Advanced Manufacturing Processes (ALL SLIDES Gaurav Arora)

7/17/2019 Advanced Manufacturing Processes (ALL SLIDES Gaurav Arora)

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ADVANCED MANUFACTURING

PROCESSES

9/15/15 visit menotes-in.e!no"e.#om $o% s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. 1



M)n($)#t(%in

• C*)nin ) %) m)te%i)& into ) n)& 0%o"(#t

t*%o(* some te#*ni(es/0%o#esses.

• 2o #o(&" e "o t*)t

34 mo&"in t*e %) m)te%i)&.

34 s*)0in it.

34 oinin it.

9/15/15 visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s.

6



C)teo%4 o$ M)n($)#t(%inP%o#esses

• P%im)%4 Fo%min P%o#esses 7A""itive8

• M)te%i)& Remov)& o% M)#*inin 7S(!t%)#tive8

• De$o%min P%o#esses 7Fo%m)tive8

• oinin o% F)!%i#)tion 7Assem!&in8

• Finis*in )n" S(%$)#e T%e)tment.

• 3(&, P%o0e%t4 En*)n#in P%o#esses 72e)t

T%e)tment8


:



Convention)& v/sUn#onvention)&

T*e m)n($)#t(%in 0%o#esses #)n !e"ivi"e" into to s(! #)teo%ies ;

S.NO.

Nature Conventional Unconventional

1. P%im)%4Fo%min7A""itive8

C)stin' Po"e%Met)&&(%4

V)%io(s R)0i"P%otot40inP%o#esses

6. M)#*inin

7S(!t%)#tive8

D%i&&in' Mi&&in'

S*)0in' et#.

V)%io(s A"v)n#e"

M)#*ininP%o#esses i.e. AFM'AM' A<M et#.

:. De$o%min7Fo%m)tive8

Met)& Fo%minP%o#esses i.e. Co&"

)n" 2ot Ro&&in.

2i* Ene%4 R)teFo%min 72ERF8' :D

&)se% Fo%min=. oinin o% <e&"in 7Atomi# )n" E3M' >3<' US< et#


=



Se&e#tion o$ MPs

• T40e o$ o%, m)te%i)&.

• N)t(%e )n" its 2)%"ness.

• Me&tin Tem0e%)t(%e o$ t*e o%, m)te%i)&

• P%o"(#tion vo&(me o% 3)t#* Si?e.


5



T40e o$ o%, m)te%i)& +N)t(%e

Met)&s )n" most )&&o4s;

•

2)ve Re&)tive&4 2i* Me&tin Tem0e%)t(%e; C)n!e 0%o#esse" in So&i" $o%m (sin M)#*inin )n"

De$o%min P%o#esses

• Poo% M)#*in)!i&it4; AMPs )%e #ommon&4 0%e$e%%e".


@



T40e o$ o%, m)te%i)& +N)t(%e

Po&4me%s )n" E0o4-!)se" Com0osites;

• >oe% Me&tin Point; C)n !e P%o#esse" in >i(i" St)te

• Some Se#on")%4 P%o#esses &i,e M)#*inin is Nee"e" to

O!t)in

• Desi%e" Dimension)& A##(%)#4 )n" S(%$)#e B()&it4

• Sin#e t*ese M)te%i)&s Gene%)&&4 Cont)in Fi!e%s )n"

Fi&&e%s' t*e4 E*i!it 3%itt&e 3e*)vio% t*e%e$o%e AMPs )%e

mo%e S(it)!&e




T40e o$ o%, m)te%i)& +N)t(%e

Ce%)mi#s;

• Us()&&4 3%itt&e; Di#(&t to P%o#ess in So&i" Fo%m

(sin Convention)& M)#*inin P%o#esses

• P%im)%4 Fo%min P%o#esses )%e (se" to C%e)te

t*e 3)si# S*)0e• AMPs )%e Use" to Give Fin)& S*)0e )n" S(%$)#e

B()&it4




3)t#* Si?e o% P%o"(#tionVo&(me

Sm)&&e% 3)t#* Si?e Re(i%es F&ei!&e M)n($)#t(%in

P%o#esses &i,e M)#*inin' *i#* #)n P%o"(#e V)%iet4 o$

Geomet%i#)& Fe)t(%es.

>)%e% 3)t#* Si?e A&&os (se o$ P%im)%4 Fo%min )n"

De$o%min 0%o#esses so )s to Oset t*e Re&)tive&4

2i* Costs o$ M)#*ine Too&s )n" Too&in

• P%im)%4 Fo%min P%o#esses F%om 5 on)%"s

• De$o%min P%o#esses Mo%e t*)n 1

• M)#*inin P%o#esses U0 to 5


9



3)t#* Si?e o% P%o"(#tionVo&(me


1



<*4 AMPs

To Meet Ne' C*)&&enin' )n" Un(s()&M)n($)#t(%in/S*)0in Re(i%ements o$ t*eP%o"(#ts M)"e o$

Di#(&t-To-P%o#ess M)te%i)&s i.e. Ti-)&&o4s'0o&4me%s' #e%)mi#s )n" #om0osites.

)n"/o%

Seve%e/>imitin M)n($)#t(%in Re(i%ements i.e.

A(tomo!i&es' Ae%os0)#e' De$ense' C(ttin Too&s'

Die )n" Mo&"s' N(#&e)%' Mi#%oe&e#t%oni#s'

3iome"i#)& .


11



MERC2ANT CIRC>E DIAGRAM 7MCD8

• Me%#*)nt; S#ientist' In"(st%i)&ist )n"P%o$esso%.

• Deve&o0e" ) !e)(ti$(& met*o" to"e)& it* #(ttin $o%#es in m)#*inin.

• Inte%estin t*ins to !e note" !4 t*eo%, "one !4 Me%#*)nt;

18 2o it )s #onst%(#te"

68 2o it *e&0s


16



Const%(#tion o$ MCD

• MCD s*oin t*e #(ttin $o%#es )n" t*ei%

%e&)tions.

• MCD is v)&i" $o% on&4 o%t*oon)& #(ttin.

• >ets t),e )n e)m0&e o$ o%t*oon)& t(%nin;

3e$o%e oin to MCD' e nee" to see *)t

)%e t*e $o%#es )#tin on t*e o(toin #*i0.

Note; 2e%e' ) #)se o$ "(#ti&e m)te%i)&

0%o"(#in #ontin(o(s #*i0 is #onsi"e%e".


1:



MCD it* #(ttin $o%#es

Re$e%en#e; M)n($)#t(%in P%o#esses 34 G*os* )n" M)&i,9/15/15 visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.1=



F%om t*e o%, si"e

• T*e%e is ) s&i0 !eteen t*e 0)%ent !o"4)n" t*e #*i0.

• T*(s' ) s*e)% $o%#e i&& )#t on t*e 0&)ne

i.e. HPs.

• T*is HPs 7s*e)% $o%#e8 is )##om0)nie" !4) no%m)& $o%#e HPn.

•

No t*e%e )%e to $o%#es *i#* )%ene#ess)%4 to )##om0&is* m)#*inin.

• T*e 0)%t i.e. #*i0 #omin o(t $%om t*e0)%ent !o"4 is )t #onst)nt ve&o#it4 i.e. HV.


15



F%om t*e too& si"e

• F%i#tion $o%#e' HF )#tin in t*eo00osite "i%e#tion !e#)(se %(!!in(0on t*e %),e $)#e o##(%s )s t*e #*i0

oes o(t.

• No%m)& $o%#e' HN to *e&0 t*e $%i#tion

$o%#e o% to )##om0&is* m)#*inin)#ts 0e%0en"i#(&)% to t*e HF.

9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.1@



Sini#)n#e o$ $o%#es

• 2e&0s in #onst%(#tin t*e MCD.

• Gene%)tion o$ %es(&t)nt $o%#e HR)#tin on t*e o%,0ie#e !e#)(se o$#onse(en#e o$ HPs + HPn to)##om0&is* m)#*inin.

• Gene%)tion o$ #om0ens)to%4 $o%#e

HR1 )#ts in ) "i%e#tion o00osite toHR.

Note; R + R1 )%e )#tion +

%e)#tion $o%#es.9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.1



Sim0&ie" MCD•Ps ; S*e)%in Fo%#e•Pn ; No%m)& Fo%#eto Ps•F ; F%i#tion Fo%#e•N ; No%m)& to F

•P? ; Fo%#eene%)te" !4 t*em)#*ine too& in#(ttin "i%e#tion7,non8•

P4 ; Fo%#e0e%0en"i#(&)% to P?•An&e !et); S*e)%0&)ne )n&e•An&e G)mm);R),e )n&e•An&e N-!)%;9/15/15

visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.1



P%o0e% Use o$ MCD

• Dete%min)tion o$ seve%)& ot*e%%e&ev)nt $o%#es $%om ) $e ,non$o%#es it*o(t m(#* #)&#(&)tions.

• E)s4 )n" (i#, ev)&()tion o$Coe#ient o$ $%i#tion 7)00)%ent8 )n""4n)mi# 4ie&" s*e)% st%ent* o$ o%,

m)te%i)&.• Deve&o0ment o$ e()tions %e&)tin

t*e v)%io(s $o%#es in m)#*inin.9/15/15


MTE + CA m)%,s.19



>imitin Con"itions $o% MCD

• MCD is v)&i" $o% o%t*oon)& #(ttin

on&4.

• R)tio o$ F/N ives )00)%ent 7not

)#t()&8 COF )t %),e $)#e.

• V)&i" $o% sin&e s*e)% 0&)ne t*eo%4.


MTE + CA m)%,s.6



Met*o"s $o% MCD n(me%i#)&

• G%)0*i#)& Met*o".

• An)&4ti#)& Met*o".

9/15/15 visit menotes-in.e!no"e.#om $o% s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. 61



G%)0*i#)& Met*o"

P%o!&em;-

D(%in t(%nin o$ ) "(#ti&e )&&o4 !4 )too& o$ H J 1K' it )s $o(n" t*)t Pᴕ

?

J

1N' P J =N' P4 J :N )n" L J

6.5. Ev)&()te' (sin MCD' t*e v)&(e o$F' N' ' Ps )n" Pn $o% t*e )!ove

m)#*inin.


MTE + CA m)%,s.66



So&(tion


MTE + CA m)%,s.6:




MTE + CA m)%,s.6=



P%o!&em No. 6

D(%in o%t*oon)& m)#*inin it* )#(ttin too&

*)vin %),e )n&e 1K' t*e #*i0t*i#,ness is

me)s(%e" to !e .= mm' t*e (n#(tt*i#,ness

!ein .15 mm. "ete%mine t*e s*e)%0&)ne )n&e

)n" )&so t*e m)nit("e o$ t*e s*e)%

st%)in.9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.65



P%o!&em No. :

Dete%mine t*e #oe#ient o$ $%i#tion)n"

(&tim)te s*e)% st%ess $o% t*e m)#*inin0%o#ess;

t1 J .65 mm' t6 J .5 mm' J 6.5

mm' J ᴕo

P? J 95 N )n" P4 J =5 N.


MTE + CA m)%,s.6@



NONTRADITIONA>/UNCONVENTIONA> MAC2ININGPROCESSES 7A"v)n#e" M)#*inin P%o#esses8

T2ESE PROCESSES USE VARIOUS TPES OF

ENERGIES AND VARIOUS MET2ODSOF

MATERIA> REMOVA>.

T2ESE DIFFER <IDE> IN NATUREAND C2ARACTERISTICS.


MTE + CA m)%,s.6



C&)ssi#)tion o$ A"v)n#e" M)#*inin P%o#esseson t*e !)sis o$ ene%ies invo&ve"

• A!%)sive et M)#*inin7AM8---Me#*)ni#)&

• U&t%)soni# M)#*inin7USM8---Me#*)ni#)&

• A!%)sive <)te% et M)#*inin7A<M8 ---Me#*)ni#)&

7Me#*)nism ;- E%osion 8

• E&e#t%o#*emi#)& M)#*inin7ECM8---E&e#t%o#*emi#)&

7Me#*)nism;- Ion "is0&)#ement8

• E&e#t%i# Dis#*)%e M)#*inin7EDM8---C*emi#)&

• E&e#t%on 3e)m M)#*inin7E3M8--- C*emi#)&

7Me#*)nism;- F(sion )n" V)0o%i?)tion8

• >)se% 3e)m M)#*inin7>3M8--- T*e%m)&

7Me#*)nism;- Me&tin' V)0o%i?)tion )n" A!&)tion8


MTE + CA m)%,s.6



A!%)sive et M)#*inin

M)te%i)& %emov)&

t),es 0&)#e "(e toim0inement o$ t*ene )!%)sive 0)%ti#&es.

P)%ti#&es move it**i* s0ee" )i% 7o% )s8st%e)m.

Si?e o$ )!%)sive

0)%ti#&es ; .65 mm"i)mete%.

Ve&o#it4 o$ )i% et J15-: m/s

Ti0 "ist)n#e J . mm9/15/15

Reference; G*os* )n" M)&i,'M)n($)#t(%in S#ien#e


MTE + CA m)%,s.69



Me#*)ni#s o$ AM

2i* ve&o#it4 )!%)sive 0)%ti#&eim0ines on t*e o%,0ie#e' t*eim0)#t %es(&ts in ) tin4 !%itt&e

$%)#t(%e )n" t*e )i%/)s #)%%ies ))4t*e "is&o"e" sm)&& 0)%ti#&e.

Mo%e s(it)!&e $o% !%itt&e m)te%i)&s7*)%"8.


MTE + CA m)%,s.:



P%o#ess 0)%)mete%s

• A!%)sive 7#om0osition' st%ent*' si?e)n" m)ss o %)te8

• G)s 7#om0osition' 0%ess(%e )n"ve&o#it48

• No??&e 7 eomet%4' m)te%i)&'"ist)n#e $%om )n" in#&in)tion to t*e

o%,0ie#e8

A&& t*ese )%e ev)&()te" !4 ("inMRR'

eomet%4 o$ #(t' %o(*ness o$ s(%$)#e9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.:1



A!%)sive

• A&(mini(m oi"e )n" Si&i#onC)%!i"e.

