Advanced Machining Processes by Hassan Abdel-Gawad El-Hofy

By Hassan Abdel-Gawad El-Hofy

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Furthermore, in lapping, polishing, and buffing, loose abrasives are used as tools in a liquid machining media as shown in Fig. 4b. 4 Abrasive machining. 4 Nontraditional Machining The greatly improved thermal, chemical, and mechanical properties of the new engineering materials made it impossible to machine them using the traditional machining processes of cutting and abrasion. This is because traditional machining is most often based on the removal of material using tools that are harder than the workpiece.

The process is, therefore, called rotary ultrasonic machining (RUM). Cruz et al. (1995) used the process for machining nonmetallic materials such as glass, alumina, ceramic, ferrite, quartz, zirconium oxide, ruby, sapphire, beryllium oxide, and some composite materials. RUM ensures high removal rates, lower tool pressures for delicate parts, improved deep hole drilling, less breakout or through holes, and no core seizing during core drilling. The process allows the uninterrupted drilling of small-diameter holes, while conventional drilling necessitates a tool retraction, which increases the machining time.

New York: Marcel Dekker, Inc. Tanigushi, N. (1983). “Current Status in and Future Trends of Ultra Precision Machining and Ultra Fine Materials Processing,” Annals of CIRP, 32 (2): 573–582. Todd, J. , and Copley, S. M. (1997). “Development of a Prototype Laser Processing System for Shaping Advanced Ceramic Material,” ASME, Journal of Manufacturing Science and Engineering, 119: 55–67. htm This page is intentionally left blank. 1 Introduction Ultrasonic machining (USM) is the removal of hard and brittle materials using an axially oscillating tool at ultrasonic frequencies [18–20 kilohertz (kHz)].

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