Table Of ContentNon-Traditional and
Advanced Machining
Technologies
Non-Traditional and
Advanced Machining
Technologies
Second Edition
Helmi Youssef and Hassan El-Hofy
.
by CRC Press
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Library of Congress Cataloging-in-Publication Data
Names: Youseff, Helmi, author. | El-Hofy, Hassan, author.
Title: Non-traditional and advanced machining technologies : machine tools
and operations / Helmi Youseff and Hassan El-Hofy.
Description: Second edition. | Boca Raton, FL : CRC Press, [2020] |
Includes bibliographical references and index.
Identifers: LCCN 2020011453 (print) | LCCN 2020011454 (ebook) | ISBN
9780367431341 (hardback) | ISBN 9781003055310 (ebook)
Subjects: LCSH: Machining. | Machining--Equipment and supplies.
Classifcation: LCC TJ1185 .Y683 2020 (print) | LCC TJ1185 (ebook) | DDC
671.3/5--dc23
LC record available at https://lccn.loc.gov/2020011453
LC ebook record available at https://lccn.loc.gov/2020011454
ISBN: 978-0-367-43134-1 (hbk)
ISBN: 978-1-003-05531-0 (ebk)
Typeset in Times
by Deanta Global Publishing Services, Chennai, India
Dedication
To our grandsons and granddaughters,
Helmi Youssef: Youssef, Nour, Anourine, Fayrouz, and Yousra
Hassan El-Hofy: Omar, Zainah, Youssef,
Hassan, Hana, Ali, and Hala
Contents
Contents
Preface......................................................................................................................xv
Acknowledgements ................................................................................................xvii
Author Biographies .................................................................................................xix
List of Symbols .......................................................................................................xxi
List of Acronyms ................................................................................................. xxiii
UNIT I N on-Traditional Machining Operations
and Non-Traditional Machine Tools
Chapter 1 Non-Traditional Machining Processes .................................................3
1.1 Introduction ..............................................................................3
1.2 Classifcation of Non-Traditional Machining Processes ...........4
1.3 Review Questions ......................................................................5
References ............................................................................................6
Chapter 2 Mechanical Non-Traditional Machining Operations and
Machine Tools ......................................................................................7
2.1 Jet Machines and Operations .....................................................7
2.1.1 Abrasive Jet Machining ................................................7
2.1.1.1 Process Characteristics and Applications ...... 7
2.1.1.2 Work Station of Abrasive Jet Machining ....... 9
2.1.1.3 Process Capabilities ....................................10
2.1.2 Water Jet Machining (Hydrodynamic Machining) .....11
2.1.2.1 Process Characteristics and Applications .....11
2.1.2.2 Equipment of WJM ..................................... 14
2.1.2.3 Process Capabilities .................................... 17
2.1.3 Abrasive Water Jet Machining .................................. 17
2.1.3.1 Process Characteristics and Applications ......17
2.1.3.2 AWJM Equipment ..................................... 21
2.1.3.3 Process Capabilities ...................................26
2.2 Ultrasonic Machining .............................................................28
2.2.1 Defnition, Characteristics, and Applications ............28
2.2.2 USM Equipment ........................................................ 31
2.2.3 Design of Acoustic Horns .........................................36
2.2.4 Process Capabilities ...................................................50
2.2.5 Recent Developments ................................................. 53
2.3 Abrasive Flow Machining ......................................................54
2.3.1 Principles ...................................................................54
vii
viii Contents
2.3.2 Process Parameters of Abrasive Flow Machining ..... 55
2.3.3 Applications of AFM .................................................60
2.4 Review Questions and Problems ............................................60
References .......................................................................................... 61
Chapter 3 Chemical and Electrochemical Non-Traditional Machining
Operations and Machine Tools ...........................................................63
3.1 Chemical Machining ...............................................................63
3.1.1 Chemical Milling ......................................................63
3.1.2 Photochemical Machining (Spray Etching) ...............70
3.2 Electrochemical Machines and Operations ............................. 74
3.2.1 Process Characteristics and Applications ................. 74
