nontraditional manufacturing - key parameters

USM

• Tool vibration frequency (high)

• Tool vibration amplitude (low)

• Abrasive grit size and type

• Feed rate of tool into work

WJC

• Water pressure (very high)

• Nozzle diameter

• Traverse speed

• Standoff distance

AWJC

• Water pressure

• Abrasive type (Al₂O₃, SiO₂, garnet)

• Abrasive grit size

• Abrasive flow rate

• Traverse speed

AJC

• Gas pressure

• Gas type (air, CO₂, nitrogen)

• Abrasive type and particle size

• Nozzle standoff distance

ECM

• Current (higher current → higher MRR per Faraday's Law)

• Electrolyte flow rate and composition

• Gap size between tool and work

• Feed rate

ECD

• Current

• Electrolyte flow

ECG

• Current

• Wheel speed

• Abrasive grit

EDM

• Discharge current

• Pulse on-time (↑ on-time → ↑ MRR, ↑ roughness, ↑ HAZ)

• Pulse off-time (too short → instability)

• Polarity

• Dielectric fluid type

Wire EDM

• Wire diameter (determines kerf width)

• Wire material (brass, copper, tungsten, molybdenum)

• Feed speed

• Dielectric method (nozzles or submersion)

EBM

• Beam current

• Accelerating voltage

• Beam focus (spot size)

• Pulse duration

• Work-to-gun distance

LBM

• Laser power

• Pulse duration

• Spot size / focus

• Wavelength (material dependent)

• Traverse speed

PAC

• Arc current

• Gas type

• Nozzle size (controls constriction)

• Cutting speed

• Standoff distance

OFC

• Fuel gas type (acetylene has highest flame temp)

• Oxygen purity and pressure

• Cutting speed

• Preheat flame size

CHM

• Etchant type and concentration

• Temperature

• Immersion time

• Maskant type