Knowledge of Science

Introduction:-       Electrochemical Machining (ECM) is based upon Faraday's law of electrolysis. Faraday's law states that the the mass of a metal altered by the electrode is proportional to the quantity of electrical charges transferred to that electrode . In ECM the removal of metal is controlled by the anodic dissolution in the electrolyte.  In ECM -  The workpiece acts as the anode The tool act as cathode. The electrodes should be placed closely with a gap of about 0.5 mm . The anodes and cathodes should be immersed into electrolyte. (Here Sodium Chloride). Working Principle of Electrochemical Machining:- The main principles of ECM are as follows -  • A potential difference is maintained between the electrodes as a result ions existing in the electrolytes migrate towards the electrodes.  • Conventionally positively charged ions are attracted towards the cathode and negative ions are attached towards to the anode. ...

Introduction:-   It is the process of impinging the high speed stream of abrasive particles by high pressure gas or air on the work surface through a nozzle and metal removal occurrs due to erosion caused by high speed abrasive particles.       In this Machining,the abrasive particle size is 10-40 micros.      Jet velocity will be 150 to 300 m|sec. And it is used to superalloys. Parts of Abrasive Jet Machine:- 1.  Gas supply 2. Filter 3. Pressure gauge 4. Regulator 5. Mixing chamber 6 . Nozzle Working Principle of Abrasive Jet Machine:- The figure shown is the above Abrasive jet Machining. It consists of a mixing chamber, gas filter, pressure gauge, regulator, and the nozzle. The filtered gas at a pressure of 2 to 8 kgf/cm2 is supplied to the mixing chamber containing the abrasive powder and vibrating at 50 Hz, where it mixes with abrasive particles and then enters into the connecting hose. The abrasive and gas mixture c...

Introduction:- The boring Machine is one of the vertalilc Machine toll used to enlarge already drilled hole.    Boring operation can be performed on lathe as that of turning where tool is stationary and workpiece is rotating,in case of boring is rotating and workpiece is stationary. Types of boring Machine:- 1 . Horizontal Boring Machine (HBM)      fig 1 2 . Vertical Boring Machine (VBM)          fig 2 3. Precision (jig) Boring Machine(PBM) fig 3 Parts of Boring Machine:- 1.  Head stock 2. Column 3.  Runway 4. End support 5. Table 6. Saddle  Application of Boring Machine:- 1. Horizontal Boring Machine can be used to drill,bore,rim holes 2 . Batch production where workpiece is less 3 .  Machining types parts like gear boxes and engine block 4. For flat surface   5. Forming  Operation 6. Turning cylindrical surface 7. Boring by tool head 8.  Boring by boring bar 9....

Introduction:- Electric discharge Machine is the process of metal removal from the work surface due to an erosion of metal caused by electric Spark discharge between the two electrode tool and the work piece. Electrical Discharge Machining is also called or known as Spark machining, spark eroding, burning, die sinking, wire burning or wire erosion. This spark near to 8000 to 12000º C. Parts of Electrical Discharge Machine :- • DC Power supply   •Voltmeter •Ammeter •Tool •Die-electric fluid •Pump •Filter •Servo- controlled feed •Fixture •Table Working of Electrical Discharge Machine :- It consists of an electric power supply, the dielectric medium, the tool, workpiece, and servo control. The workpiece is connected to the positive terminal and the tool is connected to a negative terminal of the DC power supply. An air gap of 0.005 to 0.05 mm is maintained between the tool and the work. The die electric fluid which is non-conductor of electricity is...

Introduction:- This is used to remove materials from the workpiece.In this process a high velocity jet of high temperature gas is used to melt and remove material from the workpiece. This velocity of hot gas is also known as plasma jet. The temperature range is plasma zone is 11000 degree to 28000 degree centrigate. Parts of Plasma Arc Machine:- •Plasma Gun •Power supply •Cooling Mechanism •Workpiece •Tooling Construction of Plasma Arc Machine:- The schematic arrangement of plasma arc machining is shown in Fig. • The plasma arc cutting torch carries a tungsten electrode fitted in a small chamber. • This electrode is connected to the negative terminal of a DC power supply. So it acts as a cathode. • The positive terminal of a D.C power supply is connected to the nozzle formed near the bottom of the chamber. So, nozzle acts as an anode. • A small passage is provided on one side of the torch for supplying gas into the chamber. • Since there is a water circulation a...

Introduction:- A laser beam machining is a non-conventional machining method in which the operation is performed by laser light. The laser light has maximum temperature strikes on the workpiece, due to high temp the workpiece gets melts. The process used thermal energy to remove material from a metallic surface. Parts of Laser beam Machine:- •Power supply •Flash lamp •Capacitor •Reflecting mirror •Lense •Workpiece Application of Laser beam Machine:- •The laser beam machining process is used for making very small holes. •Mass macro machining production. •LBM is used in surgery. •Selective heat treating of materials. •Complicated welding of non-conductive and refractory materials. •Micro-drilling operation. •Photography in medical science. •Spectroscopic Science. Advantage of Laser beam Machine:- •Any material can be machined including non-metal. •The production rate is high. •There is no direct contact between the tool and the work. •There is no tool wear. •No me...