3.2.2 Elements of ECM .......................................................77
3.2.3 ECM Equipment (EC Sinking Machine) ...................80
3.2.4 Process Capabilities ...................................................82
3.2.5 ECM Allied Processes ..............................................82
3.2.5.1 Shaped Tube Electrolytic Machining .........82
3.2.5.2 Electrostream (Capillary) Drilling .............85
3.2.5.3 Electrochemical Jet Drilling .......................87
3.2.5.4 Electrochemical Deburring ........................87
3.2.5.5 Electrochemical Polishing ..........................90
3.2.5.6 Electrochemical Sharpening ....................... 91
3.2.5.7 Electrochemical Grinding .........................92
3.2.5.8 Electrochemical Honing .............................94
3.3 Review Questions and Problems .............................................95
References ..........................................................................................97
Chapter 4 Thermo-Electrical Non-Traditional Machining Operations and
Machine Tools ....................................................................................99
4.1 Electrical Discharge Machines and Operations .....................99
4.1.1 Process Characteristics and Applications .................99
4.1.2 Sinking Machine ...................................................... 102
4.1.3 EDM-Spark Circuits (Power Supply Circuits) ......... 105
4.1.3.1 Resistance-Capacitance RC Circuit ......... 105
4.1.3.2 Transistorized Pulse Generator
Circuits ...................................................... 108
4.1.4 EDM Tool Electrodes .............................................. 109
4.1.5 Process Capabilities ................................................ 110
4.1.6 EDM Allied Processes ............................................. 112
4.1.6.1 Electrical Discharge Milling
(ED Milling) ............................................ 112
4.1.6.2 Electrical Discharge Wire Cutting .......... 115
4.2 Electron Beam Machining Equipment and Operations ....... 116
4.2.1 Process Characteristics and Applications ............... 116
Contents ix
4.2.2 Electron Beam Machining Equipment .................... 118
4.2.3 Process Capabilities ................................................120
4.3 Laser Beam Machining Equipment and Operations ............ 123
4.3.1 Process Characteristics ............................................ 123
4.3.2 Types of Lasers ........................................................ 125
4.3.2.1 Pyrolithic and Photolithic Lasers ............ 125
4.3.2.2 Industrial Lasers ...................................... 125
4.3.3 Laser Beam Machining Operations ........................ 127
4.3.4 LBM Equipment ....................................................... 131
4.3.5 Applications and Capabilities ................................... 132
4.4 Plasma Arc Cutting Systems and Operations ........................ 135
4.4.1 Process Characteristics............................................. 135
4.4.2 Plasma Arc Cutting Systems ....................................136
4.4.3 Applications and Capabilities of PAC ......................137
4.5 Review Questions and Problems ........................................... 139
References ........................................................................................ 143
UNIT II Advanced Machining Technology
Chapter 5 Machining of DTC Materials (Stainless Steels and Super
Alloys) by Traditional and Non-Traditional Methods ...................... 147
5.1 Introduction ........................................................................... 147
5.2 Traditional Machining of Stainless Steels ............................. 147
5.2.1 Types, Characteristics, and Applications of SSs ...... 147
5.2.2 Machinability and Machinability Ratings of SSs .......152
5.2.2.1 Free-Machining Additives of Stainless
Steels ......................................................... 152
5.2.2.2 Machinability of Free- and
Non-Free-Machining Stainless Steels ...... 153
5.2.2.3 Enhanced Machining Stainless Steels ...... 155
5.2.2.4 Machinability Ratings of Stainless Steels ......155
5.2.3 Machining and Machining Conditions of SSs ........ 156
5.3 Traditional Machining of Super Alloys ................................. 166
5.3.1 Types, Characteristics, and Applications of SAs ..... 166
5.3.2 Machinability and Machinability Rating of
Super Alloys ............................................................ 173
5.3.2.1 Machinability Aspects of Super Alloys ......173
5.3.2.2 Machinability Rating of Super Alloys ........174
5.3.3 Machining and Machining Conditions of Super
Alloys ....................................................................... 178
5.4 Non-Traditional Machining of Stainless Steels and Super
Alloys ..................................................................................... 191
5.4.1 Machining of Stainless Steels and Super Alloys
by Mechanical Techniques ...................................... 192
