Chapter Three - Machining processes utilizing mechanical energy

Abstract

Detail discussion on various advanced machining processes utilizing mechanical energy namely, Ultrasonic machining (USM), Abrasive jet machining (AJM), Water jet machining (WJM), and Ion beam machining (IBM) have been included. The fundamentals, material removal mechanism and related modeling, setup details, effects of process parameters on different outcomes, advantages and limitations of these processes have been presented in this chapter. The stationary ultrasonic machining (USM) as well as rotary ultrasonic machining (RUM) processes are applied for machining of hard and brittle materials like glass and ceramics with high accuracy those are highlighted. Rotary ultrasonic machining (RUM) is the recent development in USM which has higher machining rate and accuracy as rotary and ultrasonically vibratory abrasive bonded tool is used for machining. The abrasive jet machining (AJM) is applied for drilling, cutting, grooving and finishing operations on difficult to machine materials like glass and ceramics. In depth discussions on abrasive jet machining process have also been included. Water Jet Machining (WJM) process has been discussed in details which is utilized for cutting and drilling operation of various hazardous materials such as coal, rocks, asbestos, bones etc. for different field of applications such as mining, construction, mechanical and biomedical engineering. Ion beam machining (IBM) is one of the most advanced machining processes which utilize focused beam of ions to bombard and eject atoms from the workpiece surface by elastic collisions to crate desired shapes. IBM becomes attractive for fabrication of intricate structures especially in micro and nano range with high resolution. Recent advancements considering the latest research findings of all the advanced machining processes have also been highlighted.