advanced mfg.

Advanced Manufacturing MODULE 1

BY PROF.AVINASH

Electro-chemical Machining  ECM

 It utilizes the principle that is reverse of electroplating  Tool made as cathode & W/P made as anode  Metal ions removed from anode  Electrolyte is selected in such a way that no ions allowed to deposit on cathode

Set up of ECM  A DC power supply unit  Workpiece and work holding system  Tool and tool feed system

 Electrolyte supply system

Applications  Die sinking operations  Drilling jet engine turbine blades  Multiple hole drilling

Electron Beam Machining  When a high velocity beam of electrons strike a W/P the kinetic energy of the electrons gets converted into heat.

 Hence the W/P melts and vaporizes

Set-up of EBM  Electron gun

 Magnetic lens  Magnetic deflection coil

 Movable table  Monitoring instrument  Vacuum chamber

Applications of EBM  Mainly for welding

 Micromachining on thin materials  Engraving of metals and ceramics

 Drilling of micro-holes in turbine blades  Producing metering holes in injector nozzles of diesel engines

 To remove small broken taps from holes  Welding connections in electronics

Controlling parameters  Beam current: depends on grid voltage

 More the grid voltage is –ve, more electrons are restricted  Beam dia: depends on beam current, voltage, magnetic lens, distance between gun and W/P