• S*)0e "oes not m)tte% !(t s*)%0e"es )%e essenti)&.

• Si?e o$ A&6O: )n" SiC J 1-15 m

•

Re(se o$ )!%)sives ; Not%e#ommen"e"

• M)ss o %)te "e0en"s (0on0%ess(%e )n" o %)te o$ )s.


MTE + CA m)%,s.:6



T40i#)& %e&)tions

9/15/15 Reference;- G*os* )n" M)&i,' M)n($)#t(%inS#ien#e


MTE + CA m)%,s.::



G)s

• AM o0e%)tes )t .6 N/mm6 to 1N/mm6.

• G)s in#&("es "%4 )i%' nit%oen' #)%!on"ioi"e )n" *e&i(m.

• 2i* ve&o#it4 o!vio(s&4 #)(ses )*i* MRR even i$ t*e m)ss o %)te

is ,e0t #onst)nt.


MTE + CA m)%,s.:=



No??&e

• It is one o$ t*e im0o%t)nt e&ement o$AM.

• Contin(o(s&4 in #ont)#t so itsm)te%i)& s*o(&" !e *)%" *i#* s*o(&"not e)%.

• No%m)&&4' <C o% S)00*i%e is (se".

• Q-se#tion)& )%e) o$ o%i#e ; .5 mm6

)n" .6 mm6.

• S*)0e o$ t*e o%i#e ; %e#t)n(&)% o%

#i%#(&)%.9/15/15

visit menotes-in.e!no"e.#om $o%

s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s.

:5



No??&e ti0 "ist)n#e 7NTD8

9/15/15



:@



A00&i#)tions )n" (ses o$ AM

• No%m)&&4 (se" $o% nis*in o0e%)tion%)t*e% t*)n ) 0%o"(#tion #(ttin0%o#ess.

• A00&i#)tions in#&("e "e!(%%in't%immin' #&e)nin' 0o&is*in )n""%i&&in.

• Common m)te%i)&s on *i#* AM #)n!e )00&ie" )%e &)ss' si&i#on )n"#e%)mi#s.

9/15/15



:



<)te% et M)#*inin/<)te% etC(ttin

• <M o% <C (ses) ne' *i*0%ess(%e' *i*

ve&o#it4 st%e)mo$ )te% "i%e#te")t t*e o%,0ie#e

to #)(se #(ttino$ t*e o%,

9/15/15

Reference:- Mi,e&& P. G%ove%' F(n")ment)&s o$ mo"e%n

m)n($)#t(%invisit menotes-in.e!no"e.#om $o%


:



<M/<C

• A&so ,non !4 t*e n)me *4"%o"4n)mi# m)#*inin!(t #ommon&4 (se" n)me in in"(st%ies is <C

• To o!t)in ne st%e)m o$ )te% ) sm)&& no??&eo0enin o$ "i)mete% .1 to .= mm is (se".

• Fo% #(ttin to t),e 0&)#e' 0%ess(%e (0to = MP)is (se" )n" et %e)#*es ) ve&o#it4 o$ 9 m/s.

• No??&e (nit ; 2o&"e% o$ St)in&ess Stee& )n" ee&no??&e o$ m)"e o$ s)00*i%e' %(!4 o% "i)mon".

• Fi&t%)tion s4stem m(st !e (se" to se0)%)te#(ttin 0)%ti#&es.

9/15/15



:9



P%o#ess P)%)mete%s

• St)n" o "ist)n#e

18 It s*o(&" !e sm)&& to )voi""is0e%sion.

68 T40i#)& St)n" o "ist)n#e is :.6mm.

• Si?e o$ no??&e o%i#e

• C(ttin $ee" %)te

9/15/15



=



A00&i#)tion o$ <M

• P&)sti#s

• F&oo% ti&es

• >e)t*e%

• Met)& 0o&4me% &)mintes

• G&)ss !%e met)& &)mintes

9/15/15



=1



A00&i#)tion o$ <M

9/15/15



=6



A00&i#)tion o$ <M

9/15/15



=:



A"v)nt)es

• No #%(s*in o% !(%nin o$ o%,s(%$)#e

• Minim(m m)te%i)& &oss

• No envi%onment)& 0o&&(tion

• E)se o$ )(tom)tin t*e 0%o#ess

9/15/15



==



>imit)tion

• Not s(it)!&e $o% #(ttin !%itt&em)te%i)& !e#)(se o$ t*ei% ten"en#4 to#%)#, "(%in m)#*inin.

9/15/15



=5



A!%)sive <)te% et M)#*inin7A<M8

• Usin ve%4 *i* s0ee" 76.5 M)#*n(m!e%8 )te% et mie" it*)!%)sives to #(t )n4 t40e o$ m)te%i)&.

• MEC2ANISM ; E%osion it*o(tene%)tin *e)t .

• E&imin)tes t*e%m)& )n" me#*)ni#)&

"isto%tion #)(se" in #onvention)&m)#*inin.

9/15/15



=@



A!%)sive <)te% et M)#*inin7A<M8

• A<M s4stem #onsists o$ ;-

18 An intensie% 0(m0 to 0%ovi"e 2P)te%.

68 A!%)sive "e&ive%4 s4stem + #(ttin*e)" $o% 0%o"(#in t*e )!%)sive)te% et.

:8 Com0(te% #ont%o&&e" m)ni0(&)to% to0%ovi"e t*e "esi%e" motion o$ t*e#(ttin *e)".

=8 A #)t#*e% t*)t "issi0)tes t*e9/15/15



=



A<M

• A!%)sive 0)%ti#&es ene%)&&4 (se"#%(s*e" )%net o% )&(mini(m oi"e7.6 to .5 mm8

• G)%net is i"e&4 (se" !e#)(se o$ &o#ost )n" *i* #(ttin s0ee".

• A!%)sives ente% t*e )te% et it*

ne&ii!&e ve&o#it4.• Sm)&&e% "i) $o#(sin t(!es 0%o"(#es

mo%e ene%4. Minim(m "i) is %e&)te"

to 0)%ti#&e si?e.9/15/15



=



ET FORMER OR CUTTING 2EAD

9/15/15



=9

ET FORMER OR CUTTING



ET FORMER OR CUTTING2EAD

• On-O v)&ve

• O%i#e

• Miin #*)m!e%

• Fo#(sin t(!e

A&& t*ese )%e t*e #om0onents o$#(ttin *e)".

9/15/15



5



CATC2ER

• C)t#*e%

• CNC T)!&e

• A!%)sive Mete%in Devi#e

9/15/15



51



P%o#ess P)%)mete%s

• et Ve&o#it4;- 2i*e% t*e ve&o#it4'mo%e i&& !e t*e MRR.

• Fee" R)te;- T*e s0ee" it* *i#* et

moves 0)st t*e o%,0ie#e to $o%m )#(t.

• A!%)sive (se" )n" t*ei% si?e;- A&6O:

o% G)%net o$ si?e .6 to .5 mm )%e(se".

• <o%, m)te%i)& )n" its t*i#,ness.

• St)n" o "ist)n#e.9/15/15



56



A<M m)#*ines

• Stee&s

• Non-$e%%o(s )&&o4s

• Ti-)&&o4s' Ni-)&&o4s

• Po&4me%s

• Met)& M)t%i Com0osites

•

Ce%)mi# M)t%i Com0osites

9/15/15



5:



A00&i#)tions

• Peenin;- To in"(#e #om0%essivest%esses in ) m)te%i)&.

• C(ttin;- Fo% 6D )n" :D #(ttin.

• D%i&&in;- Fo% m),in *o&es o$ 6-= mm7"i)8

• T(%nin

• N(#&e)% P&)nt Dism)nt&in

9/15/15



5=

U>TRASONIC MAC2INING



U>TRASONIC MAC2INING7USM8

• Me#*)ni#)& m)te%i)& %emov)& 0%o#ess$o% !%itt&e m)te%i)&s (sin *i*$%e(en#4 os#i&&)tions o$ ) s*)0e"

too& (sin )!%)sive s&(%%4.• Too& m)"e (0 o$ "(#ti&e )n" to(*

m)te%i)& is %)"()&&4 $e" it* )

(ni$o%m $o%#e.• S&(%%4 #onsists o$ )te% )n"

)!%)sives.

9/15/15



55



USM

9/15/15

Re$e%en#e;- S)(%)!* S)ins T*esis' IITRoo%,ee



5@



U&t%)soni# M)#*ine

9/15/15 Re$e%en#e;- S)(%)!* S)ins T*esis' IIT



5



USM

9/15/15

Re$e%en#e;- Ve%sion 6 ME' IIT *)%)0(% notes



5



T2EOR OF USM

• A too& vi!%)tes it* )t )n (&t%)soni# $%e(en#4719-65 ,2?8 it* )n )m0&it("e o$ )%o(n" 15-5m ove% t*e o%,0ie#e.

• M)#*inin ?one is oo"e" it* *)%" )!%)sive

0)%ti#&es ene%)&&4 in $o%m o$ )te% s&(%%4 $o%m.

• As t*e too& vi!%)tes' t*e )!%)sive 0)%ti#&es )#ts)s t*e in"ente%s )n" in"ent !ot* t*e o%,0ie#e)n" too&.

• Remov)& t),es 0&)#e !4 )!%)sive )s; C%)#,initi)tion' P%o0))tion )n" !%itt&e $%)#t(%e o$ t*em)te%i)&.

9/15/15



59



Me#*)nism o$ USM

• 2)mme%in o$ )!%)sive 0)%ti#&es ont*e o%, s(%$)#e !4 t*e too&

• Im0)#t o$ t*e $%ee )!%)sive 0)%ti#&es

on t*e o%,0ie#e

• E%osion "(e to #)vit)tion

• C*emi#)& )#tion )sso#i)te" it* t*e

(i"

9/15/15



@

MRR EQPRESSION



MRR EQPRESSION

9/15/15

MRR J

S2A< T2EOR;- It *)s n(m!e% o$&imit)tions. It "oes not #o%%e#t&4 0%e"i#t t*ee$$e#ts o$ A' F )n" .

MRR in#%e)ses it* in#%e)se o$ HF. It is#on%me" !4 t*e )!ove %e&)tion. 2oeve%' in)#t()&' MRR st)%ts "e#%e)sin )$te% some

v)&(e o$ HF !e#)(se t*e )!%)sive %)ins et

Re$e%en#e;- G*os* + M)&i,' M)n($)#t(%in S#ien#e



@1



P%o#ess P)%)mete%s

• F%e(en#4

• Am0&it("e

• St)ti# &o)" 7$ee" $o%#e8

• 2)%"ness %)tio o$ t*e too& )n" t*eo%,0ie#e

• G%)in si?e

• Con#ent%)tion o$ )!%)sives in t*es&(%%4

9/15/15



@6

A3RASIVE F>UID J



A3RASIVE F>UID JS>URR

• Most #ommon )!%)sives (se";-

18 3o%on #)%!i"e 73=C8

68 Si&i#on #)%!i"e 7SiC8

:8 Co%(n"(m 7A&6O:8=8 Di)mon"

58 3o%on Si&i#)%!i"e

3=C is t*e !est )n" mo%e e#ient )monstt*e

%est !(t it is e0ensive.

9/15/15



@:

A3RASIVE F>UID J



A3RASIVE F>UID JS>URR

• <)te% is most #ommon&4 (se".

• Ot*e%s )%e !en?ene' &4#e%o& )n"oi&s.

NOTE;- It *)s !een $o(n" t*)t MRRten"s to

"e#%e)se it* in#%e)sin vis#osit4.

9/15/15



@=



M)te%i)&s A00&i#)tion

• Met)&s )n" )&&o4s 7 *)%" )n" !%itt&eon&48

• Semi#on"(#to%s

• Non met)&s

9/15/15



@5



>imit)tions

• >o MRR

• Too& e)%

• De0t* o$ *o&es )n" #)vities )%e sm)&&

9/15/15



@@

To0i#s Cove%e" ti&&



To0i#s Cove%e" ti&&=/9/616

18 A!%)sive et M)#*inin 7AM8

68 <)te% et M)#*inin 7<M8

:8 A!%)sive <)te% et M)#*inin7A<M8

=8 U&t%)soni# M)#*inin

A&& t*ese 0%o#esses (ti&i?e me#*)ni#)&ene%4 to

m)#*ine ) m)te%i)&.9/15/15



@

E>ECTROC2EMICA>



E>ECTROC2EMICA>PROCESSES

Im0o%t)nt %o(0 o$ NON-TRADITIONA> PROCESSES'

(ses e&e#t%i#)& ene%4 to %emove m)te%i)&.

E&e#t%i#)& ene%4 is (se" in #om!in)tion it*

#*emi#)& %e)#tions to )##om0&is* m)#*inin' t*(si"entie" )s e&e#t%o#*emi#)& 0%o#esses.

T*ese 0%o#esses )%e t*e %eve%se o$ e&e#t%o0&)tin.

<o%,0ie#e m(st !e ) #on"(#to% in e&e#t%o#*emi#)&m)#*inin.

9/15/15



@



E>ECTROC2EMICA> PROCESSES

• E>ECTROC2EMICA> MAC2INING 7ECM8

• E>ECTROC2EMICA> DE3URRING 7ECD8

• E>ECTROC2EMICA> GRINDING 7ECG8

ECD )n" ECG )%e t*e s0e#i)& $o%m o$ ECM.

9/15/15



@9



ECM

9/15/15

Re$e%en#e;- Mi,e&& P. G%ove%' F(n")ment)&s o$ Mo"e%n M)n($)#t(%in





T*eo%4 o$ ECM

• Too& is 0%ovi"e" it* ) #onst)nt $ee"motion.

• E&e#t%o&4te is 0(m0e" )t *i*

0%ess(%e t*%o(* t*e too& )n" t*esm)&& )0 !eteen t*e too& + t*eo%,0ie#e.

