Unconventional Machining

 EDM (continued):

o The mechanical stress occurring in the metal spreads at a definite

velocity in all directions including the one from which the shock wave
was propagated.
o When it reaches the surface and is reflected from it, the shock wave
undergoes a reversal in sign, i.e., a tensile stress is developed in the
surface layer of a magnitude that is many times more than the tensile
strength of the metal.
o As a result, particles of metal are thrown out in the direction facing
the compression shock wave.
 Unconventional Machining
 Electro Discharge Machining (EDM):

o It is a disintegration of current conducting materials by an electrical

discharge.
o Also known as Spark Erosion Machining.
o Process:
At each electrical discharge, a fused stream of electrons, flowing at
a high velocity, from one electrode to the other, produces compression
shock waves on the surface of the electrodes.
This pressure is many times more than the ultimate strength of the
material. It increases the temperature and a certain deformation of the
surface occurs.
 Unconventional Machining
 EDM (continued):

o There are four general types of electrical-discharge and

electrolytically assisted machining equipments.

 Spark-over-initiated discharge machining;

 Electrical-pulse discharge machining;
 Electrolytically assisted discharge machining;
 Contact-initiated discharge machining.
 Unconventional Machining
 Ultrasonic Machining:

o The electrical discharge machining process can be used only for the
current conducting materials. But UM is able of working on both
types of materials.
o Glass, ceramics, porcelain, quartz, germanium, silicon, rubies,
diamond, cemented carbides, etc can be machined using UM.
o It is some way similar to EDM. A shock wave is produced by
abrasive grains.
o 30 to 100 thousand / cm2 particles and 16 to 25 kc/s frequency
provide a high metal removal.
o The motion is transmitted to the abrasive grains by the vibrating
end of the tool which is connected through tool holder to magneto
strictive transducer.
o The transducer coil is supplied by current at 16-25 kc/s from an
ultrasonic generator. This current is converted by the transducer in
mechanical vibrations of same frequency.
o The vibrating system is mounted on spindle which can travel
vertically on the ways of column and applies the tool to the surface
of workpiece with a definite force.