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Questions and Answers
What distinguishes nontraditional machining processes from conventional machining processes?
What distinguishes nontraditional machining processes from conventional machining processes?
- Nontraditional processes are developed before World War II, while conventional processes were developed after.
- Nontraditional processes use mechanical, thermal, electrical, or chemical energy to remove material, while conventional processes use a sharp cutting tool. (correct)
- Nontraditional processes are less expensive than conventional processes.
- Nontraditional processes only machine metals, while conventional processes can work on both metals and non-metals.
Which factor significantly impacts the production cost of nontraditional machining processes?
Which factor significantly impacts the production cost of nontraditional machining processes?
- Expense of equipment and tooling (correct)
- Type of metals being used
- Temperature rise in the workpiece
- Geometries of the parts being machined
Why are nontraditional machining processes essential for newly developed materials?
Why are nontraditional machining processes essential for newly developed materials?
- To decrease the production cost
- To address the high hardness and strength of the materials (correct)
- To simplify machining operations
- To increase temperature rise in the workpiece
What issue do nontraditional machining processes aim to avoid, which is common in conventional machining?
What issue do nontraditional machining processes aim to avoid, which is common in conventional machining?
How are nontraditional machining processes classified based on the type of energy used?
How are nontraditional machining processes classified based on the type of energy used?
Which process involves erosion of work material by a high velocity stream of abrasives or fluid?
Which process involves erosion of work material by a high velocity stream of abrasives or fluid?
What type of energy is usually applied to a small portion of the work surface in Thermal Energy Processes?
What type of energy is usually applied to a small portion of the work surface in Thermal Energy Processes?
Which process utilizes electrochemical energy to remove material?
Which process utilizes electrochemical energy to remove material?
What is the primary method of material removal in Chemical Machining?
What is the primary method of material removal in Chemical Machining?
In which process is material removed through contact with a strong chemical etchant?
In which process is material removed through contact with a strong chemical etchant?
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Study Notes
Conventional Machining Processes
- Use a sharp cutting tool to form a chip from the workpiece
- Examples: turning, drilling, milling
Nontraditional Machining Processes
- Remove excess material using various techniques involving mechanical, thermal, electrical, or chemical energy
- Developed since World War II to respond to new machining requirements that cannot be satisfied by conventional methods
- Require expensive equipment and tooling, as well as skilled labor, increasing production cost
Importance of Nontraditional Processes
- Needed to machine newly developed metals and non-metals with special properties (high hardness and strength) that are difficult to machine by conventional methods
- Needed for unusual and/or complex part geometries that cannot be accomplished by conventional machining
- Needed to avoid surface damage and provide better surface finish
- Needed to avoid temperature rise or residual stress in the workpiece
Classification of Nontraditional Processes
Mechanical Energy Processes
- Ultrasonic Machining
- Water jet cutting
- Abrasive water jet cutting
- Abrasive jet machining
- Erosion of work material by a high velocity stream of abrasives or fluid (or both)
Electrochemical Machining Processes
- Electrochemical machining
- Electrochemical deburring
- Electrochemical grinding
- Use electrochemical energy to remove material (reverse of electroplating)
Thermal Energy Processes
- Electric Discharge Processes
- Electron Beam Machining
- Laser Beam Machining
- Arc-Cutting Processes
- Oxyfuel-Cutting Processes
- Apply thermal energy to a small portion of the work surface, causing removal by fusion and/or vaporization
Chemical Machining Processes
- Chemical milling
- Chemical blanking
- Chemical engraving
- Photochemical machining
- Remove material through contact with a strong chemical etchant
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