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Man Pro > Study Guide Q: Ultrasonic (Hydrodynamic) > Flashcards

Study Guide Q: Ultrasonic (Hydrodynamic) Flashcards

1
Q

What does NON TRADITIONAL MACHINING refer to?

A

Refers to cutting methods that are unusual, uncommon or
specialized – generally anything apart from cutting with blades or bonded abrasives

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2
Q

What are 2 abrasive cutting techniques that are considered NON - TRADITIONAL?

A

ULTRASONIC MACHINING & ABRASIVE JET MACHINING

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3
Q

What is the process of ULTRASONIC MACHINING?

A

A tool is used which doesn’t come in contact with the work piece, but just vibrates up and down at high frequencies using slurry (a mixture of water and grit)

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4
Q

In ULTRASONIC MACHINING what types of tough materials can it be made of?

A

Copper, Brass or Aluminum which absorb impacts without fracturing

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5
Q

In ULTRASONIC MACHINING how can cutting debris be seperated?

A

Usually separated out via magnets, filters or centrifuge, depending on the nature of the workpiece

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6
Q

Describe the process of ABRASIVE JET MACHINING

A

Grit is introduced into a stream of compressed air (or CO2 or N2), and then forced through a nozzle. The result is a highly concentrated tight (0.005” minimum width) beam of grit at 150-300 m/s.

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7
Q

What can the nozzles be made of in ABRASIVE JET MACHINING?

A

Tungsten Carbide or Sapphire

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8
Q

What technique is used in CHEMICAL MACHINING?

A

“Etching”, which is the removal of material through chemical reaction.

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9
Q

What are the partical chemical reagent or “Echant” required for steels and stainless steels?

A

Steels: sodium hydroxide for aluminum, hydrochloric and nitric acids
Stainless Steels: iron chloride

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10
Q

What is the material called that is used to selectively protect the workpiece parts from the “Etchant”?

A

MASK or MASKANT

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11
Q

In craeting somethign like a cricuit board what is the specific type of MASK or MASKANT used?

A

Photosensative Maskant or PHOTORESIST

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12
Q

What is the specific type of CHEMCIAL MACHINING that uses PHOTORESIST?

A

PHOTOCHEMICAL MACHINING

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13
Q

Describe the process of PHOTOCHEMICAL MACHINING

A

Step 1: Start with GRP Board & Print Phototool from CAD
Step 2: Put Board nd Phototool together
Step 3: Develop (like an old photo using UVLight)
Step 4: Put into chemical bath and Etch
Step 5: Proceed as CHEMICAL MACHINING

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14
Q

Since maskant is inevitably undercut bet the etchant it can be used only to make reallly shallow indentations/holes, so what are the two ways it can be done?

A

CHEMICAL MILLING & CHEMICAL BLANKING

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15
Q

What is a related process to CHEMICAL MACHINING?

A

ELECTROCHEMICAL MACHINING

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16
Q

Describe the process of ELECTROCHEMCAL MACHINING

A

This uses the reverse of electroplating to remove metal from a workpiece that forms the anode in an electrochemical cell. No maskants are needed
and no reagent. A salt electrolyte must be pumped between the shaped tool (cathode) and workpiece.Deep cavities are possible with essentially no tool wear, no cutting forces and no heat distortion. Power demand is high.

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17
Q

What is the process that is similar to spark plug?

A

ELECTRIC DISCHARGE MACHINING, EDM,or SPARK EROSION

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18
Q

What is the process of SPARK EROSION and how is it similar to the function of a spark plug?

A

A tool is used as one electrode and the workpiece (which must be electrically conductive) is used for the other. High voltage between the two will generate sparks that vaporize the part.

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19
Q

What is one type of EDM which is used to create holes of any cross section?

A

PLUNGE EDM (aka RAM, SINKER, CAVITY or VOLUME)

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20
Q

What is used in to worked between tool and part in EMD?

A

A DIELECTRIC (non-electrically conductive) fluid, such as oil or silicone

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21
Q

How many types of EDM are there?

A

There are 3 types
PLUNG EDM
TRAVELING WIRE
SMALL HOLE EDM

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22
Q

Describe PLUNGE EDM

A

Very similar to ULTRASONIC MACHINING but instead of slurry it uses a DIELECTRIC and the DIELECTRIC moves out of the process

23
Q

What can the electrode be made of in PLUNGE EDM?

A

Copper, Graphite, or Tungsten

24
Q

What is another form of EDM where the components are arranged like a “Band Saw” which is used to cut very fine slots?

A

TRAVELING WIRE or WIRE EDM

25
Q

Describe the process of TRAVELING WIRE

A

The wire is fed continuasly between supply spool and the take-up spool to form an electrode with the workpiece. It gets thinner as a consequence of sparking and vaporization. Sparking will occur between the wire and workpiece creating curve larger than the wire diameter

26
Q

What is the wire made of used in TRAVELING WIRE?

A

Brass (plain or coated) from 0.01” to as small as 0.001” diameter

27
Q

In TRAVELEING WIRE what are the GUIDES made of and how are they controlled?

A

GUIDES are made of carbide or diamond and are generally under CNC positional control

28
Q

What is the other type of EDM that is similar to PLUNGE EDM?

