Machines slot
hello friends, now we will cover any aspects related to non-traditional machining process, such as their types, parts, workflow, application, advantages, disadvantages, etc.
Non-traditional machining processes widely useful when there are many hard and brittle consumables such as tungsten carbide, high speed steel, stainless steel, ceramic, etc. Which cannot be machined by conventional machining process.
Nowadays, all these non-traditional machining processes are fully automated, running on cnc equipment.
Most of the conventional machining processes, such as lathes, planers, milling machines, drilling machines, slotting machines, molding machines and etc. Already discussed in the previous post.
Here we agree to know only about the non-traditional processing process.
So, without delay, let's get started
What is an unconventional machining procedure?
An unconventional process is an ordinary type of machining because there is no direct communication between the tool and the workpiece in this process.In an unconventional machining process, a form of energy (such as mechanical energy, electrical energy, chemical energy, etc.) Is used to remove unwanted material from a given workpiece.
To support the workpiece in these types of processes fixtures are always used in processing.
This is also called non-traditional processing or non-traditional processing.
So if i keep saying those names, don't get confused.
Advantages of unconventional machining process
It has good accuracy.Has a good surface.Complicated shapes are easily produced.Long service life tool.High metal removal rate.
Lack of unconventional machining process
Current process cost is high.Skilled operator required.Its setting is complicated.Classification of non-traditional machining process
- Based on mechanical energy- based on electrical energy- based on chemical and electrochemical energy- based on based on thermal energybased on mechanical energy
Based on electrical energy
Based on chemical and electrochemical energy
Heat energy based
Types of non-traditional machining processes
Many of the common types of non-traditional machining processes that are used for machining with different energy sources are discussed:
Abrasive blastingultrasonic machiningelectrochemical machining (ecm)electrical discharge machining (ed)electron beam machininglaser machiningelectrochemical grindingabrasive blasting
Abrasive blasting is a non-traditional mechanical energy-based machining process that is mostly used in hard metal processing.
In this treatment, a concentrated stream of abrasive particles such as aluminum oxide, silicon carbide, diamond powder, glass particles, etc. Are forced to strike the workpiece at high speed.
These high-speed abrasive particles cut metal into tiny pieces.See. The pictures show the process of abrasive blasting and their workflow, detailed below. Air or gas such as nitrogen, carbon dioxide, etc. Is compressed in a gas compressor. Where the density and pressure of the gas increases.It now sends the pressurized gas to the filtration unit, where dust and other suspended particles are removed.Then it sends the clean gas to the dryer, where it is humidified. Absorbed.Now this purest and dryest gas is sent to the mixing chamber where the abrasive particles are located in the abrasive feeder. (The size of abrasive particles is from 10 to fifty micrometers)now these abrasive particles and gas under significant pressure (about 850 kpa) are sent to the nozzle (nozzle diameter ranges from 0.18 to zero.80 mm), where its pressure the energy is converted into kinetic energy.The speed of the abrasive particles leaving the nozzle ranges from 150 to 300 m/s.The distance between the workpiece and the nozzle (tungsten) is no more than 2 mm.Now these high-speed abrasive particles hit the workpiece. These high speed abrasive particles remove material through micro-cutting manipulation and through brittle fracture of the working material. Using abrasive blasting
Used when drilling and cutting hard metals.Used for brittle and heat-sensitive consumables such as glass, mica, ceramic, sapphire, quartz, etc.Used for radio components.Advantages of abrasive blastingHigh surface quality.Suitable for processing heat-sensitive materials.It is not subject to vibration.Low initial cost compared to typical non-traditional procedures.Thin cuts can be made.
Disadvantages abrasive blasting
Low metal removal rate.Nozzle life is limited and must be changed frequently.Abrasive particles it is unacceptable to reuse in this process. This machine cannot be used for soft and ductile material.
Ultrasonic processing
Ultrasonic processing also represents is an unconventional process based on mechanical energy. Which is used for cutting brittle and hard materials.
During ultrasonic processing, ultrasonic waves are converted into mechanical vibrations due to the magnetostrictive effect.
The ultrasonic machine generates a frequency of $20,000 up to 30 thousand hz.
This process is needed for metal cutting in many industries due to its loyal cost, no heat generation and efficient processing.
Look at the pictures the sonication process and their workflow are detailed below.