• E&e#t%o&4te is so #*osen t*)t t*e)no"e is "isso&ve" !(t no "e0ositiont),es 0&)#e on t*e #)t*o"e.

9/15/15



1



P%o#ess P)%)mete%s

• Poe% S(00&4 ;

18 T40e Di%e#t C(%%ent.

68 Vo&t)e 6 to :5 vo&ts.

:8 C(%%ent 5 to =' A

=8 C(%%ent Densit4 .1 to 5A/mm6

• <o%,in )0 ; .1 to 6 mm

•

Fee" %)te ; .5 to 15 mm/min9/15/15



6



Cont"

• E&e#t%o"e m)te%i)& ; 3%)ss' 3%on?e +Co00e%

• Av. Ro(*ness 7R)8 ; .6 to 1.5 m

• E&e#t%o&4te ; 18 M)te%i)& ; N)C& )n" N)No:

68 Tem0e%)t(%e ; 6-5 oC

:8 F&o %)te ; 6 &0m 0e% 1 A =8 P%ess(%e ; .5 to 6 !)%

58 Di&(tion ; 1 /& to 5 /&

9/15/15



:



C*)%)#te%isti#s o$ ECM

• Too& + <o%, M)te%i)& e&e#t%i#)&

#on"(#tive

• Atomi# >eve& Disso&(tion.

• S(%$)#e Finis* E#e&&ent.

• A&most St%ess F%ee M)#*ine" S(%$)#e.

• No T*e%m)& D)m)e.

9/15/15



=



To0i#s $o% 0%esent)tion

1. G%een M)n($)#t(%in

6. S(%$)#e Eninee%in

:. U&t%) P%e#ision G%in"in

=. Co%%osion A T40e o$<e)%

5. Atomi# >)4e% De0osition7A>D8

@. A!%)sive F&o

M)#*inin 7AFM8

. F&ei!&e M)n($)#t(%inS4stems

. R)0i" P%otot40in 7RP8

9. Sm)%t M)te%i)&s

1.E0&osive <e&"in

11.P%o"(#t "esin )n"

Deve&o0ment16.Po"e% Met)&&(%4

1:.Po&4me% M)t%i Com0osites

1=.G%o(0 te#*no&o4

15.Me)s(%ement )n"Ins0e#tion

[email protected]%i#tion Sti% <e&"in

9/15/15



5

E&e#t%o#*emist%4 o$ ECM



E&e#t%o#*emist%4 o$ ECM0%o#ess

• T*e met)& $%om t*e )no"e is"isso&ve" e&e#t%o#*emi#)&&4 )n"*en#e t*e MRR !)se" on FARADAS

&)s i&& "e0en" on )tomi# ei*t'v)&en#4' t*e #(%%ent 0)sse" )n" t*etime $o% *i#* t*e #(%%ent is 0)sse".

• At #)t*o"e' on&4 26 )s is evo&ve")n" no ot*e% %e)#tion t),es 0&)#e't*(s s*)0e o$ too& %em)ins

(n)e#te".9/15/15



@

Re)#tions )t Ano"e +



Re)#tions )t Ano"e +C)t*o"e

9/15/15

Re$e%en#e ; Ve%sion 6' ME IIT *)%)0(%visit menotes-in.e!no"e.#om $o%


Re)#tions )t Ano"e +



Re)#tions )t Ano"e +C)t*o"e

Ano"e;- Fe Fe6 6e-

C)t*o"e;- 26O 6e- 26 6O2-

Fe6 6O2- Fe7O286

Fe 26O Fe7O286 26

9/15/15



ECM E(i0ment



ECM E(i0ment

9/15/15

Re$e%en#e ; Ve%sion 6' ME IIT *)%)0(%visit menotes-in.e!no"e.#om $o%


9

ECM i



ECM e(i0ment

• Poe% S(00&4 7 5 to =' A8

• E&e#t%o&4te Fi&t%)tion )n" "e&ive%4

s4stem

• Too& $ee" s4stem

• <o%,in T)n,

9/15/15



E& t & t



E&e#t%o&4te

• F(n#tions o$ E&e#t%o&4te;-

18 S*o(&" #om0&ete t*e e&e#t%i#)&#i%#(it.

68 A&&o "esi%)!&e m)#*inin%e)#tions.

:8 C)%%ies ))4 *e)t ene%)te"

"(%in

0%o#ess.

=8 C)%%ies ))4 0%o"(#ts o$ %e)#tion

$%om9/15/15



1

E& t & t



E&e#t%o&4te

• P%o0e%ties o$ e&e#t%o&4te to se%ve t*e$(n#tion;

18 2i*&4 e&e#t%i#)& #on"(#tive.

68 >o vis#osit4 + *i* s0e#i# *e)t.

:8 C*emi#)& st)!i&it4

=8 Resist)n#e to $o%m)tion o$ 0)ssive&m on /0

58 Non #o%%osive' non toi#' %e)"i&4)v)i&)!&e )n" #*e)0.

9/15/15



6

M t i & R & R t



M)te%i)& Remov)& R)te

• MRR J 7A I 8/ 7 F8 ,/s

*e%e' A J Atomi# ei*t o$ o%,0ie#e

I J C(%%ent' )m0e%es

J V)&en#4 o$ o%, m)te%i)& F J F)%)")4s #onst)nt J 9@5=

#o(&om!s

Vo&(met%i# MRR J 7A I 8/ 7 F8 W X mm:/s

*e%e X is t*e "ensit4 o$ o%, m)te%i)&.

9/15/15



:

P !& ECM



P%o!&em ; ECM

C)&#(&)te t*e MRR )n" t*e e&e#t%o"e $ee" %)te in t*e ECM o$

)n

i%on s(%$)#e t*)t is 65 65 mm6 in #%oss-se#tion (sin N)C& in

)te% )s e&e#t%o&4te. T*e )0 !eteen t*e too& )n" t*e o%,

0ie#e is .65 mm. T*e s(00&4 vo&t)e is 16 V. T*e s0e#i#

%esist)n#e o$ e&e#t%o&4te is : Y-#m.

So&(tion;- Use MRR $o%m(&) )n" %esist)n#e + %esistivit4%e&)tion

9/15/15



=

P !& N 6



P%o!&em No.6

In ECM o0e%)tion o$ 0(%e i%on )ne(i&i!%i(m )0 o$ 6 mm is to !e,e0t. Dete%mine s(00&4 vo&t)e' i$

t*e tot)& ove%vo&t)e is 6.5 V. T*e%esistivit4 o$ t*e e&e#t%o&4te is 5 Y-mm )n" t*e set $ee" %)te is .65

mm/min.

9/15/15



5

P P t ECM



P%o#ess P)%)mete%s ; ECM

• Fee" R)te ; Mo%e $ee" %)te %es(&ts in mo%e MRR.Im0%oves s(%$)#e nis* )n" to&e%)n#e #ont%o&.

• C(%%ent ; Mo%e #(%%ent &e)"s to *e)tin o$e&e#t%o&4te )n" %es(&ts in *i*e% evo&(tion o$

*4"%oen )n" &e)"s to "%o0 in vo&t)e.• Con#ent%)tion ; >o #on#ent%)tion %es(&ts in

!ette% s(%$)#e nis* )n" ne% to&e%)n#e #ont%o&.

• Vo&t)e ; >oe% vo&t)e "e#%e)ses t*e

e(i&i!%i(m m)#*inin )0 )n" %es(&ts in !ette%s(%$)#e.

9/15/15


s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. @

A" t " >i it ti



A"v)nt)es )n" >imit)tions

• Com0&e :-D s(%$)#es #)n !em)#*ine"

• No #(tte%s m)%,s' so !ette% s(%$)#e

nis*• Too& e)% is 0%)#ti#)&&4 ni& so mo%e

0%o"(#ts #)n !e 0%o"(#e" 0e% too&.

• S*)%0 inte%io% e"es )%e "i#(&t to0%o"(#e.

• Use o$ #o%%osive me"i) )s

e&e#t%o&4tes m),es it "i#(&t to9/15/15



E& t i Di * M *i i 7EDM8



E&e#t%i# Dis#*)%e M)#*inin 7EDM8

• M)te%i)& %emov)& !4 ) #ont%o&&e"e%osion t*%o ) se%ies o$ e&e#t%i#s0)%,.

• M)in&4 $o% e#onomi# m)#*inin o$et%eme&4 &o m)#*in)!i&it4 7 E;-

S(0e% )&&o4s' )"v)n#e" #e%)mi#s )n"#om0osites8

9/15/15





9/15/15

Re$e%en#e ; *tt0;//in$o*ost.nmt.e"(/Z&)#o!so/S(0e%)&&o4[6S&i"es.0"$


s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. 9



9/15/15

Re$e%en#e ; *tt0;//in$o*ost.nmt.e"(/Z&)#o!so/S(0e%)&&o4[6S&i"es.0"$



E& t i Di * M *i i 7EDM8



E&e#t%i# Dis#*)%e M)#*inin 7EDM8

9/15/15



T*eo%4



T*eo%4

• <*en ) "is#*)%e t),es 0&)#e!eteen to 0oints o$ )no"e )n"#)t*o"e' t*e intense *e)t ene%)te"

ne)% t*e ?one me&ts )n" ev)0o%)test*e m)te%i)&s in t*e s0)%,in ?one.

• I$ !ot* t*e e&e#t%o"es )%e o$ s)me

m)te%i)&' t*e )no"e e%o"es $)ste%.• G)0 !eteen too& )n" /0 is #)&&e"

)s s0)%, )0.

9/15/15



Me#*)ni#s o$ EDM



Me#*)ni#s o$ EDM

9/15/15


s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. 9:

Se(en#e o$ events in EDM




1. <it* t*e )00&i#)tion o$ vo&t)e' )ne&e#t%i# e&" !(i&"s (0 !eteen t*eto e&e#t%o"es )t t*e 0osition o$

&e)st %esist)n#e.6. T*e ioni?)tion &e)"s to t*e

!%e),"on o$ "ie&e#t%i# *i#*

%es(&ts in t*e "%o0 o$ t*e vo&t)e)n" t*e !einnin o$ o o$ #(%%ent.

:. E&e#t%ons )n" ions mi%)te to )no"e

)n" #)t*o"e )t ve%4 *i* #(%%ent9/15/15


s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. 9=





=. Co&(mn o$ v)0o(% !eins to $o%m )n" &o#)&ise"me&tin o$ o%, st)%ts. T*e "is#*)%e #*)nne&#ontin(es to e0)n" )&on it* ) s(!st)nti)&in#%e)se o$ tem0e%)t(%e )n" 0%ess(%e.

5. <*en t*e 0oe% is sit#*e" o' #(%%ent "%o0s'no $(%t*e% *e)tin )n" "is#*)%e #o&&)0ses.Po%tion o$ met)& ev)0o%)tes )n" 0o%tion o$met)& i&& !e ee#te" )n" %em)inin so&i"ies.

@. A tin4 #%)te% is t*(s ene%)te" )t t*e s(%$)#e.

9/15/15



Me#*)ni#s o$ EDM



Me#*)ni#s o$ EDM

• M)te%i)& %emov)& $%om t*e #)t*o"e is#om0)%)tive&4 &ess t*)n $%om t*e )no"e;-

18 T*e moment(m it* *i#* t*e st%e)mo$ e&e#t%ons st%i,es t*e )no"e is m(#* &)%et*)n t*)t "(e to im0inement o$ 0ositiveions.

68 T*e 04%o&4sis o$ "ie&e#t%i# (i" #%e)tes )

t*in &m o$ #)%!on on t*e #)t*o"e. :8 A #om0%essive $o%#e is "eve&o0e" on t*e

#)t*o"e.

9/15/15


s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. 9@

P%o#ess P)%)mete%s



P%o#ess P)%)mete%s

• O0en #i%#(it vo&t)e' Vo 7 Vo&ts8

• <o%,in vo&t)e' V 7@5-= Vo&ts8

• M)im(m C(%%ent' Io 7= Am08

• P(&se on time' ton 76-6 s8• P(&se o time' to

• S0)%, G)0' \ 7.165-.165 mm8

• Po&)%it4 ; St%)i*t 0o&)%it4 ; too& 7-ve8

• Die&e#t%i# me"i(m

• Ete%n)& (s*in t*%o(* t*e s0)%, )0

9/15/15



C*)%)#te%isti#s o$ EDM




• T*e 0%o#ess #)n !e (se" to m)#*ine )n4o%,0ie#e !(t it m(st !e e&e#t%i#)&&4 #on"(#tive.

• M)te%i)& %emov)& "e0en"s (0on t*e%m)&0%o0e%ties 7X' ]m ' C0 ' 8 o$ o%, m)te%i)& %)t*e%

t*)n its st%ent*' *)%"ness et#.• P*4si#)& too& is %e(i%e" )n" eomet%4 o$ too& is

0ositive im0%ession o$ t*e eomet%i# $e)t(%e to!e m)#*ine".

• Too& e)% "e0en"s on t*e%m)& 0%o0e%ties o$ too&m)te%i)&

9/15/15







• T*o(* t*e &o#)& tem0e%)t(%e %ise is%)t*e% *i*' sti&& "(e to ve%4 sm)&& 0(&seon time' t*e%e is no eno(* time $o% t*e

*e)t to "i(se )n" t*(s )&most noin#%e)se in !(&, tem0e%)t(%e t),es0&)#e. T*(s' *e)t )e#te" ?one is &imite"to 6-= mi#%omete% o$ t*e s0)%, #%)te%.

• T)0e% #(t )n" ove% #(t not "esi%)!&e !(to##(%s "(%in "%i&&in.

9/15/15



Die&e#t%i#



Die&e#t%i#

• It s*o(&" !e t*e%m)&&4 %esist)nt. It s*o(&" not"isso#i)te.

• Gene%)&&4' ,e%osene )n" "eionise" )te% is(se" )s "ie&e#t%i# (i".

