1. What tool materials are often used in Ultrasonic Machining? 2. What are the i
ID: 2996502 • Letter: 1
Question
1. What tool materials are often used in Ultrasonic Machining? 2. What are the important factors in choosing tool materials for Ultrasonic Machining? 3. What are the limitations of the Ultrasonic Machining process? 4. What are the advantages of water-jet cutting? 5. What are the typical work materials used in water-jet cutting? 6. In comparison to Pure Water-Jet Cutting, defined earlier, what are the advantages/disadvantages of the Abrasive Water-Jet Cutting? Name a few. 7. In Abrasive Water-Jet Cutting, what keeps the abrasive jet from machining the orifice (nozzle tip)? 8. What types of materials are machined with the Abrasive Jet Machining process? 9. What is the nature of the surface obtained by EDM? 10. What effect would increasing the voltage have on the metal removal rate in EDM?Explanation / Answer
1) Best suited material so far is Medium Togh steel which offers best compromise between cutting rate and tool wear
2) Material used for Ultrasonic machining Tool must be ductile and strong as it has to hit abrasive slurry as many times as the workpiece has to, so it must be hard enough yet ductile enough to sustain high frequency vibrations
3)Low material removal rate, tool is very prone to wear, power consumption is high, difficult design of the tool, depth of cut is bound by restricted slurry movement
4)No starting hole is required, enviromentally clean and effecient, no heat produced, minimal burr produced, cut finish is very appreciable, surface finish is good, any contour canbe cut
5)equipments used in water jet cutting are namely fluid pump, accumulator, sapphire nozzle, valves and pipes
6)advantages of AJM are low noise level, pumping of gas is easier than water, range of water jet ejecting from nozzle is very low compared to abrasive jets
disadvantages of AJM are embedding of abrasive in workpiece, possibility of stray action, abrasive powder can not be reused
7) the nozzle material is kept hard than the abrasive, generally nozzles are made of tungsten carbide and saffire.
8)hard and brittle metals, alloys, non-metallic materials (eg silicon , glass)
9)as EDM removes material from successive spark generation the surface has many ups and downs at micro level
10)material removal rate will increase as small amount of time will be given on vapourizing of conductive bridge
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