Unit 2
Need for NTM • For machining steel alloys of Increased strength . For machining alloys in advanced industries Development of cutting [Link] and processing parts of complicated shapes
CLASSIFICATION OF NTM 1 Mechanical Processes • AJM) • (USM) •(WJM) • (AWJM) [Link] Processes • (EDM) • (LJM) • (EBM)[Link] Processes • (ECM) • (ECG) • (EJD) [Link] Processes •
(CHM) • (PCM). difference between conventional [tradional] and non conventional [non traditional] -Conventional-1The cutting tool and work piece are always in physical contact 2High metal removal
[Link] ostandmaintenancecostislow [Link] mechanicalenergyNonConventional-1There is no physical contact between tool and work piece,[Link] material removal
[Link] cost and maintenance cost is high 4.t NTM uses energy in-directf [Link] AJM abrasive jet machining Working • Abrasive particles are made to impinge on the work material at a high
velocity @ 150 to 300 m/s. • The jet of abrasive is carried by carrier gas or air. High velocity jet of abrasive isgenerated by converting the pressure energy of carrier gas or air to its kinetic energy. • The
nozzle directs the abrasive jet in a controlled manner onto the work material, so that the distance between the nozzle and the work piece and the impingement angle can be set desirably. • High velocity
abrasive particles remove the material by micro-cutting action as well as brittle fracture of work [Link] Advantages• Material utilization is high. • It can machine thin materials. • It is not reactive
with any workpiece material. • No tool changes are [Link] Applications 1. Drilling holes, cutting slots, cleaning hard surfaces, deburring, and polishing, 2. Deburring of cross holes, slots, and threads
in small precision parts that require a burr-free finish, such as hydraulic valves, aircraft fuel systems, and medical appliances. 3. Machining intricate shapes or holes in sensitive, brittle, thin, or difficult-to-
machine [Link] Jet Machining (WJM) Machining Setup 1 -Hydraulic pump-hydraulic pump suplies oil at high presur to drive reciprocating plunger pump [Link]-The intensifier converts the
energy from the low-pressure hydraulic fluid into ultrahigh-pressure [Link]- The accumulator maintains the continuous flow of the high-pressure water and eliminates pressure fluctuations
3..High-pressure tubing- High-pressure tubing transports pressurized water to cutting head..4 Catcher- The catcher acts as a reservoir for collecting the machining debris entrained in the water jet
WJMWorking • Water is pumped at a sufficiently high pressure,using intensifier technology. • When water at such pressure is passed through an orifice of 0.2- 0.4 mm diameter, the potential energy of
water is converted into kinetic energy, yielding a high velocity jet with velocity • When this water jet strikes a workpiece surface over a small area, the erosive force of water removes the material rapidly.
• The water, in this case, acts like a saw and cuts a narrow groove in the workpiece [Link] • It has multidirectional cutting capacity. • No heat is produced. • Cuts can be started at any
location without the need for predrilled holes. • There is no deflection to the rest of the [Link] Cutting ,Drilling,deburring,Cutting of printed circuit electrostatic-Discharge Machining
(EDM) Principle • Material removal is based upon the electro-discharge erosion effect of electric sparks occurring between two electrodes that are separated by a dielectric liquid. • Metal removal takes
place as a result of the generation of extremely high temperatures generated by the high-intensity discharges that melt and evaporate the two electrodes i.e. workpiece and [Link] of EDM
electrode materials High electrical conductivity High thermal conductivity Less tool wear ,Cost – cheap Advantages EDM• Any materials that are electrically conductive can be machined by EDM. •
Edge machining and sharp corners are possible in EDM process.• The process produces good surface finish, accuracy and [Link] and automotive industries. • Deep
cavities, slots and ribs can be easily made bEDMwashing machine agitators, electronic components,Micro-EDM process can successfully produce micro-pins, micro-nozzles and micro-cavities.
