Non-Traditional Manufacturing Processes

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Non-Traditional Manufacturing Processes
Chemical Machining (CM)
Electrochemical Machining (ECM)
Electro-Discharge Machining (EDM)
Laser cutting
Ultrasonic Machining (USM)
Water-Jet and Abrasive Water-Jet Machining
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Chemical Machining
Etching
Chemical reaction between reagent (in gas,
solution, or paste form) and workpiece.
Main uses - Shallow, wide cavities on plates,
forgings, castings ? reduce weight - Electronics
manufacturing (wafer fabrication) - Hydrogen
Flouride, Hydrofloric acid etching of glass
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Photo-Chemical Machining
Main uses - Flat springs, metal bookmarks,
encoder wheels, lead frames for IC chips,
sieves for medical applications, microwave oven
filters, heat-sinks for PCBs
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Electrochemical Machining (ECM)
Reverse of electro-plating (workpiece is anode)
Main uses - Dies and glass-making molds, turbine
and compressor blades, Holes, Deburring
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Electro-Discharge Machining (EDM)
Electrode EDM
- Sparks between electrode-workpiece - Dielectric
flushes the metal powder - Inexpensive, precise,
complex shapes - Workpiece must be a conductor
source iprod.auc.dk
Wire-cut EDM
source www.magnix.co.kr
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Laser cutting
Light Amplification by Stimulated Emission of
Radiation
- High energy density (small focus area) - Uses
Cutting, welding, precision holes - Common
lasers CO2, NdYAG - Continuous power or Pulsed
(more precise)
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Ultrasonic Machining
Main uses of USM - Welding plastics (package
sealing) - Wire-bonding (IC chips) - Machining
brittle materials
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Water-Jet, Abrasive Water-Jet Machining
- Workpiece is fractured by impact from high
pressure (400 MPa) water-jet - No heat ? no
thermal stress, damage
Common applications - Fast and precise cutting
of fabrics - Vinyl, foam coverings of car
dashboard panels - Plastic and composite body
panels used in the interior of cars - Cutting
glass and ceramic tiles