Advanced Manufacturing Techniques for Modern Materials
The reverse of electroplating. Material is dissolved atom-by-atom from a conductive workpiece via electrolysis in an electrolyte solution.
Controlled chemical etching dissolves material from specific zones.
Excellent for miniaturized components in electronics and medical devices. 4. Applications of NCM Processes Non Conventional Machining Process Ppt
Use real-world examples to explain why these methods are used.
Chemical etchants attack exposed areas of a workpiece. Chemical resistant "maskants" protect the zones meant to remain intact.
Slicing weight-reduction pockets into large aerospace wing panels (Chemical Milling). Chemical etchants attack exposed areas of a workpiece
Introduction to material removal without direct tool-to-workpiece mechanical contact.
A tool shaped to match the desired cavity vibrates at an ultrasonic frequency (typically 20 kHz to 40 kHz) with a low amplitude. An abrasive slurry (usually silicon carbide or boron carbide mixed with water) flows between the tool and the workpiece. The vibrating tool forces the abrasive grains to strike the workpiece surface, eroding material through micro-chipping.
Easily shapes materials regardless of their hardness, brittleness, or strength. The micro-abrasive action cuts
A high-velocity stream of gas (air or nitrogen) focused with fine abrasive particles strikes the workpiece surface. The micro-abrasive action cuts, cleans, or deburrs the material.
Constant DC source, tool (cathode), workpiece (anode), high-velocity electrolyte (NaCl or NaNO3cap N a cap N cap O sub 3
Components for electronics and medical implants require micro-machining capabilities that traditional tools cannot physically scale down to achieve. Key Differences: Conventional vs. Non-Conventional Conventional Machining Non-Conventional Machining Tool Material Must be harder than the workpiece Hardness is irrelevant; relies on energy forms Tool-Workpiece Contact Direct physical contact No direct physical contact (gap maintained) Mechanism of Removal Plastic deformation / Shear chip formation Melting, vaporization, ionic dissolution, erosion Material Waste High (large chips produced) Low (microscopic debris or sludge) Surface Finish Limited by tool geometry and vibration Extremely high precision and surface finish Noise & Pollution High noise and physical scrap Silent operations; handles chemical/sludge waste 2. Classification of Non-Conventional Machining Processes