Non-Traditional Machining
Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) © MPGroover 2007
26 NONTRADITIONAL MACHINING AND THERMAL
CUTTING PROCESSES
Review Questions
26.1 Why are the nontraditional material removal processes important? Answer. Reasons for importance of are nontraditional material removal processes (1) the need to shape new metal alloys and non-metals that are difficult to machine by conventional processes; (2) the requirement of unusual and complex workpart geometries; and (3) the need to avoid surface damage which is often associated with conventional machining. 26.2 There are four categories of nontraditional machining processes, based on principal energy form. Name the four categories. Answer. The four categories are (1) mechanical, but not including conventional machining; (2) electrical; (3) thermal; and (4) chemical. 26.3 How does the ultrasonic machining process work? Answer. In ultrasonic machining, abrasives contained in a slurry are driven at high velocity against the work by a tool vibrating at low amplitude and high frequency. The tool oscillates in a direction perpendicular to the work surface, and is fed slowly into the work, so that the shape of the tool is formed in the part. The abrasives, impinging against the work surface, perform the chip removal. 26.4 Describe the water jet cutting process. Answer. Water jet cutting uses a high-pressure, high-velocity stream of water directed at the work surface to cut the work. 26.5 What is the difference between water jet cutting, abrasive water jet cutting, and abrasive jet cutting? Answer. WJC cuts with a narrow, high velocity water stream; AWJC adds abrasive grits to the water stream; and AJM cuts with abrasive particles that have been added to a high velocity air stream. 26.6 26.7 Name the three main types of electrochemical machining. Answer. The three types are electrochemical machining, deburring, and grinding. Identify the significant disadvantages of electrochemical machining.
26 NONTRADITIONAL MACHINING AND THERMAL
CUTTING PROCESSES
Review Questions
26.1 Why are the nontraditional material removal processes important? Answer. Reasons for importance of are nontraditional material removal processes (1) the need to shape new metal alloys and non-metals that are difficult to machine by conventional processes; (2) the requirement of unusual and complex workpart geometries; and (3) the need to avoid surface damage which is often associated with conventional machining. 26.2 There are four categories of nontraditional machining processes, based on principal energy form. Name the four categories. Answer. The four categories are (1) mechanical, but not including conventional machining; (2) electrical; (3) thermal; and (4) chemical. 26.3 How does the ultrasonic machining process work? Answer. In ultrasonic machining, abrasives contained in a slurry are driven at high velocity against the work by a tool vibrating at low amplitude and high frequency. The tool oscillates in a direction perpendicular to the work surface, and is fed slowly into the work, so that the shape of the tool is formed in the part. The abrasives, impinging against the work surface, perform the chip removal. 26.4 Describe the water jet cutting process. Answer. Water jet cutting uses a high-pressure, high-velocity stream of water directed at the work surface to cut the work. 26.5 What is the difference between water jet cutting, abrasive water jet cutting, and abrasive jet cutting? Answer. WJC cuts with a narrow, high velocity water stream; AWJC adds abrasive grits to the water stream; and AJM cuts with abrasive particles that have been added to a high velocity air stream. 26.6 26.7 Name the three main types of electrochemical machining. Answer. The three types are electrochemical machining, deburring, and grinding. Identify the significant disadvantages of electrochemical machining.