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Material Removal Processes:
Nonconventional Processes

Ultrasonic Machining

In this method the workpiece does not come into contact with the machining tool as they are separated by a liquid in which abrasive grains are suspended and which is given the desired suspension by mixing equal volumes of water and fine grains of boron oxide together. The mixture is driven at high velocity against the workpiece by a tool that vibrates at low amplitudes and high frequencies. The tool is slowly fed into the piece so the shape of the tool is formed in the part due to the oscillation of the tool.

Abrasive-Jet Machining

In this method liquids with abrasive particles suspended in them are forced out of a nozzle under very high pressure which results in a jet stream that is used in deburring, drilling, the cutting of thin sheets and sections and similar processes.

Chemical Machining

In chemical machining, after the surfaces which are not to be machined are covered with neoprene rubber or enamel, the piece is dipped in a chemical etch that reacts with the unprotected metal and dissolves the chemical compound that results. Very fine details can be attained from this method, as well as high quality, chip-free surfaces.

Electrochemical Machining

Electrochemical machining uses anodic dissolution to remove material from the workpiece. The tool, a copper ring that is connected to a cathode and is separated from the part by a small gap through which an electrolyte rapidly flows, determines the shape of the piece. Low-voltage, high-amperage direct current is used. The amperage plays an important part in deciding the rate of metal removal during the electrochemical machining process.

Electrodischarge Machining

Electrodischarge machining removes metal through an electric arc between the electrode, which forms the shape of the finished piece, and the workpiece. The two are kept apart with a dielectric liquid which is pumped through the area between them. This liquid also serves as a coolant and removes the metallic dust that has been taken from the surface of the workpiece. Sparks, generated by a pulsating direct-current power supply that is connected to the work and the tool, occur across the gap between the electrode and the workpiece, which ionizes the fluid.

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