A

SMALL HOLE EDM, except that the tools are circular, small diameter, rotated during descent, and hollow to permit high pressure
dielectric to be pumped down through the bore.

29
Q

What is a technique that is not used mcuh anymore?

A

ELECTRON BEAM MACHINING (EBM)

30
Q

Describe the process of EBM

A

A vintage technique that uses a high energy stream of electrons to vaporize a workpiece upon impact. An electon cloud is driven from a source and a beam is formed, focused, guided, and accelerated(200,00 km/s) by electromagnets. Process takes place in a vacum & x-rays are generated and requires shielding with lead or concrete

31
Q

What is the process that replaced ELECTRON BEAM MACHINING?

A

LASER BEAM MACHINING, since it does not need shielding nor a vacuum

32
Q

Describe the process of LASER BEAM MACHINING

A

Each laser type generates light of a particular wavelength,
with each being more or less suited to cutting a particular material.

33
Q

What are the different laser types in LASER BEAM MACHINING?

A

“Gas Lasers” such as CO2
“Solid State Lasers” of Ruby or Nd:YAG (neodymium-doped yttrium aluminum garnet)
“Excimer Lasers” designed to emit in the UV

34
Q

What types of materials can LASER BEAM MACHINING cut?

A

Metals, Plastics, Ceramics, Minerals, Wood,
etc. and depending on part reflectivity, heat
conduction, and melting/evaporation
characteristics.

35
Q

Since LASER BEAM MACHININING requires a lens system that needs to be precise and focused what do they emply to keep it that way?

A

Focusing is often assisted by curved mirrors and electromagnetic coils. LBM systems can also employ a gas stream of N2 or Ar though a nozzle positioned close to the surface being machined, to blow away the debris.

36
Q

What are the 2 main categories that LASER MACHINING falles into?

A

LASER CUTTING & LASER ETCHING (or ENGRAVING) both of which create a “HEAT AFFECTED ZONE” and can create intricate designs

37
Q

What is commonly cut with LASER CUTTING?

A

Sheets of Material

38
Q

What is the gas used instead of INERT GAS in LASER CUTTING?

A

Oxygen (O2) and it raises the cutting temperature

39
Q

Describe what LASER ETCHING is

A

Used to remove material from the surface of a workpiece, and can be performed with or without an inert gas. the precise removal of material through vaporization creates very fine detail.When combined with MULTI-AXIS CNC positioning, laser machining can be performed on 3D surfaces.

40
Q

What is the lower cost alternative to LASER MACHINING that can also cut through plates?

A

PLASMA CUTTING

41
Q

What is unique about PLASMA CUTTING regarding the workpiece and plasma?

A

The workpiece must be electrically conductive, and it isn’t possible to etch or engrave.

42
Q

Describe PLASMA CUTTING

A

An electric arc is generated between an electrode and workpiece. A compressed gas is then fed to the arc through a nozzle. The
arc turns the gas stream into a superheated jet of ionized plasma, which melts the workpiece and blows the molten debris out

43
Q

What are other tools that can be used in PLASMA CUTTING that are capable of following complex paths?

A

Handheld plasma cutting torches & CNC Table Cutters

44
Q

What are the gases that are incled in plasma for PLASMA CUTTING?

A

Compressed Air, O2 (oxygen), N2 (nitrogren), H35 (35% hydrogen + 65% argon) and F5 (5% hydrogen + 95% nitrogen).

45
Q

What can be used in Cooling/shieldeing for PLASMA CUTTING.

A

Air, Nitrogen, CO2 or Water

46
Q

What are the modern improvements in PLASMA CUTTING?

A

The introduction of vertically oriented plasma cutters with a smaller footprint, and CNC 3D PLASMA CUTTING employing a torch on the end of a robotic-style arm with multiple degrees of freedom.

47
Q

What is the type of cutting that does not make a “Heat Effected Zone” but instead cools the workpiece while cutting?

A

HYDRODYNAMIC MACHINING or WATER JET CUTTING

48
Q

What are the types of HYDRODYNAMIC CUTTING?

A

Plain WATER JET CUTTING & ABRASIVE WATER JET CUTTING

49
Q

Describe Plain WATER JET CUTTING

A

Uses a very high pressure jet of water directed through a fine nozzle, at
pressures between 30,000 -100,000 psi.

50
Q

What can Plain WATER JET CUTTING cut?

A

It can quickly erode away soft materials like plastic or rubber. Wood can be cut, but water absorption can result in swelling. This type of cutting can be noisey, but it also cuts very cool, thereby eliminating melting, distortion, or changes in material properties.

51
Q

What HYDRODYNAMIC MACHINING process is used for hard materials lke metals and ceramics?

A

ABRASIVE WATER JET CUTTING

52
Q

In ABRASIVE WATER JET CUTTING what is the abriasive grit usually?

A

“Garnet”, which is non-toxic and can be recycled for repeated use before
eventually becoming a benign landfill waste.

53
Q

What is a common thing cut using ABRASIVE WATER JET CUTTING?

A

Granite kitchen countertops are routinely cut this way. 3D MULTI-AXIS CNC control has also revolutionized the process.

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