Introduction:- It is a subtractive manufacturing process that removes material from the surface of a part through high frequency,low amplitude vibration of a tool against the material surface in the presence of fine abrasive particles.   Parts of Ultrasonic Machine:- Power Supply Electro-mechanical transducer Velocity Transformer Tool Abrasive Slurry Abrasive gun Workpiece Types of ultrasonic machining:- • Roatary Ultrasonic Vibration Machine • Chemical assisted Ultrasonic machine Application of Ultrasonic Machine:- This process is used for drilling both circular and non-circular holes in very hard materials like carbide, ceramics, etc. This process is best suited for brittle materials. The machining operation is simple and requires less time. This process is economical. Glass, Ceramic, tungsten land semi-precious stones can be machined. A semi-skilled operator can operate the machine. Better efficiency can be achieved. Good surface finish. It is suitable fo...

Introduction:- Drilling is basically a single purpose machine tool as its main purpose is to make holes in the workpiece by using of a rotating tool called drill bit or the twist drill. The material is removed from the workpiece by the shearing and extrusion process. Parts of Drilling Machine:- •Bed •Steeped pulley •Pillar •Spindle •Swivel table •Chuck •Motor •Drill bit •Hand wheel Types of Drilling Machine:- •Portable drilling •Sensitive drilling •Upright or column drilling •Radical drilling •Gang drilling •Multi spindle drilling •Vertical Turret type drilling •Automatic drilling •Deep hole drilling •Turret hole drilling Specifications of Drilling Machine:- •Portable drilling machine is specified by the maximum diameter of the drill which can be held. •Sensitive and the upright drilling machine are specified by the diameter of the largest workpiece that can be held. •The radical drill machine is specified by the length of the arm and Column diameter. •Multiple ...

Introduction:- Planer Machine is a machine in which unwanted material is cut from the workpiece to produce a flat surface on a work piece. unlike shpaer machine,more then one tool can be set and perform the operation. Parts of Planer Machine:-  •Bed •Column or housing •Table •Cross rail  •Tool head •Driving •Feed mechanism Types of Planer Machine:- •Double housing Planer •Pit Planer •Open side •Edge Planer •Divided Table Planer  Operation of Planer Machine:- Planing Flat horizontal surfaces Planing Flat vertical surfaces Planing angular surfaces and machining dovetails Planing curved surfaces Planing slots and grooves Application of Planer Machine:- •Used for flat surface •Cutting angular surface •Cutting slots and groove Advantage of Planer Machine:- •Great accuracy •Good surface finish •Low maintenance •More then one tool is performed Disadvantage of Planer Machine:- •Machine cost is high •Power consumed is high •Skilled workers required •Only to...

Introduction:- it is a reciprocating type of Machine basically used for producing the horizontal, vertical,flat surface.The shaper holds the single point cutting tool in ram and workpiece is fixed in the table, during the return stock of metal cutting. parts of shper Machine:- •Base  •Column •Table •Cross rail •Ram •Clapper Box •Elevating screw Types of shaper machine:- •Standard shaper •Vertical shpaer •Horizontal shaper •Geared shaper •Universal shaper •Crank shaper •Draw cut shaper •Hydrolic shaper •Counter shaper  Operation of shpaer machine:- •Vertical cutting operation •Horizontal cutting operation •Inclined cutting operation •Angular cutting operation •Irregular cutting operation Application of shaper machine:- •Internal spllines •Gear teeth •Keyway in pully •Contour of concave or convex  Advantage of shaper machine:- •Tool cost is low. •Workpiece hold easily. •Produces falt and angular surface. •Setup of shaper is very easy and tool •change...

Introduction:- Milling is a process performed with a machine in which the cutters rotate to remove the material from the work piece present in the direction of the angle with the tool axis.With the help of milling Machine one can perform many operation and functions starting from the small objects to large one . Parts of Milling Machine:- •Base •Column •Knee •Saddle •Table •Over-arm •Spindle or arobor •Aboror supporter •Ram •Milling head Types of Milling Machine:- • Horizontal or Plain Milling Machine •Vertical Milling Machine •Universal Milling Machine •Simplex Milling Machine •Duplex Milling Machine •Triplex Milling Machine •Rotary Table Milling Machine •Tracer Controlled Milling Machine •CNC Milling Machine •Drum Milling Machine Operation of Milling Machine:- •Plain Milling or Slab milling •Up and down milling  •Face milling •End milling •Gang milling •Straddle milling •Groove milling •Gear milling •Side milling •T-slot milling Application of milling mach...