• It s*o(&" 0%ovi"e o4en $%ee s(%$)#e.

• It s*o(&" *)ve st%on "ie&e#t%i# %esist)n#e sot*)t it "oes not !%e), e&e#t%i#)&&4 )n" )t t*e

s)me time ionise *en e&e#t%ons #o&&i"e it*t*e mo&e#(&es.

• Die&e#t%i# me"i(m s*o(&" !e (s*e" %e(&)%&4

9/15/15



Too& m)te%i)&s + 0%o0e%ties



0 0

• E&e#t%o"e s*o(&" not e)% !4 im0inement o$

ions.• >o#)&i?e" tem0 %ise s*o(&" !e &ess.

• Im0)%tment o$ s*)0e on t*e too& s*o(&" !e e)s4.

• 2i* e&e#t%i#)& #on"(#tivit4' so t*)t #o&" emission

o$ e&e#t%ons t),es 0&)#e )n" &ess !(&, *e)tins*o(&" o##(%.

• 2i* t*e%m)& #on"(#tivit4' $o% t*e s)me *e)t &o)"'&o#)& tem0 %ise o(&" !e &ess.

• 2i* "ensit4 so t*)t &ess "imension)& &oss o%in)##(%)#4.

• 2i* me&tin 0oint' $o% t*e s)me &o)"' &e)"s to&ess too& e)%.

9/15/15



Cont"



Cont"

• G%)0*ite• E&e#t%o&4ti# o4en $%ee #o00e%

7"ensit4' e&e#t%i#)& #on"(#tivit4'

t*e%m)& #on"(#tivit4 is *i* !(t#ost&48

• Te&&(%i(m #o00e% ; 99[ C( )n" .5[

te&&(%i(m• 3%)ss

9/15/15



F&(s*in



F&(s*in

• F&(s*in %e$e%s to t*e met*o" in*i#* t*e "ie&e#t%i# (i" os!eteen t*e too& )n" t*e o%,0ie#e

• T*e "e!%is s*o(&" !e %emove"(i#,&4

• S*o%t #i%#(itin )n" &o m)te%i)&

%emov)& %)te 0%o!&ems i&& o##(% it*0oo% (s*in

• O0tim(m "ie&e#t%i# (s*in %)te o$

)!o(t 1:m&/s *i&e m)#*inin AISI 19/15/15


s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. 1:

F&(s*in met*o"



F&(s*in met*o"

1. No%m)& F&o

6. Reve%se F&o

:. et F&(s*in

=. Imme%sion F&(s*in

9/15/15


s&i"es' t(to%i)& s*eet' )tten")n#e'MTE + CA m)%,s. 1=

No%m)& F&o



No%m)& F&o

• In t*is met*o" (i" is int%o"(#e"(n"e% 0%ess(%e t*%o(* one o% mo%e0)ss)es in t*e too& )n" t*en $o%#e"

t*%o(* t*e )0 !eteen t*e too&)n" o%,0ie#e.

• T*e &o#)tion o$ (s*in s*o(&" !e in

)%e)s *e%e t*e "ee0est m)te%i)& isto !e %emove".

• T*is met*o" #)n !e (se" !4 m),in

*o&e in o%,0ie#e it*o(t *)%min it9/15/15



Reve%se F&o



Reve%se F&o

• To %e"(#e t*e t)0e% 0%o"(#e"' t*e%eve%se o #)n !e (se".

• Sin#e t*e #*i0s )%e oin t*%o(*

t*e o%,0ie#e so no si"e s0)%,s i&&0%o"(#e.

• T40i#)& 0%ess(%e "ie%enti)&s )%e @5

to 9 ,P).• Reve%se o is )#*ieve" !4 )00&4in

v)#((m to t*e m)ni$o&".

• P)%ti#(&)%&4 s(it)!&e $o% "ee0 #)vit49/15/15


MTE + CA m)%,s.1@

et F&(s*in



et F&(s*in

• Di%e#t et is (se" $o% (s*in )t t*em)#*inin ?one.

• Use" $o% m)#*inin o$ &on n)%%o

s&ot o% #)vit4 in ) o%,0ie#e.• M)#*inin time is &one% in t*is #)se.

• Im0o%t)nt #*)%)#te%isti#s ;

"ist%i!(tion o$ t*e no??&es' o %)tes')n&es o$ no??&es )n" #)vit4 &)4o(t.


MTE + CA m)%,s.1

Imme%sion F&(s*in



Imme%sion F&(s*in

• It is 0ossi!&e to )&&o t*e #(ttin tot),e 0&)#e it*o(t )n4 0(m0in o$t*e (i" )n" !4 sim0&e imme%sion.

• A &itt&e )it)tion m)4 !e 0%ovi"e" !4%e&)tive movement o$ t*e too& )n" !4)""in ) vi!%)tion.

• T*is is #)&&e" imme%sion (s*in.


MTE + CA m)%,s.1

A00&i#)tions



A00&i#)tions

• A&& #on"(#tin met)&s )n" )&&o4s.• 3&in" #om0&e #)vities

• Mi#%o *o&es $o% no??&es

• T*%o(* #(ttin o$ non #i%#(&)% *o&es

• N)%%o s&ots


MTE + CA m)%,s.19

A"v)nt)es



A"v)nt)es

• M)te%i)& %emov)& %)tes )%e )&most#om0)%)!&e it* t*)t o$ #onvention)&m)#*inin 0%o#esses

• An4 #om0&e s*)0e %e(i%e" in "ies )n"mo(&" #)n !e m)"e e)si&4.

• T*e 0%o#ess is not )e#te" !4 t*e *)%"nesso$ t*e o%, m)te%i)&

• A#t()& s(%$)#e 0%o"(#e" #onsists o$ sm)&&#%)te%s' *i#* m)4 *e&0 in %etention o$&(!%i#)nts.


MTE + CA m)%,s.11

Dis)"v)nt)es



Dis)"v)nt)es

• <e)% %)te o$ too& is *i*' so sometimesmo%e t*)n one too& m)4 !e %e(i%e" tonis* t*e o!

• <o%,0ie#e s*o(&" !e e&e#t%i#)&&4 #on"(#tive

• T*e ene%4 %e(i%e" $o% t*e o0e%)tion is*i*e% t*)n #onvention)& 0%o#ess )n"*en#e i&& !e mo%e e0ensive

• S(%$)#e ten"s to !e %o(* $o% &)%e%m)te%i)& %emov)& %)tes


MTE + CA m)%,s.111

To0i#s Cove%e" ti&&



6@/9/616 18 A!%)sive et M)#*inin

7AM8

68 <)te% et M)#*inin7<M8

:8 A!%)sive <)te% etM)#*inin 7A<M8

=8 U&t%)soni# M)#*inin

(ti&i?es

7Me#*)ni#)& Ene%48

1. E&e#t%o#*emi#)& M)#*inin7ECM8

6. E&e#t%i# Dis#*)%eM)#*inin 7EDM8

(ti&i?es

7 E&e#t%i# C*emi#)& Ene%48


MTE + CA m)%,s.116

E&e#t%o o0ti#)&- t*e%m)&



0%o#esses• >)se% 3e)m M)#*inin 7>3M8• E&e#t%on 3e)m M)#*inin 7E3M8

A&so ,non )s t*e%m)& !e)m

0%o#esses

Me#*)nism o$ m)te%i)& %emov)& ;-

Me&tin )n" R)0i" v)0o%i?)tion "(e

to intense

*e)tin !4 t*e e&e#t%ons )n" &)se%!e)m


MTE + CA m)%,s.11:

E&e#t%on 3e)m M)#*inin



E&e#t%on 3e)m M)#*inin

• E3M is e(i0ment intensive 0%o#essi.e. e(i0ment is t*e *e)%t o$m)#*inin 0%o#ess.

• In E3M' e&e#t%on !e)m (n is t*e*e)%t o$ t*e 0%o#ess.

• E3 (n o0e%)tes (n"e% v)#((m.

• T*e *o&e st%(#t(%e 7net s&i"e8 is(n"e% v)#((m.


MTE + CA m)%,s.11=

E&e#t%on 3e)m G(n



9/15/15

Re$e%en#e ;- Ve%sion 6' ME' IIT *)%)0(%visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.115

E3 G(n T*eo%4



E3 G(n T*eo%4

• C)t*o"e ; T(nsten o% T)nt)&(m'&)ment t40e #)t*o"es.

• Potenti)& "ie%en#e )00&ie" )#%oss

&)ment so t*)t its tem0e%)t(%e oes)!o(t 65KC

• T*e%mo-ioni# e&e#t%ons )%e emitte"

!4 #)t*o"e on#e it %e)#*es 65KC• As #)t*o"e is ne)tive&4 !i)se"' so

e&e#t%ons )%e %e0e&&e" !4 #)t*o"e9/15/15


MTE + CA m)%,s.11@

E3 G(n T*eo%4



E3 G(n T*eo%4

• (st net to #)t*o"e' !i)s %i" isim0o%t)nt 0)%t o$ (n !e#)(se it#ont%o&s t*e o o$ e&e#t%on.

• T*is is )&so ne)tive&4 !i)se" so t*)te&e#t%ons "o not et #o&&e#te" on it o%%)t*e% #on#ent%)te".

• Fo&&oe" to t*is' t*e%e is )no"e *i#*is 0ositive&4 !i)se".


MTE + CA m)%,s.11

E3 G(n T*eo%4



E3 G(n T*eo%4

9/15/15

• E&e#t%ons et )tt%)#te" !4 )no"e )n")##e&e%)te".

• As t*e4 0)ss t*is )no"e se#tion' t*e4

)#*ieve ) ve&o#it4 *i#* is *)&$ o$ve&o#it4 o$ &i*t.

• So' t*e4 )%e *i*&4 ene%eti#.


MTE + CA m)%,s.11

E3 G(n T*eo%4



E3 G(n T*eo%4

• Fo&&oin t*e )no"e' t*e%e )%e tomo%e se#tions;-

M)neti# &ens )n"

A0e%t(%e

• F(n#tion o$ m)neti# &ens is to $o#(s

o% #on#ent%)te t*e !e)m o$e&e#t%ons.

• A0e%t(%e is to #)0t(%e t*e st%)4

e&e#t%ons )n" *e&0s in #on#ent%)tin9/15/15


MTE + CA m)%,s.119

E3 G(n T*eo%4



E3 G(n T*eo%4

• E&e#t%om)neti# &ens' *i#*(&tim)te&4 $o#(sin t*e e&e#t%on!e)m onto t*e o%,0ie#e.

• Dee#to% #oi&s *e&0s in "ee#tin t*e!e)m

7in #)se i$ "esi%e" eomet%4 )s not

)#*ieve"8

• Te&es#o0e )n" I&&(min)to% ; A&in t*e

e&e#t%on !e)m it* t*e o%,0ie#e9/15/15


MTE + CA m)%,s.16

E3 G(n T*eo%4



E3 G(n T*eo%4

• V)#((m )e 0o%t ; Fo% me)s(%in o%monito%in t*e v)#((m insi"e t*e(n

• Di(sion 0(m0 ; Fo% m)int)ininv)#((m in t*e (n.

• T40i#)&&4' 1-= - 1-@ To%% 0%ess(%e is

m)int)ine" insi"e (n. 7 1 To%% J 1 mm o$ 2 8

• V)#((m is t*e ne#ess)%4 #on"ition

$o% E3M9/15/15


MTE + CA m)%,s.161

E3 G(n T*eo%4



E3 G(n T*eo%4

• S&otte" "is# ; P(%0ose o$ s&otte" "is#is to %est%i#t t*e v)0o%^s inte%)#tionit* e&e#t%on in"o o% o!st%(#tin

t*e in"o o$ e&e#t%ons.• It is s4n#*%oni?e" it* e&e#t%on !e)m

)n" )&&os e&e#t%on !e)m to inte%)#t

t*e o%,0ie#e !(t not t*e o%,0ie#ev)0o%s.


MTE + CA m)%,s.166

P)%ts o$ E3 (n



P)%ts o$ E3 (n• C)t*o"e

• 2i* vo&t)e 0oe% s(00&4

• 3i)s %i" ; 0(&se mo"e o0e%)tion

• Ano"e

• M)neti# &ens• A0e%t(%e

• E&e#t%om)neti# &ens ; $o#(ssin &ens

• Dee#to% #oi&s

• >i*tin s4stem )n" te&es#o0e $o% )&inment

• Rot)tin s&otte" "is#

• V)#((m 0(m0s ; "i(sion 0(m0


MTE + CA m)%,s.16:

Di(sion 0(m0



9/15/15

Re$e%en#e ;- Ve%sion 6' ME' IIT *)%)0(%visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.16=

Me#*)nism o$ M)te%i)&&



%emov)&• T*e%mo - ioni# e&e#t%ons• A##e&e%)tion o$ e&e#t%ons "(e to )no"e

0otenti)&

• 2i* ve&o#it4 !e)m o$ e&e#t%on• S*)0in )n" $o#(sin o$ e&e#t%on !e)m

• Im0inement o$ *i* ve&o#it4 e&e#t%on!e)m on t*e o%,

• S0ot si?e ; 1 1 mi#%on

• 2e)tin' Me&tin )n" V)0o%i?)tion


MTE + CA m)%,s.

165

Cont"



Cont"

• >o#)&i?e" *e)tin !4 $o#(se"e&e#t%on !e)m

• G%)"()& $o%m)tion o$ *o&e !4

0enet%)tion o$ me&t-v)0o%i?)tion $%ont• Penet%)tion ti&& )(i&i)%4 s(00o%t

• E0(&sion o$ )n4 mo&ten m)te%i)& )t

t*e to0 !4 *i* v)0o(% 0%ess(%e o$)(i&i)%4 m)te%i)&


MTE + CA m)%,s.