Ultrasonic processing workflow
First of all, low-frequency electric current is sent from the battery (power supply) .This low frequency current is converted into high frequency current through some electrical equipment.This high frequency current is forced through the converter. The transducer converts this high frequency electrical quality into a high frequency mechanical vibration.This mechanical vibration is passed through the amplifier.The amplifier amplifies this high frequency vibration and sends it to a horn.The horn, also known as a transmitted instrument holder this heightened vibration to the instrument. When the tool vibrates at an ultrasonic frequency.The abrasive gun is used to provide abrasive slurry (such as aluminum oxide, silicon carbide, boron carbide, diamond dust, etc.), And the mixture of abrasive slurry and water is directed between the tool and the workpiece. As the tool vibrates, the abrasive slurry also begins to vibrate at a similar high frequency.This abrasive slurry affects the workpiece and gives it a metallic appearance.
Using ultrasonic machining
Used for making small holes.This is the most suitable machine for processing hard and brittle materials.With the help of this, a cavity or hole is easily made in the dies.
Advantages of ultrasonic machining
The workpiece is not subjected to any stress after machining.Extremely hard and brittle materials are easily removed.Excellent precision and surface finish are achieved.Very low maintenance.This procedure remains natural as it takes place in the absence of any chemical reactions and heating.It is suitable for both conductive and non-conductive materials.
Disadvantages of ultrasonic machining
However, the metal removal rate is low and may not always be able to work for adult machining operations.The initial price and the initial cost of the equipment are too high. The power consumption is rather high.The suspension may need to be replaced frequently. Equipment life is short.
Electrochemical machining (ecm)
Electrochemical machining is an unconventional processing procedure made from electrochemistry into which metals are removed electrochemical dissolution. The described process is opposite to the galvanic process.
Electrochemical processing software works according to faraday's law of electrolysis.
The tool must be connected to the negative terminal (as a cathode) of the battery, and the workpiece connects to the positive terminal (as an anode) of the battery.
Both are placed at a distance in the electrolyte solution.
When applied to the electrode with a direct current (from three to 30v) the metal begins to move away from the workpiece.
See the picture describes the process of electrochemical processing and the sequence of their performance. See below for details.
Working procedure for electrochemical machining
In echo, nacl is usually idle in liquid as an electrolyte.The tool is connected to the negative terminal and the workpiece is docked with positive terminal.When current passed through the electrodes between the anode or workpiece and the cathode or tool, the reaction took place >naci = (na ) (ci-)h20 =( h ) ( oh-) positive ions move towards the tool, and negative ions to the workpiece.So the hydrogen ion moves towards the tool.As the hydrogen reaches the tool, it takes some of the electrons from it and turns into a gas. This gas is released into the environment.
Use of electrochemical processing
Echo it is used in the processing of disk or turbine rotor blades. It is worth using for slotting the thinnest walled collets.Ecm is used to create the inner profile of the inner cam.Ecm is also used in satellite rings and connecting rods, gear machining and long parts. Profiles and more.
Advantages of electrochemical machining
Machining very complex surfaces is possible.One tool is allowed to be used for processing many workpieces. .Metal machining does not need tool strength and tool rigidity.Ecm provides a significant surface area.
Disadvantages of electrochemical machining
High initial machine cost.Design and tool system complexity.Fatigue properties of the machined surface are reduced.Non-conductive materials fail to look machined.Blind holes cannot be machined with ecm.Electrodischarge machining (edm)
This machining process uses an electric spark to cut off metal.
Erosion and evaporation.
This process takes place in a dielectric liquid. In this non-traditional machining process, both the workpiece and the tool are made of conductive material.
Look at the drawing of the edm process and its workflow, detailed below. Edm workflow
First of all, the workpiece and equipment are immersed in a dielectric fluid. This dielectric fluid helps to control the arc discharge.The smallest gap (about half a millimeter) is present between the workpiece and the tool.The electrode is supplied with a high frequency current, it provides a spark between the tool and the workpiece.Due to erosion and evaporation metal ions begin to leave the workpiece.Chips and suspended particles are removed between the workpiece and the tool, so as not to provoke a short circuit. It is real due to the continuous supply of dielectric liquid.
Electro discharge machining application
It is specially used by stamping masters.Finished productlong side hole
Advantages of edm
With this process it is possible to cut any conductive material.Complex seal sections and complex shapes can be produced with high precision.This process does not need burrs.Thin sections can be easily formed without deforming any parts.Hard materials can be cut easily.
Disadvantages of edm
Equipment wear is greater in this type of machining.Good electrical conductors can only be made by edm.
