1.1 INTRODUCTION:
In a machining process, mainly two types.
1) Traditional Machining Process (TM)
2) Non-Traditional Machining Process (NTM)
As new technology development in field of space research, missile and nuclear industries, very precise and complicated parts are required and demanded by these industries. New developments in material science taking place in manufacturing field to meet the new challenges. After World War II, many new materials and unconventional methods of forming difficult to machine metals have emerged which are being put to commercial use with time. The meaning of unconventional used in meaning of harden steel, metal matrix composites (MMC), composites, tungsten, etc., are not easily machined by conventional machining
…show more content…
Material removal rate (MRR)
2. Tool wear rate (TWR)
3. Surface roughness (SR)
1.5 COMPONENTS OF WIRE EDM
1.6 ADVANTAGES OF WIRE EDM
1. As continuously travelling wire is used as the negative electrode, so electrode fabrication is not required as in EDM.
2. There is no direct contact between the work piece and the wire, eliminating the mechanical stresses during machining.
3. WEDM process can be applied to all electrically conducting metals and alloys irrespective of their melting points, hardness, toughness or brittleness.
4. Users can run their work pieces over night or over the weekend unattended.
1.7 DISADVANTAGES OF WIRE EDM
1. High capital cost is required for WEDM process.
2. There is a problem regarding the formation of recast layer.
3. WEDM process exhibits very slow cutting rate.
4. It is not applicable to very large work piece.
1.8 APPLICATIONS OF WIRE EDM
1. Aerospace, Medical, Electronics and Semiconductor applications
2. Tool & Die making industries.
3. For cutting the hard Extrusion Dies.
4. In making Fixtures, Gauges & Cams.
5. Cutting of Gears, Strippers, Punches and Dies
6. Manufacturing hard Electrodes.
7. Manufacturing micro-tooling for Micro-EDM, Micro-USM and such other micromachining
Which the ability to control the flow of electricity it made it easier to regulate heat and you could weld on different types of metals.
Usually bond two dissimilar metals are joined using this process of welding, especially to weld one metal over a base metal extending to large areas. Production of corrosion free sheets and plate stock for making processing equipment for different operations in the chemical industries and petroleum industries are the major applications. Explosion welding general requires no filling metals, and external agencies for production of heat are also not required. Diffusion does not occur during the processes. The metal parts are metallurgically bonded, in many cases it results in a mechanical interlocking that is occurred as locking formed by a rippled or wavy interfaces between the surface of metals. The process of welding one metal plate on another can be described with help of Figure
Thermo-mechanically affected zone (TMAZ): In this region, the material has been plastically deformed by the friction stir welding tool, and the heat from the process will also have exerted some influence on the material. In the case of aluminium, it is possible to get significant plastic strain without recrystallization in this region, and there is generally a distinct boundary between the recrystallized zone and the deformed zones of the TMAZ. In the earlier classification, these two sub-zones were treated as distinct microstructural regions. However, subsequent work on other materials has shown that aluminium behaves in a different manner to most other materials, in that it can be extensively deformed at high temperature without recrystallization. In other materials, the distinct recrystallized region (the nugget) is absent, and the whole of the TMAZ appears to be recrystallized. This is certainly true of materials which have no thermally induced phase transformation which will in itself induce recrystallization without strain, for example pure titanium, b titanium alloys, austenitic stainless steels and copper. In materials such as ferritic steels and a-b titanium alloys (e.g.Ti-6Al-4V), understanding the microstructure is made more difficult by the thermally induced phase transformation, and this can also make the HAZ/TMAZ boundary difficult to identify
Welding must be done carefully to avoid contamination and machining must be done precisely. Titanium is very reactive to atmospheric gases and can result in degradation in the material. Titanium is weldable in annealing conditions but provide limited weld ductility and heat affected zone ductility. It can also be significantly strengthened by cold working.
If you need to unjoin two pieces of metals you will have to cut it with a torch and you have to cut it just right you can’t mess the metal
Semiconductors allow the flow of both ions and electrons through the sample but not completely free; and its
The use of thinner gauge Ti and Ni alloys is pushing the aircraft engine industry to ensure high quality welds can be made with lower levels of heat input. Every part we produce goes through our nondestructive laboratory to test the welds under x-ray or die penetrant.
This demonstration can be done with copper in the form of shot, pellets, thicker wire, or bars, but is a great deal slower than with copper
Aluminium (AL) alloy 6061 is one of the most extensively used of the 6000 series aluminium alloys. Among the various useful aluminium alloys, aluminium alloy 6061 is typically characterized by properties such as fluidity, cast ability, corrosion resistance and high strength-weight ratio. Aluminium-based alloy MMCs has received increasing attention in recent decades as engineering applications. This alloy has been commonly used as a base metal for MMCs reinforced with a variety of fibres, particles and whiskers. Tungsten carbide (WC) is approximately two times stiffer than steel, with a Young's modulus of approximately 550GPa, and is much denser than steel or titanium.
occurs within this step. The wire mesh travels through a press that forces the pulp mixture against the wire to
When tested in the lab, it was found that Advance Wire was mediocre in conductivity & abrasiveness, while also being heavier than all other samples.
Mechanical pulping is typically used for softwood.One of the advantages of mechanical pulping is it has a great yield around 95% from dry weight of input material,however it requires great energy, because the resulted paper are opaque, weaker and easily to discoloration with the exposure to the light.The mechanical pulps are more weaker than the chemical pulps, however it ia more cheaper to produce (about 50% of the costs of chemical pulp). Moreover, they give the yield with the ranging from 85–95%24.
The program is loaded and finally an operator runs a test of the program to ensure there are no problems. This trial run is referred to as "cutting air" and it is an important step because any mistake with speed and tool position could result in a scraped part or a damaged machine. There are many advantages to using CNC Machining. The process is more precise than manual machining, and can be repeated in exactly the same manner over and over again. Because of the precision possible with CNC Machining, this process can produce complex shapes that would be almost impossible to achieve with manual machining. CNC Machining is used in the production of many complex three-dimensional shapes. It is because of these qualities that CNC Machining is used in jobs that need a high level of precision or very repetitive tasks. Other than that, there has some problem that always occur in CNC machine such as electrical fault, parameter issues, door and safety interlocks and others. If you are considering a career in CNC Machining, it would be useful to have a background in mathematics, industrial arts and mechanical drafting, as well as computer usage. There are many common problem of CNC Machining such as the material burns on outside edge, the material burns on outside edge, the material burns on internal corners of mould, the tool is burnt, burnt edges of holes, raised mark along edge of moulding, rough edge, cutter marks visible, component moves sideways and component not the correct
We live in a time where technology is improved and advanced every single day. The health care environment is no exception. The technology used for health care is constantly being refined and advanced in hopes to allow even better and more efficient care. One of these technological advancements that could revolutionize health care is 3D printing. Benefits 3D printing could provide include construction of prosthetic limbs as well as anatomical models aimed at determining patients’ needs and many more (Ventola, 2014). However, there are also disadvantages of this technology and one of the main disadvantages is the security issues it presents. There are both advantages and disadvantages of 3D printing but there is no denying the promise of this technology and the potential impact it could have.
CNC machining it works particularly well for hard, relatively brittle materials like steels and other metal alloys to produce high accuracy parts with well-defined properties and normally be more homogeneous and predictable in quality.