16@

P%o#ess P)%)mete%s



o#ess ) ) e e s

• T*e )##e&e%)tin vo&t)e 71 ,V8

• T*e !e)m #(%%ent 765 A 1 A8

• P(&se "(%)tion 75 s 5 ms8• Ene%4 0e% 0(&se 7 1 /0(&se8

• Poe% 0e% 0(&se

• >ens #(%%ent

• S0ot si?e 71 m 5 m8

• Poe% "ensit4


MTE + CA m)%,s.

16

Cont"



• Poe% "ensit4 is ) "e%ive" v)%i)!&e*i#* !)si#)&&4 in"i#)tes *o $)st it#)n m)#*ine.

• Poe% "ensit4 "e0en"s (0on .E. )n"s0ot si?e.

• Poe% "ensit4 "e0en"s (0on

)##e&e%)tin vo&t)e' !e)m #(%%ent)n" 0(&se time.

• MRR in E3M is ove%ne" !4 Poe%

"ensit49/15/15


MTE + CA m)%,s.

16

E3M Set-U0



0

9/15/15

Re$e%en#e;- .s&i"es*)%e.netvisit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.

169

P%o!&em no.1



• Fo% #(ttin ) 15 m i"e s&ot in ) 1mm t*i#, t(nsten s*eet' )n e&e#t%on!e)m it* 5 ,< 0oe% is (se".

Dete%mine t*e s0ee" o$ #(ttin.

So&(tion ;- Use MRR )n" Poe%

E0%ession.


MTE + CA m)%,s.

1:

E0%ession o$ e&e#t%on "e0t*



0 0

L J 76.@ Q 1-1 V6 8 / X _*e%e' L J %)ne in mm'

V J )##e&e%)tin vo&t)e in V'

X J "ensit4 o$ m)te%i)& in ,/mm:


MTE + CA m)%,s.

1:1

P%o!&em no. 6



• D(%in "%i&&in o$ *o&es in ) stee&o%,0ie#e !4 E3M' )n )##e&e%)tinvo&t)e o$ 15 ,V is (se". Dete%mine

t*e e&e#t%on %)ne.

• So&(tion ;- Use 0enet%)tion' vo&t)e

)n" "ensit4 %e&)tions*i0.


MTE + CA m)%,s.

1:6

M)te%i)&s A00&i#)tion' >imit)tionset#



et#.

• A&& m)te%i)&s #)n !e m)#*ine".• Ve%4 *i* s0e#i# ene%4

#ons(m0tion' ne#essit4 o$ v)#((m'

e0ensive m)#*ine.• S*)0e A00&i#)tion ;- D%i&&in ne

*o&es' #(ttin #onto(%s in s*eets )n"

#(ttin n)%%o s&ots.


MTE + CA m)%,s.

1::

>)se% 3e)m M)#*inin



• >)se% is ) *i*&4 #o*e%ent !e)m o$e&e#t%o-m)neti# %)"i)tion it*)ve&ent* v)%4in $%om .1- m.

• >)se%s (se" ;- R(!4 &)se% ' CO6 N6

&)se%.

• Me#*)nism ;- Uti&i?in t*e ene%4 o$

#o*e%ent 0*otons o% &)se% !e)m'*i#* is most&4 #onve%te" intot*e%m)& ene%4 (0on inte%)#tion it*

most o$ t*e m)te%i)&s9/15/15


MTE + CA m)%,s.

1:=

>)se% 3e)m M)#*inin ; MEC2ANICS



• Inte%)#tion o$ &)se% !e)m it* o%,

m)te%i)&'

• 2e)t #on"(#tion )n" tem0e%)t(%e

%ise'

• Me&tin' V)0o%i?)tion )n" A!&)tion.9/15/15


MTE + CA m)%,s.

1:5

>3M ; T*e >)sin P%o#ess



• >)sin 0%o#ess "es#%i!es t*e !)si#o0e%)tion o$ &)se%' i.e. ene%)tion o$#o*e%ent 7!ot* tem0o%)& )n" s0)ti)&8

!e)m o$ &i*t !4 `&i*t )m0&i#)tiona(sin `stim(&)te" emissiona.


MTE + CA m)%,s.

1:@

>)sin A#tion ; T*eo%4



4

• T*e%e is ) )s in ) #4&in"%i#)& &)ss vesse&. T*is )s is #)&&e" t*e &)sin me"i(m.

• One en" o$ t*e &)ss is !&o#,e" it* )1[ %ee#tive mi%%o% )n" t*e ot*e% en" is*)vin ) 0)%ti)&&4 %ee#tive mi%%o%.

• Po0(&)tion inve%sion #)n !e #)%%ie" o(t !4e#itin t*e )s )toms o% mo&e#(&es !4

0(m0in it it* )s* &)m0s. T*enstim(&)te" emission o(&" initi)te &)sin)#tion.


MTE + CA m)%,s.

1:

Cont"



• Stim(&)te" emission o$ 0*otons #o(&"!e in )&& "i%e#tions. Most o$ t*estim(&)te" 0*otons' not )&on t*e

&onit("in)& "i%e#tion o(&" !e &ost)n" ene%)te )ste *e)t. T*e0*otons in t*e &onit("in)& "i%e#tiono(&" $o%m #o*e%ent' *i*&4"i%e#tion)&' intense &)se% !e)m.


MTE + CA m)%,s.

1:

So&i" St)te >)se%




MTE + CA m)%,s.

1:9

So&i" St)te >)se% O0e%)tion



• T*e )s* t(!e is o0e%)te" in 0(&se"mo"e !4 #*)%in )n" "is#*)%in o$t*e #)0)#ito%. T*(s t*e 0(&se on time

is "e#i"e" !4 t*e %esist)n#e on t*e)s* t(!e si"e )n" 0(&se o time is"e#i"e" !4 t*e #*)%in %esist)n#e.

T*e%e is )&so ) *i* vo&t)e sit#*ins(00&4 $o% initi)tion o$ 0(&ses.


MTE + CA m)%,s.

1=

A00&i#)tion




MTE + CA m)%,s.

1=1

A00&i#)tion




MTE + CA m)%,s.

1=6

A"v)nt)es



• In &)se% m)#*inin t*e%e is no 0*4si#)& too&. T*(s nom)#*inin $o%#e o% e)% o$ t*e too& t),es 0&)#e.

• >)%e )s0e#t %)tio in &)se% "%i&&in #)n !e )#*ieve")&on it* )##e0t)!&e )##(%)#4 o% "imension' $o%mo% &o#)tion

• Mi#%o-*o&es #)n !e "%i&&e" in "i#(&t to m)#*inem)te%i)&s

• T*o(* &)se% 0%o#essin is ) t*e%m)& 0%o#essin!(t *e)t )e#te" ?one s0e#i)&&4 in 0(&se &)se%0%o#essin is not ve%4 sini#)nt "(e to s*o%te%0(&se "(%)tion.


MTE + CA m)%,s.

1=:

>imit)tions



• 2i* initi)& #)0it)& #ost• 2i* m)inten)n#e #ost

• Not ve%4 e#ient 0%o#ess

• P%esen#e o$ 2e)t Ae#te" one s0e#i)&&4 in )s )ssist CO6 &)se%

#(ttin


MTE + CA m)%,s.

1==

C)stin



• P%im)%4 met*o" o$ 0%o"(#in 0)%ts o%#om0onents.

• It me)ns 0o(%in mo&ten met)& into )%e$%)#to%4 mo(&" it* ) #)vit4 o$ t*e s*)0eto !e m)"e' )n" )&&oin it to so&i"i$4.

• <*en so&i"ie"' met)& o!e#t is t),en o(t$%om mo(&" eit*e% !4 !%e),in o% t),in

t*e mo(&" )0)%t.• T*e so&i"ie" o!e#t is #)&&e" #)stin.


MTE + CA m)%,s.

1=5

C)stin P%o#esses



1. E0en")!&e mo&" 0%o#esses - mo&" iss)#%i#e" to %emove 0)%t – A"v)nt)e; mo%e #om0&e s*)0es 0ossi!&e

– Dis)"v)nt)e; 0%o"(#tion %)tes o$ten &imite"!4 time to m),e mo&" %)t*e% t*)n #)stinitse&$

6. Pe%m)nent mo&" 0%o#esses - mo&" is

m)"e o$ met)& )n" #)n !e (se" tom),e m)n4 #)stins – A"v)nt)e; *i*e% 0%o"(#tion %)tes

– Dis)"v)nt)e; eomet%ies &imite" !4 nee" to9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.

1=@

C)stin Te%ms



9/15/15

Re$e%en#e ;- P. N. R)o' M)n($)#t(%in Te#*no&o4'Vo&(me-1 visit menotes-in.e!no"e.#om $o%

s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.

1=

G)tin "esin



9/15/15

Re$e%en#e ;- P. N. R)o' M)n($)#t(%in Te#*no&o4'Vo&(me-1 visit menotes-in.e!no"e.#om $o%


MTE + CA m)%,s.

1=

G)tin S4stem Desin



• O!e#tive is to && t*e mo(&" in t*esm)&&est time.

• T*e time $o% #om0&ete &&in o$ )

mo(&" te%me" )s 0o(%in time.• St)n")%" met*o"s to #)&#(&)te t*e

0o(%in time $o% "ie%ent #)stin

m)te%i)&s.


MTE + CA m)%,s.

1=9

A"v)n#e" C)stin P%o#esses



• V)#((m Mo(&" C)stin• S(ee?e C)stin

• Ev)0o%)tive P)tte%n C)stin

• Ce%)mi# S*e&& C)stin• Contin(o(s C)stin


MTE + CA m)%,s.

15

V)#((m Mo(&" C)stin



9/15/15

Re$e%en#e;- Mi,e&& P. G%ove%' F(n")ment)&s o$ Mo"e%nM)n($)#t(%in


MTE + CA m)%,s.

151

Ev)0o%)tive P)tte%n C)stin7EPC8



7EPC8

• E0)n"e" Po&4st4%ene C)stinP%o#ess/

• >ost Fo)m C)stin/

• >ost P)tte%n C)stin/• Ev)0o%)tive Fo)m P%o#ess/

• F(&& Mo&" P%o#ess.


MTE + CA m)%,s.

156

Investment C)stin



9/15/15Re$e%en#e;- Mi,e&& P. G%ove%' F(n")ment)&s o$ Mo"e%n

M)n($)#t(%in


MTE + CA m)%,s.

15:

EPC



• T*is is simi&)% to Investment #)stine#e0t $o)m is (se" inste)" o$ ).

• T*is 0%o#ess t),es )"v)nt)e o$ t*e

&o !oi&in 0oint o$ $o)m to sim0&i$4t*e investment #)stin 0%o#ess !4%emovin t*e nee" to me&t t*e )

o(t o$ t*e mo&".


MTE + CA m)%,s.

15=

EPC ;- T*eo%4



• It (ses ) mo&" o$ s)n" 0)#,e" )%o(n") 0o&4st4%ene $o)m 0)tte%n t*)tv)0o%i?es *en t*e mo&ten met)& is

0o(%e" into it.• T*e 0o&4st4%ene $o)m 0)tte%n

#ont)ins s0%(e' %ise%s )n" )tin

s4stem' )n" i$ nee"e" inte%n)& #o%es.• T*e mo&" "oes not *)ve to !e

o0ene" into #o0e )n" "%) se#tions.9/15/15


MTE + CA m)%,s.

155

EPC



9/15/15

Re$e%en#e;- Mi,e&& P. G%ove%' F(n")ment)&s o$ Mo"e%nM)n($)#t(%invisit menotes-in.e!no"e.#om $o%


MTE + CA m)%,s.

15@

Common&4 C)st Met)&s



• C)st I%on• A&(mini(m A&&o4s

• Stee&s

• Ni#,e& A&&o4sSi?e %)ne ;- .5 , to seve%)& tonnes.

Minim(m )&& t*i#,ness ;- 6.5mm 7no (00e%

&imit8 T40i#)& s(%$)#e nis* ;- 6.5 to 65 m 7RMS8

T40i#)& &ine)% to&e%)n#e ;- b.5mm/mm


MTE + CA m)%,s.

15

M)#*inin

• M)#*inin is ) 0%o#ess o$ %)"()& %emov)& o$



• M)#*inin is ) 0%o#ess o$ %)"()& %emov)& o$e#ess m)te%i)& $%om t*e %) 7s*eet/%o"8 in t*e$o%m o$ #*i0s.

• T*e $o%m o$ m)#*ine" #*i0s "e0en" m)in&4 (0on ;-

1. <o%, m)te%i)&

6. M)te%i)& )n" eomet%4 o$ t*e #(ttin too&

:. >eve&s o$ #(ttin ve&o#it4 )n" $ee" )n" )&so to

some etent on "e0t* o$ #(t=. M)#*inin envi%onment o% #(ttin (i" t*)t

)e#ts tem0e%)t(%e )n" $%i#tion )t t*e #*i0-too&)n" o%,-too& inte%$)#es.


MTE + CA m)%,s.

15

Me#*)nism o$ #*i0$o%m)tion



$o%m)tion


MTE + CA m)%,s.

159

Me#*)nism o$ #*i0$o%m)tion



$o%m)tion


MTE + CA m)%,s.

1@

Cont"



• T*e (n#(t &)4e% "e$o%ms into ) #*i0 )$te% itoes t*%o(* ) 0&)sti# "e$o%m)tion in t*e0%im)%4 s*e)% ?one.

• (st )$te% its $o%m)tion' t*e #*i0 os ove%

t*e %),e s(%$)#e o$ too& )n" st%on )"*esion!eteen t*e too& )n" t*e ne&4 $o%me" #*i0s(%$)#e %es(&ts in some sti#,in.

• T*(s' t*e #*i0 m)te%i)& )t t*is s(%$)#e(n"e%oes ) $(%t*e% 0&)sti# "e$o%m)tion'"es0ite o$ sti#,in.


MTE + CA m)%,s.

