0.004-0.010 dia)
• Extremely detailed geometry
• Very little material loss due to cutting
• Can cut thick, soft, light materials like fiberglass insulation up
to 24” thick or thin, fragile materials
• Very low cutting forces and simple fixturing
• Water jet erodes work at kerf line into small particles
 Waterjet Machining (WJM)

• Water inlet pressure

between 20k-60k psi
• Forced through hole in
jewel 0.007-0.020” dia
• Sapphires, Rubies with 50-
100 hour life
• Diamond with 800-2,000
hour life, but they are
pricey
 Waterjet Machining (WJM)
Abrasive WJ Cutting
• Used to cut much harder materials
• Water is not used directly to cut material as in Pure, instead
water is used to accelerate abrasive particles which do the
cutting
• 80-mesh garnet (sandpaper) is typically used though 50 and
120-mesh is also used
• Standoff distance between mixing tube and workpart is
typically 0.010-0.200 – important to keep to a minimum to
keep a good surface finish
 Waterjet Machining (WJM)

• Evolution of mixing tube technology

• Standard Tungsten Carbide lasts 4-6
hours (not used much anymore)
• Premium Composite Carbide lasts
100-150 hours
• Consumables include water,
abrasive, orifice and mixing tube
 Waterjet Machining (WJM)
Tolerances
• Typically +/- 0.005 inch
• Machines usually have repeatability of 0.001 inch
• Comparatively traditional machining centers can hold tolerances 0f 0.0001
inch with similar repeatability
• WJ tolerance range is good for many applications where critical tolerances
are not crucial to workpart design
 Waterjet Machining (WJM)
When is it Practical?
The cutter is commonly connected to a
high-pressure water pump, where the
water is then ejected from the nozzle,
cutting through the material by spraying it
with the jet of high-speed water.
It’s practical to use it to cut any kind of
material. In waterjet cutting, there is no
heat generated. This is especially useful
for cutting tool steel and other metals
where excessive heat may change the
properties of the material. Waterjet
cutting does not leave a burr or a rough
edge, and eliminates other machining
operations such as finish sanding and
grinding. It can be easily automated for
production use.
 Waterjet Machining (WJM)
Advantages
•Cheaper than other processes.
• Cut virtually any material. (pre hardened
steel, mild steel, copper, brass, aluminum;
brittle materials like glass, ceramic, quartz,
stone)
• Cut thin stuff, or thick stuff.
• Make all sorts of shapes with only one tool.
• No heat generated.
• Leaves a satin smooth finish, thus reducing
secondary operations.
This part is shaped with
• Clean cutting process without gasses or
waterjet using one tool.
oils. Slots, radii, holes, and
• Modern systems are now very easy to profile in one 2 minute
learn. setup.
• Are very safe.
• Machine stacks of thin parts all at once.
 Waterjet Machining (WJM)
• Unlike machining or grinding, waterjet
cutting does not produce any dust or particles
that are harmful if inhaled.
• The kerf width in waterjet cutting is very
small, and very little material is wasted.
• Waterjet cutting can be easily used to produce
prototype parts very efficiently. An operator
can program the dimensions of the part into the
control station, and the waterjet will cut the
part out exactly as programmed. This is much
faster and cheaper than drawing detailed prints
of a part and then having a machinist cut the
part out. Get nice edge quality from
• Waterjets are much lighter than equivalent different materials.
laser cutters, and when mounted on an
automated robot. This reduces the problems of
accelerating and decelerating the robot head, as
well as taking less energy.
 Waterjet Machining (WJM)
Disadvantages
•One of the main disadvantages of
waterjet cutting is that a limited number
of materials can be cut economically.
While it is possible to cut tool steels, and
other hard materials, the cutting rate has
to be greatly reduced, and the time to cut
a part can be very long. Because of this,
waterjet cutting can be very costly and
outweigh the advantages.
• Another disadvantage is that very thick
parts can not be cut with waterjet cutting
and still hold dimensional accuracy. If Waterjet lag
the part is too thick, the jet may dissipate
some, and cause it to cut on a diagonal,
or to have a wider cut at the bottom of
the part than the top. It can also cause a
rough wave pattern on the cut surface.
 Waterjet Machining (WJM)
• Taper is also a problem with waterjet cutting in very
thick materials. Taper is when the jet exits the part at a
different angle than it enters the part, and can cause
dimensional inaccuracy. Decreasing the speed of the head
may reduce this, although it can still be a problem.

Stream lag caused inside corner

damage to this 1-in.-thick stainless
steel part. The exit point of the stream
lags behind the entrance point,
causing irregularities on the inside
corners of the part. The thicker the
material is or the faster an operator
tries to cut it, the greater the stream
lag and the more pronounced the
damage.