Electron beam machining
This is an unconventional process based on thermoelectric energy that does not use tools.This machining procedure works on the basic principle of converting the kinetic energy of electrons into thermal energy.
When a high-speed electron strikes a workpiece, they convert their kinetic energy into thermal energy.
This thermal energy evaporates the content on the surface of the workpiece.
This process is performed in a vacuum, in another situation, the electron works with a particle of air masses and loses its energy before hitting the material. It is most often used for drilling holes of any degree.
See the figure shows the process of electron beam processing that the workflow is detailed below.
Workflow electron beam processing
First, the electron gun produces electron particles with maximum speed.These electron particles move towards the anode. The anode is placed after the cathode tube.Now it passes a high-intensity electron beam through magnetic lenses. There is a chain of lenses that only cares about the converging electrons passing through it. It absorbs all outgoing electrons and low energy electrons. Which provides a high quality electron beam.This electron beam now passes through an electromagnetic lens and a deflection coil that focuses the electron beam on a single resource.A high-intensity electron beam hits a part of the workpiece, where the kinetic energy of the electrons is converted into thermal energy.Due to this high temperature, created by the conversion of kinetic activity into thermal energy, the substance melts and evaporates, due to which the material begins to be removed (cut) .The whole process takes place in a vacuum chamber, otherwise these electrons meet air particles on the way and lose their own kinetic energy.
Electron beam processing application
Used for producing very small holes from 100 micrometers to 2 millimeters.Used for making holes in diesel engine injectors.Used in the aerospace industry for printing turbine blades. For supersonic propulsion and in nuclear reactors.
Advantages of electron beam processing
It can be used to design very small holes in various shapes .It can process any material, regardless of its hardness or other third party properties.It provides a good surface finish.Highly reactive materials are easy to machine because the processing is delivered in a vacuum.
Disadvantages of electron beam processing
High capital cost .Requires operator skill.Slow material removal rate.Requires regular maintenance maintenance.It is difficult to create a perfect vacuum.
Laser beam processing
Laser beam processing is also an unconventional processing process that is based on thermoelectric energy in which there is a laser beam to heat up the material.
In this kind of processing, metal is removed from the surface of the workpiece by melting and evaporating metal particles.
This is an unconventional processing process , which does not use any tools.Used for processing both metallic, similarly non-metallic materials.
Mainly necessary for cutting materials and drilling holes.
please see the picture of the laser beam processing and telephone production process, detailed below.
Working procedure of laser beam processing
Firstly, the laser material ( the vacuum (discharge) tube of the laser is filled with co2) or other gases.Now turn on the power switch to slot machines new which the flash lamp is connected. This lamp produces light energy, which is used to excite the electrons of the atom.The atoms of the laser substance absorb energy from the light energy produced by the flash lamp, and it converts the lower energy level of the atomic orbital electron to a higher energy level. This is the unstable state of the atom.This energy is initially completely immersed in the laser material. After the atom has absorbed enough energy, it will continuously emit energy.This laser light is collected by a focusing lens directed at the workpiece.The laser that is directed at the workpiece starts to melt or vaporize the surface of the workpiece and processing takes place.
Application of laser beam processing
Used for drilling small holes with a diameter of about 0.005mm. In refractory and ceramic materials.Used for drilling holes and cutting both metals, never non-metals.Mainly used in the aerospace industry.Used for stylish profiles where tooling is not possible.
Advantages of laser beam processing
It can drill and cut all articles.High surfaces are obtained in this processing business.The tool is not applicable to our blog processing process .Micro-holes can be drilled accurately.Very hard materials can be processed with a laser beam.High precision can be achieved.Disadvantages of laser processing
High capital and maintenance costs.It should not be used for making blind holes.Laser has the potential to cause danger.Electrochemical grinding
Electrochemical grinding workflow
The grinding wheel is attached to a spindle made of diamond particles. The spindle is used to rotate the grinding wheel. The grinding wheel rotates at a speed of 900 to 1800 rpm.The workpiece is connected to the positive terminal, and the tool must be connected to the negative terminal.A gap of two and a half mm is maintained in the process. The electrolyte flows between the generic gap.Sodium chloride and sodium nitrate are used as electrolytes.The electrolyte also functions as a coolant. It is filtered and redistributed.
If this informative article is chosen for you, and in addition you want to provide specific information about slot machines new, i beg you to visit our personal resource.