1@1

Cont"



• Un"e% s(it)!&e #on"itions' t*em)#*inin o0e%)tion is smoot* )n"st)!&e )n" 0%o"(#es #ontin(o(s

%i!!on &i,e #*i0s.• At some *i* s0ee"' t*e tem0e%)t(%e

in#%e)ses )n" t*e ten"en#4 o$ t*e

0&)sti#)&&4 "e$o%me" m)te%i)& to)"*e%e to t*e %),e $)#e in#%e)ses)n" ) &(m0 i$ $o%me" )t t*e #(ttine"e. T*is is #)&&e" ) !(i&t-(0 e"e


MTE + CA m)%,s.

1@6

T40es o$ #*i0s



• Contin(o(s #*i0s it*o(t 3UE;-1. D(#ti&e m)te%i)&

6. Sm)&& (n#(t t*i#,ness

:. 2i* #(ttin s0ee"=. >)%e %),e )n&e

5. S(it)!&e #(ttin (i"


MTE + CA m)%,s.

1@:

T40es o$ #*i0s• Contin(o(s #*i0s it* 3UE;-



1. St%one% )"*esion !eteen #*i0s )n"

too& $)#e

6. >o %),e )n&e

:. >)%e (n#(t t*i#,ness

•. Dis#ontin(o(s #*i0s;-

1. >o #(ttin s0ee"

6. 3%itt&e o%, m)te%i)&:. Sm)&& %),e )n&e

=. >)%e (n#(t t*i#,ness9/15/15


MTE + CA m)%,s.

1@=

M)#*in)!i&it4



• M)#*in)!i&it4 *i#* &oose&4 me)nst*e e)se o$ m)#*inin.

• Fo% ) iven o0e%)tion' t*em)#*in)!i&it4 "e0en"s (0on;-

1. M)#*inin $o%#es )n" 0oe%

#ons(m0tion;- <*en t*e st%ent* o$ t*etoo& is ) m)tte% to o%%4 )!o(t' t*is#%ite%ion is to !e #onsi"e%e".


MTE + CA m)%,s.

1@5

M)#*in)!i&it4



6. Too& &i$e;- T*e &ent* o$ t*e 0e%io"$o% *i#* ) too& #)n !e (se" is"ene" )s too& &i$e. T*is is )&so

&in,e" it* t*e 0%o"(#tivit4 )n"e#onomi#s )n" #)n !e ve%4 oo"in"e $o% )n ove%)&& ("ment o$ )m)#*inin o0e%)tion.

:. S(%$)#e nis*;- B()&it4 o$ nis* #)n!e #on#e%ne" in some sit()tions.


MTE + CA m)%,s.

1@@

Non Di(sion <e&"in



• T*e t*%ee 0%in#i0)& )4s in *i#* non$(sion e&"in is m)"e to o##(% )%e

718 !4 0%ess(%e )n" %oss "e$o%m)tion'

#)&&e" )s pressure welding;(2) !4 $%i#tion )n" mi#%os#o0i#

"e$o%m)tion' #)&&e" friction welding;and

(3) by "i(sion' it*o(t o% it* some"e$o%m)tion' #)&&e" diusion welding


MTE + CA m)%,s.

1@

E0&osive <e&"in



• A t40e o$ non $(sion e&"in.• T*e ,e4 $e)t(%e o$ )&& non $(sion

e&"in 0%o#esses is t*)t welds can

be produced without the needfor melting or fusion.


MTE + CA m)%,s.

1@

P%in#i0&es o$ E0&osive<e&"in



• <e&"in )%%)nement#onsists o$ t*%ee#om0onents -

– 3)se #om0onent – P%ime #om0onent

– E0&osive.

• 3)se #om0onent

%em)ins st)tion)%4's(00o%te" !4 )nvi&.

0%ime#om0onent

3)se#om0onent

E0&osive

Component arrangemenfor explosion welding

Deton)to%


MTE + CA m)%,s.

1@9

P%in#i0&es o$ E0&osive<e&"in



• P%ime #om0onent is0&)#e" eit*e% 0)%)&&e& o%)t )n )n&e to t*e !)se.

•

E0&osive is "ist%i!(te"ove% to0 s(%$)#e o$0%ime #om0onent.

• U0on "eton)tion' 0%ime

#om0onent #o&&i"es

it* !)se #om0onent

to #om0&ete e&"in.Action between componentsduring explosion welding.

Deton)tion

P%ime#om0onent

et

3)se#om0onent

<e&"


MTE + CA m)%,s.

1

ATOMIC 3ONDING




MTE + CA m)%,s.

11

P%o#ess V)%i)!&es )n" Cont%o&s



V)%i)!&es• Co&&ision Ve&o#it4

• Co&&ision An&e

• P%ime Com0onent Ve&o#it4

T*ese )%e Cont%o&&e" 34;

• Com0onent M)ss• E0&osive C*)%e

• Initi)& Geomet%4 - St)n"o Dist)n#e o%An&e

E0&osiveP%ess(%e

2V

4

1P

density plate=

ρ

V J #*)%e ve&o#it4


MTE + CA m)%,s.

16

APP>ICATIONS



• M)o% )%e)s o$ t*e (se o$ t*is met*o" )%e*e)t e#*)ne% t(!e s*eets )n" 0%ess(%evesse&s.

• oinin o$ "issimi&)% met)&s - A&(mini(m to

stee&' Tit)ni(m )&&o4s to C% Ni stee&' C( tost)in&ess stee&' T(nsten to Stee&' et#.

• Att)#*in #oo&in ns .

• oinin o$ 0i0es )n" t(!es.

• Ot*e% )00&i#)tions )%e in #*emi#)& 0%o#essvesse&s' s*i0 !(i&"in in"(st%4 et#.


MTE + CA m)%,s.

1:

ADVANTAGES



• Et%eme&4 &)%e s(%$)#es #)n !e!on"e".

• No ee#t on 0)%ent 0%o0e%ties.• Sm)&& ()ntit4 o$ e0&osive (se".

• C)n !on" m)n4 "issimi&)%' no%m)&&4

non-e&" )!&e met)&s.• Minim(m t(%in/is.


MTE + CA m)%,s.

1=

P&)sm) A%# <e&"in 7PA<8



• P&)sm) me)ns ) )s t*)t *)s !een *e)te"to ) s(#ient&4 *i* tem0e%)t(%e so t*)t itis t%)ns$o%me" into )n ioni?e" #on"ition)n" is )!&e to #on"(#t )n e&e#t%i# #(%%ent.

• P&)sm) )%# e&"in is )n ine%t )s non-#ons(m)!&e e&e#t%o"e e&"in met*o"'(ti&i?in ) t%)ns$e%%e"' #onst%i#te" )%#.

• P&)sm) )%# e&"in 7PA<8 is ) )"v)n#e"ve%sion o$ t*e t(nsten ine%t )s 7TIG8e&"in 0%o#ess


MTE + CA m)%,s.

15




MTE + CA m)%,s.

1@

PA<



• As t*e o%i#e )s 0)sses t*%o(* t*e to%#*to t*e o%, 0ie#e' it is *e)te" !4 t*e )%#'ets ioni?e" )n" 0)sses t*%o(* t*e )%##onst%i#tin no??&e )t )n )##e&e%)te" %)te.

• Sin#e t*is o )&one m)4 not !e )"e()teto 0%ote#t t*e mo&ten 0(""&e $%om)tmos0*e%i# #ont)min)tion' )(i&i)%4s*ie&"in )s is 0%ovi"e" t*%o(* )n o(te%)s #(0 on t*e to%#*.


MTE + CA m)%,s

1

Advantages of lasma!elding



g•

>ess sensitivit4 to #*)nes in A%# &ent*.

• Re#esse" e&e#t%o"e %e"(#es t*e 0ossi!i&it4 o$t(nsten in#&(sions in t*e e&" )n" #)n

s(!st)nti)&&4 in#%e)se t*e 0e%io" !eteene&e#t%o"e "%essins %es(&tin in in#%e)se" &i$e.

• <e&" in ) sin&e 0)ss (0 to @ mm 0&)tes in

s()%e !(tt 0osition )n" 1 mm 0&)tes in on&4to 0)sses.


MTE + CA m)%,s

1

Cont".



• e4*o&e mo"e o$ e&"in ives sm)&&e%*e)t )e#te" ?one %es(&tin in %e"(#e"st%ent* &oss )t t*e oint $o% *e)tt%e)te" met)&s' 0%omotes &ess %)in%ot* *i#* ives !ette% "(#ti&it4.

• Re"(#e" e&" time %es(&ts in &essem!%itt&ement !4 #)%!i"es )n"

#om0&e inte%met)&&i# #om0o(n"s $o%st)in&ess stee& )n" s(0e% )&&o4s.


MTE + CA m)%,s

19

Cont"



• E()&i?)tion o$ "isto%tion st%esses%es(&ts in &ess %esi"()& st%ess.c >ess &&e% met)& %e(i%e" in ,e4*o&e

mo"e sini#)nt&4 %e"(#es 0o%osit4.


MTE + CA m)%,s

1

Ultrasonic "#riction$!elding



• T*e so(%#e o$ motion in $%i#tione&"in #)n !e 0(%e me#*)ni#)&vi!%)tion o% (&t%)soni#)&&4 in"(#e"

vi!%)tion.• <*en (&t%)soni# vi!%)tions )%e

em0&o4e" t*e 0%o#ess is #)&&e" )s(&t%)soni# e&"in.

• Am0&it("e )n" $%e(en#4 is "ie%ent$%om #onvention)& $%i#tion e&"in.


MTE + CA m)%,s

11

Fo(% v)%i)tions o$ US<



• As 0e% A<S;-1. S0ot

6. Rin

:. >ine=. Se)m


MTE + CA m)%,s

16

U&t%)soni# s0ot e&"in s4stem



9/15/15

)8 Gene%)& Di)%)m $o% &)0 oint_ !8 C&ose vie $o% "i%e#tion


MTE + CA m)%,s

1:

P%in#i0&e



• Its ) so&i" st)te e&"in 0%o#ess in*i#* to #om0onents )%e *e&"toet*e% (n"e% #&)m0in $o%#e.

•

Os#i&&)to%4 s*e)% st%esses )%e )00&ie")t inte%$)#e to #)(se #o)&es#en#e.

• Os#i&&)to%4 motion !%e),s "on t*e

s(%$)#e &ms to )&&o intim)te#ont)#t )n" st%on met)&&(%i#)&!on"in !eteen s(%$)#es.


MTE + CA m)%,s

1=

Cont"



• 2e)tin )t inte%$)#es t),es 0&)#e "(eto inte%$)#i)& %(!!in )n" 0&)sti#"e$o%m)tion !(t t*e tem0e%)t(%e %ise

is !e&o t*e me&tin 0oint o$m)te%i)&s.

• No &&e% met)&s' (es' s*ie&"in)ses et#. )%e %e(i%e" in US<.


MTE + CA m)%,s

15

P%o#ess P)%)mete%s



•

U&t%)soni# T%)ns"(#e% ;- Conve%ts t*ee&e#t%i#)& ene%4 into *i* $%e(en#4vi!%)tion)& ene%4.

• T40i#)& F%e(en#4 %)ne;- 15 to 5 ,2?.

• Am0&it("e %)ne ;- .1 to .1: mm.• C&)m0in 0%ess(%e )%e e&& !e&o t*ose (se"

in #o&" e&"in.

• <e&"in time ;- >ess t*)n : se#on"s.

• <o%,0ie#e t*i#,ness ;- T40i#)& #)se &ess t*)n: mm.


MTE + CA m)%,s

1@

A"v)nt)es



• Use" in *e)&t* #)%e in"(st%ies "(e to #&e)n e&"s.

• In#%e)se" ei!i&it4 )n" ve%s)ti&it4.

•

Possi!i&it4 to oin &)%e st%(#t(%es70o&4me%s/0&)sti#s #)se on&48.

• F)st' e#onomi#)& )n" e)si&4 )(tom)te".


MTE + CA m)%,s

1

A00&i#)tions



•

E&e#t%oni# )00&i)n#es &i,e sit#*es' senso%s )n" ")t) sto%)e ,e4s.

• Assem!&4 o$ A&(mini(m s*eet met)& 0)ne&s.

• <e&"in o$ t(!es to s*eets in so&)% 0)ne&s.

• <i%e te%min)tions )n" s0&i#in in e&e#t%i#)&)n" e&e#t%oni#s in"(st%4.

• Me"i#)& 0)%ts &i,e &te%s' #)t*ete%s' me"i#)&

)%ment )n" m)s,s.


MTE + CA m)%,s

1

Di(sion <e&"in 7DF<8



• So&i" st)te e&"in %es(&ts $%om t*e)00&i#)tion o$ *e)t )n" 0%ess(%e.

• Us()&&4 in #ont%o&&e" )tmos0*e%e'

it* s(#ient time )&&oe" $o%"i(sion )n" #o)&es#en#e to o##(%.

• P%im)%4 me#*)nism ;- So&i" st)te

"i(sion' *i#* invo&ves mi%)tion o$)toms )#%oss t*e inte%$)#e !eteen#ont)#tin s(%$)#es.


MTE + CA m)%,s

19

DF<



• Ot*e% n)mes $o% t*is 0%o#ess;-18 Di(sion 3on"in_

68 So&i" St)te 3on"in_

:8 P%ess(%e 3on"in_=8 2ot P%ess 3on"in_

58 2ot P%ess(%e 3on"in_

@8 Fo%e <e&"in.


MTE + CA m)%,s

19

P%in#i0&e ste0s o$ DF<



18 Initi)& As0e%it4 Cont)#t.68 Fi%st St)e De$o%m)tion )n"

Inte%$)#i)& 3o(n")%4 $o%m)tion.

:8 Se#on")%4 st)e %)in !o(n")%4mi%)tion )n" 0o%e e&imin)tion.

=8 T*i%" st)e vo&(me "i(sion )n"

0o%e e&imin)tion.


