Advanced Machining Processes by Hassan Abdel-Gawad El-Hofy

By Hassan Abdel-Gawad El-Hofy

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3 Workpiece impact-hardness. The machining rate is affected by the ratio of the tool hardness to the workpiece hardness. In this regard, the higher the ratio, the lower will be the material removal rate. For this reason soft and tough materials are recommended for USM tools. The machining rate is affected by the tool shape and area. An increase in the tool area decreases the machining rate due to the problem of adequately distributing the abrasive slurry over the entire machining zone. It has been reported by McGeough (1988) that, for the same machining area, a narrow rectangular shape yields a higher machining rate than a square cross-sectional one.

The source of heat required for material removal can be the plasma during electrodischarge machining (EDM) and plasma beam machining (PBM), photons during laser beam machining (LBM), electrons in case of electron beam machining (EBM), or ions for ion beam machining (IBM). For each of these processes, the machining medium is different. 6 Mechanical machining processes. While electrodischarge occurs in a dielectric liquid for EDM, ion and laser beams are achieved in a vacuum during IBM and LBM as shown in Fig.

More attention is, therefore, directed toward machining processes where the mechanical properties of the workpiece material are not imposing any limits on the material removal process. In this regard, the nonconventional machining techniques came into practice as a possible alternative concerning machinability, shape complexity, surface integrity, and miniaturization requirements. Innovative machining techniques or modifications to the existing method by combining different machining processes were needed.

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