LBM [laser beam machimimg] Working • LASER machining is localized, non-contact thermal machining and is almost reaction-force free. • LBM uses a laser beam (narrow beam of intense
monochromatic light) to machine or cut required shapes or profile in almost all materials. • The laser beam is focused onto the work-piece and can be moved. • Photon energy is absorbed by target
material in the form of thermal energy or photochemical energy. • The high amount of heat thus generated either melts, burns, or vaporizes away the material at the focused region. • Any material that
can properly absorb the laser irradiation ca be laser machined e.g. hard and brittle materials as well as soft materials such as metals, ceramics, leatherLBM Advantages • Tool wear and breakage are not
encountered. • Holes can be located accurately by using an optical laser system for [Link] is extremely rapid and the setup times are economical. LBM Applications• Electronic and
automotive [Link] can cut wood, plastics, leather,glass,ceramics and fiber opticsLBM is used for making very accurate sized holes as small as 5 microns in metals, ceramics and composites without
wrapage.
Rapid Prototyping-Defining RP • The Layer-by Layer fabrication of three dimensional physical models directly from a CAD data. Applications of RPT • Automobile & Aerospace Industry • Medical
applications • Toys manufacturing • Development of master patterns in casting/moulding RPT Process Steps 1. Geometric Modeling- Model of Golf Ball designed in Software 2. Tessellation of the
geometric model- 3D CAD model is converted into Standard Tessellation Language (STL) file format. • 2. 3D CAD model is converted into Standard Tessellation Language (STL) file format. 3. Slicing of the
model into layers- In this step, the model in STL file format is sliced into closely spaced parallel horizontal [Link] of RPT Liquid based 1. Stereo-lithography Powder based1. Selective Laser
Sintering, Solid based 3. Fused-deposition Modeling STEREOLITHOGRAHY Principle • Stereo-lithography (STL) is a process for fabricating a solid plastic part out of a photosensitive Liquid polymer using a
directed laser beam to solidify the polymer. • Part fabrication is accomplished as a series of layers, in which one layer is added onto the previous layer to gradually build the desired three-dimensional
geometry. Selective Laser Sintering (SLS) Working Principle • Selective laser sintering (SLS) uses a moving laser beam to sinter heat-fusible powders in areas corresponding to the CAD geometric model
one layer at a time to build the solid part. • After each layer is completed, a new layer of loose powders is spread across the surface using a counter-rotating roller • SLS uses moving laser beam to sinter
heat-fusible powders in areas corresponding to CAD geometric model, one layer at a time to build the solid part. • After each layer is completed, a new layer of loose powders is spread across the surface
using a counter-rotating roller. • The powders are preheated to just below their melting point to facilitate bonding and reduce distortion. • Layer by layer, the powders are gradually bonded into a solid
mass that forms the 3D part geometry Fused Deposition Modeling Working Principle • Fused-deposition modeling (FDM) is an RP process in which a filament of wax or polymer is extruded onto the
existing part surface from a work-head to complete each new layer. • The work head is controlled in the x-y plane during each layer and then moves up by a distance equal to one layer in the zdirection.
• The starting material is a solid filament with typical diameter 1.25 mm fed from a spool into the work head that heats the material to about 0.5C above its melting point before extruding it onto the part
surface. • The extrudate is solidified and cold welded to the cooler part surface in about 0.1 second. The part is fabricated from the base up, using a layer-by-layer procedure similar to other RP systems
Fdm advntges cost effactive,produce strong part,no need for part clean up,nontoxic Comparisons of RPT
Stereolithography Inkjet Based Fused Deposition Modeling Selective Laser Sintering (SLS)
Speed Average Poor Poor Average to good
Accuracy Very good Excellent Fair Good
Strengths • Large part size • Accuracy • Accuracy Finish • Price • Materials • Accuracy Materials
Weaknesse • Post processing • Messy • Speed • Limited materials Part size • Speed • Part size • Size and weight System
liquid
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