MTE + CA m)%,s

191

S#*em)ti# o$ :-ste0 me#*)nisti#mo"e& o$ "i(sion e&"in




MTE + CA m)%,s

196

P%o#ess P)%)mete%s



•

Tem0e%)t(%e• Time

• P%ess(%e

Amonst t*e t*%ee' tem0e%)t(%e is mo%e

im0o%t)nt. 7A%%*eni(s Re&)tions*i0 8

D J Do e-B/,T

D J Di(sion #oe#ient )t tem0e%)t(%e T'

, J 3o&t?m)nns Const)nt'

B J A#tiv)tion Ene%4 $o% "i(sion to o##(%.

9/15/15


MTE + CA m)%,s

19:

Cont"



• Time is im0o%t)nt !e#)(se "i(siont),es time to o##(%' sin#e $o% )tomsto (m0 $%om site to site t),es time.

T*(s' t*e "ist)n#e ove% *i#*"i(sion o##(%s "e0en"s on time;-

J C 7Dt8

.5

*e%e J "i(sion "ist)n#e' D JDi(sion Coe#ient' t J time' C J#onst)nt.9/15/15


MTE + CA m)%,s

19=

A"v)nt)es



•

Met)&s )s e&& )s #e%)mi#s #)n !e oine""i%e#t&4 to $o%m ) #om0&ete&4 so&i" st)tee&"

• Dissimi&)% m)te%i)&s eit*e% !4 #&)ss o% t40e'

in#&("in met)&-to-#e%)mi# oints' #)n !e oine" "i%e#t&4 o% it* t*e )i" o$ )#om0)ti!&e &&e% o% inte%me"i)te.

• >)%e )%e)s #)n !e !on"e" o% e&"e"'0%ovi"e" (ni$o%m intim)te #ont)#t #)n !eo!t)ine" )n" s(st)ine".


MTE + CA m)%,s.195

Cont"



• T*e%e i&& !e no *e)t-)e#te" ?one)s s(#*' sin#e t*e enti%e )ssem!&4 in*i#* t*e "i(sion e&" is !einm)"e is vi%t()&&4 )&)4s *e)te" tot*e s)me tem0e%)t(%e.


MTE + CA m)%,s.19@

A00&i#)tions



•

T*e 0%o#ess is e#onomi#)& on&4 *en #&ose"imension)& to&e%)n#es' e0ensive m)te%i)&s' o%s0e#i)& m)te%i)& 0%o0e%ties )%e invo&ve".

• One e#e&&ent e)m0&e' *oeve%' is tit)ni(m $o%

)e%os0)#e )00&i#)tions.• Ot*e% met)&s )n" )&&o4s t*)t #)n !e "i(sion

e&"e" )%e ni#,e& )&&o4s' &o-#)%!on stee&s' )n")&(min(m )&&o4s.

•

Dissimi&)% met)& #om!in)tions' )s e&& )s m)n4#om!in)tions o$ #e%)mi#s o$ simi&)% )n""issimi&)% #om0osition #)n !e "i(sion e&"e".


MTE + CA m)%,s.19

STANDARDIATION



• It is ) 0%o#ess o$ $o%m(&)tin )n")00&4in %(&es $o% o%"e%&4 )00%o)#* to) s0e#i# )#tivit4 $o% t*e !enet )n"it* t*e #oo0e%)tion o$ )&& #on#e%ne"in 0)%ti#(&)%.

• T*is is "one $o% t*e 0%omotion o$ove%)&& e#onom4' t),in "(e )##o(nto$ $(n#tion)& #on"itions )n" s)$et4%e(i%ements.


MTE + CA m)%,s.19

Con#e0t o$Inte%#*)ne)!i&it4



• In m)ss 0%o"(#tion' t*e %e0etitive0%o"(#tion )n" t*ei% #om0onentsenti%e&4 "e0en"s (0oninte%#*)ne)!i&it4.

• <*en one #om0onents )ssem!&es0%o0e%&4 7)n" *i#* s)tises t*e$(n#tion)&it4 )s0e#ts o$ t*e)ssem!&4/0%o"(#t8 it* )n4 m)tin#om0onent' !ot* #*osen )t %)n"om't*en it is ,non )s


MTE + CA m)%,s.199




• In ot*e% o%"s' it is ) #on"ition *i#*eists *en to o% mo%e items0ossess s(#* $(n#tion)& )n" 0*4si#)&#*)%)#te%isti#s so )s to !e e(iv)&entin 0e%$o%m)n#e )n" "(%)!i&it4_ )n")%e #)0)!&e o$ !ein e#*)ne" one$o% t*e ot*e% it*o(t )&te%)tion o$ t*e

items t*emse&ves' o% o$ )"oininitems' e#e0t $o% )"(stment' )n"it*o(t se&e#tion $o% t )n"


MTE + CA m)%,s.6




•

As 0e% ISO-IEC' inte%#*)ne)!i&it4 is t*e)!i&it4 o$ one 0%o"(#t' 0%o#ess o% se%vi#e to!e (se" in 0&)#e o$ ot*e% to $(&&& t*e s)me%e(i%ements.

• T*is #on"ition t*)t eist !eteen "evi#es o%s4stems t*)t e*i!it e(iv)&ent $(n#tion)&it4'inte%$)#e $e)t(%es )n" 0e%$o%m)n#e to )&&oone to !e e#*)ne" $o% )not*e%' it*o(t

)&te%)tion' )n" )#*ieve t*e s)me o0e%)tion)&se%vi#e is #)&&e" inte%#*)ne)!i&it4.


MTE + CA m)%,s.61

E)m0&e



•

I$ e !(4 ) s0)%, 0&( o$ s#oote% $%om t*em)%,et )n" t*en e n" t*)t it ts in t*et*%e)"e" *o&e 0ositione" in t*e #4&in"%i#)&*e)" o$ ) s#oote% )(tom)ti#)&&4. <e (st nee"

to s0e#i$4 t*e si?e o$ t*e s0)%, 0&( to t*es*o0,ee0e%. T*e t*%e)"e" *o&e )n" s0)%,0&( "imensions )%e st)n")%"i?e" )n""esine" to t it* e)#* ot*e%.

St)n")%"i?)tion is ne#ess)%4 $o%inte%#*)ne)!&e 0)%ts )n" its im0o%t)nt $o%e#onomi# %e)sons.


MTE + CA m)%,s.66

E)m0&e o$inte%#*)ne)!i&it4




MTE + CA m)%,s.6:

>imits' Fits' To&e%)n#es )n" ISOSt)n")%"s



• In In"i) e $o&&o In"i)n St)n")%"s.

• T*e 3(%e)( o$ In"i)n St)n")%"s 73IS8

%e#ommen"s ) *o&e-!)sis s4stem)n" t*e (se o$ s*)$t-!)sis s4stem is)&so in#&("e".

•

T*is st)n")%" (ses te%ms $o%"es#%i!in ) s4stem o$ &imits )n" ts.


MTE + CA m)%,s.6=

Te%mino&oies



• S*)$t ; Se%ves $o% s0e#i#)tion o$ )&&o(te% e&ements o$ 0)%t' in#&("int*ose e&ements' *i#* "o not *)ve#4&in"%i#)& s*)0e.

• 2o&e ; Inne% e&ements o$ 0)%t%e)%"&ess o$ s*)0e.

• In )n )ssem!&4' t*e s*)$t is#onsi"e%e" )s t*e m)&e 0)%t )n" *o&e)s $em)&e.


MTE + CA m)%,s.65

Convention)& "i)%)m




MTE + CA m)%,s.6@

Te%mino&oies



• 3)si# si?e ; T*e !)si# si?e o% nomin)&si?e is t*e st)n")%" si?e $o% t*e 0)%t)n" is s)me $o% !ot* *o&e )n" s*)$t.

•

A#t()& si?e ; It is t*e "imension )sme)s(%e" on ) m)n($)#t(%e" 0)%t. Iti&& neve% !e e()& to !)si# si?e )n" itis it*in 0%e"ete%mine" &imits.

• >imits o$ si?e ; M)im(m )n"Minim(m 0e%missi!&e si?e o$ t*e 0)%t.


MTE + CA m)%,s.6

Te%mino&oies



•

M)im(m &imit ; M)im(m si?e 0e%mitte"$o% t*e 0)%t.

• Minim(m &imit ; Minim(m si?e 0e%mitte"$o% t*e 0)%t.

• e%o &ine ; In %)0*i#)& %e0%esent)tion o$&imits )n" ts' ) ?e%o &ine is ) st%)i*t &ineto *i#* t*e "evi)tions )%e %e$e%%e" to.

• It s*os t*e !)si# si?e )n" it is &ine o$?e%o "evi)tion.


MTE + CA m)%,s.6

Te%mino&oies



• Devi)tion ; Die%en#e !eteen )si?e7 )#t()& o% &imit o$ si?e8 )n" !)si#si?e.

•

U00e% "evi)tion ; Die%en#e !eteenm)im(m &imit )n" t*e !)si# si?e.

• >oe% "evi)tion ; Die%en#e !eteent*e minim(m &imit )n" #o%%es0on"in!)si# si?e.

• To&e%)n#e ; Die%en#e !eteenm)im(m &imit )n" minim(m &imit.9/15/15


MTE + CA m)%,s.69

Fits



• T*e %e&)tions*i0 !eteen to 0)%tsto !e )ssem!&e" 7*o&e )n" s*)$t8it* %es0e#t to t*e "ie%en#e in t*ei%si?es is #)&&e" )s t.

• T40es ;-

)8 C&e)%)n#e Fit

!8 T%)nsition Fit#8 Inte%$e%en#e Fit


MTE + CA m)%,s.61

Fits



• C&e)%)n#e t ; It is ) t t*)t )&)4sen)!&es ) #&e)%)n#e !eteen t*e*o&e )n" s*)$t. T*e &oe% si?e o$ *o&eis %e)te% o% e()& to t*e (00e% si?eo$ s*)$t.


MTE + CA m)%,s.611

Fits



• Inte%$e%en#e Fit ; A t *i#* ens(%es) inte%$e%en#e !eteen *o&e )n"s*)$t. T*e (00e% &imit si?e o$ *o&e issm)&&e% o% )t &e)st e()& to t*e &oe%&imit si?e o$ s*)$t.


MTE + CA m)%,s.616

Fits



•

T%)nsition Fit ; It is ) t in *i#* !ot*#&e)%)n#e )n" t%)nsition t m)4o##(% in )n )ssem!&4.


MTE + CA m)%,s.61:

In"i)n St)n")%"s 7ISO8



•

In In"i)n st)n")%"' t*e tot)& %)ne o$si?es (0to :15 mm *)s !een#ove%e" in to 0)%ts.

•

Si?es (0to 5 mm )%e #ove%e" inIS;919 )n" si?es $%om )!ove 5 to:15 mm )%e #ove%e" in IS ;611.

• 2o&es "esin)tion ; A to ' A' 3)n" C.

• S*)$t "esin)tion ; ) to ?' ?) ' ?! )n"

? .9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.61=

In"ivi"()& To&e%)n#e o$ ISOs4stem




MTE + CA m)%,s.615

2o&es )n" S*)$ts"esin)tion

•



•

E)m0&e ; 552_ 55 J 3)si# si?e_ 2 J Position o$ *o&e .%.t ?e%o

&ine_

J To&e%)n#e %)"e i.e. IT.

@m9_ @ J 3)si# si?e o$ s*)$t_

m J 0osition o$ s*)$t .%.t?e%o &ine_

9 J To&e%)n#e %)"e i.e.9/15/15


MTE + CA m)%,s.61@

2o&es )n" S*)$ts"esin)tion

•1/:



•

i J .=57D81/:

.1D *e%e' D J Di)mete%_

A!ove $o%m(&) is (se" $o% IT5 to IT1@.

• Fo% IT1 J .: .D_

• Fo% IT J .5 .16D_

• Fo% IT1 J . .6D.


MTE + CA m)%,s.61

C)stin

•



•

C)stin is ) 0%o#ess in *i#* mo&tenmet)& os !4 %)vit4 o% ot*e% $o%#e into) mo&" *e%e it so&i"ies in t*e s*)0e o$t*e mo&" #)vit4.

• P%in#i0&e o$ #)stin ; me&t t*e met)&' 0o(%it into ) mo&"' )n" &et it #oo& )n" so&i"i$4.

• et t*e%e )%e m)n4 ot*e% $)#to%s t*)t

m(st !e #onsi"e%e" to )##om0&is* )s(##ess$(& #)stin o0e%)tion.


MTE + CA m)%,s.61

Te%mino&oies in #)stin




MTE + CA m)%,s.619

Cont"

•



•

In ) t40i#)& s)n" #)stin mo&"s ; mo&"s#onsists o$ to *)&ves.

• One *)&$ is ,non ) #o0e 7(00e% one8 )n"se#on" *)&$ is ,non )s "%) 7&oe% one8.

• T*e &ine se0)%)tin t*e to *)&ves o$mo&" is #)&&e" )s 0)%tin &ine.

• In s)n" #)stins t*e mo&" #)vit4 is $o%me"

!4 me)ns o$ 0)tte%n' *i#* is m)"e o$oo"' 0&)sti#' met)& et#.


