Nontraditional Manufacturing - Principles

USM

High-frequency, low-amplitude tool vibration (perpendicular to surface) drives abrasive particles in a slurry against the workpiece. Abrasives do the actual material removal — the tool shape is transferred into the part.

WJC

High-pressure, high-velocity stream of water directed at work surface. The kinetic energy of water erodes the material. No heat generated.

AWJC

WJC with abrasive particles (aluminum oxide, silicon dioxide, or garnet) added to the jet stream. Abrasives greatly increase cutting power, enabling metal cutting.

AJM

High-velocity stream of GAS (not water) carrying small abrasive particles is directed at the work surface. The gas stream causes abrasive impact and erosion

ECM

Reverse of electroplating. Work (anode, +) is dissolved by anodic dissolution in an electrolyte bath while tool (cathode, −) maintains a close gap. Electrolyte flows rapidly to carry away dissolved material.

ECD

Adaptation of ECM used specifically to remove burrs and sharp corners left on holes after conventional drilling. Same anodic dissolution principle.

ECG

Combines electrochemical dissolution with abrasive grinding. Most material removal (~90%) by electrochemical action; abrasives (~10%) clean the surface and remove remaining oxide layer.

EDM

Series of rapid electrical sparks across a small gap between electrode (tool) and conductive workpiece in a dielectric fluid. Sparks cause localized melting and vaporization. Dielectric flushes away material. Tool shape transfers to workpiece.

Wire EDM

Special form of EDM where a thin continuously-fed wire (0.076–0.30 mm diameter) acts as electrode to cut narrow kerfs. Wire is constantly advanced from supply spool to take-up spool to maintain constant diameter.

EBM

High-velocity electrons (~75% speed of light) focused to a tiny spot (down to 0.025 mm) via electromagnetic lens. Kinetic energy converts to extreme thermal energy on impact → melting and vaporization.

LBM

Light energy from a laser focused to a small spot. High power density causes material removal by vaporization and ablation. LASER = Light Amplification by Stimulated Emission of Radiation.

PAC

Gas (air, N₂, argon, or O₂) ionized by high-voltage arc between electrode and workpiece → plasma. Plasma constricted through nozzle to form very high temperature, high velocity jet (10,000–14,000°C). Material is melted and blown away.

OFC

Preheat flame raises steel to ignition temperature, then a high-pressure oxygen jet creates an exothermic oxidation reaction that burns through the metal. Primary removal mechanism is CHEMICAL (oxidation), not just heat.

CHM

Chemical etchants selectively dissolve material from unprotected surfaces. A maskant protects areas that should not be removed. The exposed areas are chemically etched.