MTE + CA m)%,s.66

Met)& #)stin 0%o#esses

•



•

S)n" C)stin 0%o#esses• Pe%m)nent mo&" #)stin 0%o#esses

3)si# 0e%m)nent mo&" #)stin 0%o#ess

Die #)stin

Cent%i$()& #)stin

• Ot*e% E0en")!&e mo&" #)stin 0%o#esses S*e&& mo&"

V)#((m Mo&"

E0en"e" Po&4st4%ene 0%o#ess Investment #)stin


MTE + CA m)%,s.661

3)si#s o$ s)n" #)stin




MTE + CA m)%,s.666

Investment #)stin




MTE + CA m)%,s.66:

Investment #)stin t*eo%4



18 P%o"(#tion o$ ) 0)tte%ns_68 Att)#*ment o$ seve%)& 0)tte%ns to s0%(e

t%ee to $o%m 0)tte%n t%ee_

:8 Co)tin o$ 0)tte%n t%ee it* %e$%)#to%4m)te%i)&_

=8 F(&& mo&" is #o)te" it* s(#ient%e$%)#to%4 m)te%i)& to m),e it %ii"_

58 2o&"in t*e mo&" in inve%te" 0osition)n" *e)te" to me&t t*e ) )n" 0e%mitit to "%i0 o(t o$ t*e #)vit4


MTE + CA m)%,s.66=

Cont"



@8 Po(%in o$ mo&ten met)& )$te%ens(%in t*)t )&& t*e )#ont)min)nts )%e e&imin)te" $%omt*e #)vit4_

8 Mo&" !%e),in $%om nis*e" 0)%ts)n" )%e se0)%)te" $%om t*e s0%(et%ee.


MTE + CA m)%,s.665

A"v)nt)es

•



•

P)%ts o$ %e)t #om0&eit4 #)n !e#)st_

• C&ose "imension)& #ont%o&

to&e%)n#es o$ b.5mm )%e0ossi!&e_

• Goo" s(%$)#e nis* is 0ossi!&e_

•

<) #)n !e %e(se"_• T*is is net s*)0e 0%o#ess.


MTE + CA m)%,s.66@

A00&i#)tions

•



Com0&e m)#*ine%4 0)%ts'• 3&)"es )n" ot*e% #om0onents $o%

t(%!ine enines'

•

ee&%4 )n" Dent)& t(%es.


MTE + CA m)%,s.66

Pe%m)nent mo&" #)stin0%o#ess




MTE + CA m)%,s.66

Ste0s in 0e%m)nent mo&"#)stin



18 Mo&" is 0%e*e)te" )n" #o)te"_68 Co%es )%e inse%te" i$ ne#ess)%4' )n"

mo&" is #&ose"_

:8 Mo&ten met)& is 0o(%e" into t*emo&"_

=8 Mo&" is o0ene" )n" nis*e" 0)%t is

t),en o(t


MTE + CA m)%,s.669

T*eo%4

• Met)&s #ommon&4 #)st in 0e%m)nent mo&"s )%e



e ) s #o o 4 #)s 0e ) e o "s ) e)&(min(m' m)nesi(m' #o00e%-!)se" )&&o4s)n" #)st i%on.

• Co%es #)n !e (se" to $o%m inte%io% 0)%ts in#)stin/0%o"(#t.

• I$ t*e #o%es )%e im0ossi!&e to t),e o(t' s)n"#o%es #)n !e (se"' in *i#* #)se t*e #)stin0%o#ess is %e$e%%e" )s semi-0e%m)nent mo&"#)stin.

• Mo&"s )%e #ommon&4 m)"e o$ #)st i%on o% stee&.


MTE + CA m)%,s.6:

A"v)nt)es

•



Goo" s(%$)#e nis* )n" #&ose"imension)& #ont%o&'

• Mo%e %)0i" so&i"i#)tion #)(se" !4

t*e met)& mo&" %es(&ts in ne% %)inst%(#t(%e' so st%one% #)stins )%e0%o"(#e"'

• P%o#ess is !est s(ite" to *i* vo&(me0%o"(#tion )n" #)n !e )(tom)te")##o%"in&4'


MTE + CA m)%,s.6:1

A00&i#)tions

•



A(tomotive 0istons'• P(m0 !o"ies'

• C)stins $o% )i%#%)$ts )n" missi&es.


MTE + CA m)%,s.6:6

Die C)stin

•



T40e o$ 0e%m)nent mo&" #)stin.• Mo&ten met)& is ine#te" into t*e

mo&" #)vit4 (n"e% *i* 0%ess(%e.

•

T40i#)& 0%ess(%e %)nes $%om to :5M0).

• Mo&"s in t*is #)stin )%e #)&&e" )s

"ies.• P%ess(%e is m)int)ine" "(%in

so&i"i#)tion )$te% *i#* mo&" iso0ene" )n" t*e 0)%t is %emove".9/15/15


MTE + CA m)%,s.6::

Die C)stin M)#*ines

•



Die #)stin o0e%)tions )%e #)%%ie" o(t in"ie #)stin m)#*ines.

• Mo"e%n "ie #)stin *)s ) $)#i&it4 to #&oset*e to *)&ves o$ mo&" )##(%)te&4 )n"

,ee0 t*em #&ose" ti&& t*e mo&ten met)& is0o(%e" into t*e #)vit4.

• To t40es o$ m)#*ine ; 2ot #*)m!e% )n"Co&" #*)m!e%' "ie%enti)te" !4 *o t*emo&ten met)& is ine#te" into t*e #)vit4.


MTE + CA m)%,s.6:=

2ot C*)m!e% M)#*ine




MTE + CA m)%,s.6:5

Ste0s in 2ot C*)m!e%#)stin



18 <it* "ie #&ose" )n" 0&(ne%it*"%)n' mo&ten met)& os intot*e #*)m!e%_

68 P&(ne% $o%#es t*e met)& in #*)m!e%to o into "ie' m)int)inin0%ess(%e "(%in #oo&in )n"so&i"i#)tion_

:8 P&(ne% is it*"%)n' "ie is o0ene")n" so&i"ie" 0)%t is ee#te".

=8 Finis*e" 0)%t is 0%o"(#e".9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.6:@

T*eo%4

•



T40i#)& 0%ess(%e %)nes $%om to :5MP).

• Most&4 ine#tion s4stem is imme%se"into t*e mo&ten met)&' t*(s its)00&i#)tion is &imite" to &o me&tin0oint met)&s t*)t "o not #*emi#)&&4)tt)#, t*e 0&(ne% ot*e% me#*)ni#)&

#om0onent.• P%o"(#tion %)tes 5 0)%ts 0e% *o(%.

• Met)&s in#&("e ?in#' tin' &e)" )n"9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.6:

Co&" C*)m!e% Die #)stin




MTE + CA m)%,s.6:

T*eo%4 o$ #o&" #*)m!e% "ie#)stin

• Mo&ten met)& is 0o(%e" into )n (n*e)te"



0#*)m!e% $%om )n ete%n)& me&tin #ont)ine%')n" ) 0iston is (se" to ine#t t*e met)& (n"e%*i* 0%ess(%e into t*e "ie #)vit4.

•

Ine#tion 0%ess(%es in t*is #)se ; 1= to 1=MP).

• P%o"(#tion #4#&es )%e &ess t*)n *ot #*)m!e%.

• Neve%t*e&ess' t*is #)stin 0%o#ess is *i*

0%o"(#tion o0e%)tion.


MTE + CA m)%,s.6:9

Cont"

•



M)te%i)&s #ommon&4 #)st !4 t*is0%o#ess )%e )&(mini(m' !%)ss' )n"m)nesi(m )&&o4s.

• Mo&"s )%e m)"e (0 o$ too& stee&'mo&" stee& ' t(nsten )n"mo&4!"en(m.

• >(!%i#)nts m(st )&so !e s0%)4e" to0%event sti#,in.


MTE + CA m)%,s.6=



Cent%i$()& C)stin

•



Cent%i$()& #)stin %e$e%s to #)stinmet*o" in *i#* mo&" is %ot)te" )t*i* s0ee" so t*)t #ent%i$()& $o%#e"ist%i!(tes t*e mo&ten met)& to t*eo(te% %eions o$ t*e "ie #)vit4.

• T40es ;-

)8 T%(e #ent%i$()& #)stin_

!8 Semi #ent%i$()& #)stin_

#8 Cent%i$(e #)stin.9/15/15


MTE + CA m)%,s.6=6

T%(e Cent%i$()& C)stin

•



Mo&ten met)& is 0o(%e" into ) %ot)tinmo&" to 0%o"(#e ) t(!(&)% 0)%t.

• E)m0&es in#&("e ; 0i0es' t(!es'!(s*ins )n" %ins.

• Mo&ten met)& is 0o(%e" into ) *o%i?ont)&%ot)tin mo&" )t one en".

• T*e *i* s0ee" %ot)tion %es(&ts in

#ent%i$()& $o%#es t*)t #)(se t*e met)&to t),e t*e s*)0e o$ t*e mo&" #)vit4.


MTE + CA m)%,s.6=:

T%(e #ent%i$()& #)stin




MTE + CA m)%,s.6==

T%(e #ent%i$()& #)stin

•

i " ! i$ &



C)stins m)"e !4 t%(e #ent%i$()&#)stin )%e #*)%)#te%i?e" !4 *i*"ensit4' es0e#i)&&4 in t*e o(te%%eions o$ t*e 0)%t.

• An4 im0(%ities in t*e #)stin ten" to!e on t*e inne% )&& )n" #)n !e%emove" !4 m)#*inin i$ ne#ess)%4.


MTE + CA m)%,s.6=5

Semi #ent%i$()& #)stin

•

C i$ & $ i " "



Cent%i$()& $o%#e is (se" to 0%o"(#eso&i" #)stins.

• T*e mo&"s )%e "esine" it* %ise%s )tt*e #ente% to s(00&4 $ee" met)&.

• E)m0&es ; *ee&s )n" 0(&&e4s

• E0en")!&e mo&"s )%e o$ten (se" insemi-#ent%i$()& #)stin


MTE + CA m)%,s.6=@

Semi #ent%i$()& #)stin




MTE + CA m)%,s.6=

Cent%i$(e C)stin

•

T* &" i " i " it* t



T*e mo&" is "esine" it* 0)%t#)vities ))4 $%om t*e )is o$%ot)tion' so t*)t mo&ten met)& 0o(%e"into t*e mo&" is "ist%i!(te" to t*ese

#)vities !4 #ent%i$()& $o%#e.

• T*is 0%o#ess is (se" $o% sm)&&e%0)%ts.


MTE + CA m)%,s.6=

Cent%i$(e C)stin




MTE + CA m)%,s.6=9

A"v)nt)es

• C)stins o$ *o&&o 0)%ts nee"s no #o%e_



• So&i" )s e&& )s *o&&o 0)%ts #)n !em)n($)#t(%e" it* e)se_

• No 0)tte%n %e(i%ements in t%(e #ent%i$()&

#)stin_• Dense #)stins )%e 0%o"(#e" !4 t*is

met*o"_

• Mo%e t*)n one #)stin #)n !e m)"e

sim(&t)neo(s&4' !4 *)vin seve%)& mo&"#)vities.


MTE + CA m)%,s.65

CO6 0%o#ess

• T*is 0%o#ess is essenti)&&4 ) s)n" mo&"in* * " i "



0%o#ess *e%e t*e s)n" mi "oes not#ont)in )n4 oi&' %esin o% #&)4 )s t*e !on"in)ents.

• T*is e&imin)tes t*e (se o$ "%ies )n" t*e*e)tin #4#&e.

• Inste)"' t*e s)n" mi #ont)ins 6-@[ o$so"i(m si&i#)te so&(tion.

• T*is s)n" mi *)s ) ve%4 *i* o)!i&it4 to&& (0 #o%ne%s )n" int%i#)te #onto(%s.


MTE + CA m)%,s.651

Cont"

•

T* " i * " " ! i CO6



T*e s)n" is *)%"ene" !4 0)ssin CO6 $o% )!o(t ) min(te.

• T*e CO6 )s $o%ms ) e), )#i" t*)t

*4"%o&4ses t*e so"i(m si&i#)teso&(tion to $o%m )mo%0*o(s si&i#)*i#* )#ts )s t*e !on".

•

So"i(m si&i#)te itse&$ )&so 0%ovi"essome !on"in )#tion.


MTE + CA m)%,s.656

>imit G)(es

•

A &i it i $ ! i t " t !



A &imit )(e is $)!%i#)te" to !e )%eve%se %e0&i#) o$ t*e 0)%t "imension)n" is "esine" to #*e#, t*e"imension )t one o% mo%e o$ its

to&e%)n#e &imits.

• A &imit )(es #onsists o$ to )(esin one 0ie#e;-

)8 GO )(e.

!8 NOT GO )(e.9/15/15


MTE + CA m)%,s.65:

>imit G)(es

•

T* GO i " t * , t*



T*e GO )(e is (se" to #*e#, t*e"imension )t its m)im(m m)te%i)&#on"ition_ t*)t is t*e minim(m si?e$o% )n inte%n)& $e)t(%e )n" it is t*e

m)im(m si?e $o% )n ete%n)&$e)t(%e.

• T*e NOT GO )(e is (se" to #*e#,

t*e "imension )t its minim(mm)te%i)& #on"ition.

• M)te%i)&s (se" to m),e )(es )%e9/15/15visit menotes-in.e!no"e.#om $o%s&i"es' t(to%i)& s*eet' )tten")n#e'

MTE + CA m)%,s.65=

Common >imit G)(es

•

S $ * $t 7 t &



Sn)0 )(e $o% s*)$ts 7ete%n)&"imension8.

• P&( )(e $o% *o&es 7inte%n)&"imension8.


MTE + CA m)%,s.655

SNAP GAUGE

•

T* i t $ C * "



T*e sn)0 )(e #onsists o$ C-s*)0e"$%)me it* )in s(%$)#es &o#)te" int*e )s o$ t*e $%)me.

• It *)s to )(e !(ttons' t*e %st!ein t*e GO )(e' )n" t*e se#on"!ein t*e NOT GO )(e.

• T*is )(e is (se" $o% #*e#,in

o(tsi"e "imensions &i,e "i)mete%'i"t*' t*i#,ness et#.


MTE + CA m)%,s.65@

SNAP GAUGE




MTE + CA m)%,s.65

RING GAUGES

•

Rin )(es )%e (se" to $o% #*e#,in



Rin )(es )%e (se" to $o% #*e#,in#4&in"%i#)& "i)mete%s.

• Fo% ) iven )00&i#)tion' it *)s to0)i% o$ )(es' one Go )n" se#on"NOT GO )(e.

• E)#* )(e is ) %in *ose o0eninis m)#*ine" to one o$ t*e to&e%)n#e

&imits o$ t*e 0)%t "i)mete%.


MTE + CA m)%,s.65

P&( )(e

Advanced Manufacturing Processes (ALL SLIDES Gaurav Arora)

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