Hybrid Machining Processes (eBook)

Preface 6
Contents 8
1 Overview of Hybrid Machining Processes 10
Abstract 10
1.1 Evolution of Advanced Machining Processes 10
1.2 Need and Introduction of Hybrid Machining Processes 13
1.3 Classification of Hybrid Machining Processes 13
1.4 Applications of Hybrid Machining Processes 16
References 16
2 Electrochemical Hybrid Machining Processes 17
Abstract 17
2.1 Electrochemical Grinding (ECG) 18
2.1.1 Introduction 18
2.1.2 Equipment and Working Principle 18
2.1.3 Process Mechanism and Parameters 19
2.1.4 Advantages, Limitations and Applications 21
2.2 Electrochemical Honing (ECH) and Pulsed ECH 21
2.2.1 Introduction 21
2.2.2 Equipment and Working Principle 22
2.2.2.1 Finishing of Internal Cylinders by ECH 22
2.2.2.2 Finishing of Gears by ECH 23
2.2.3 Process Parameters and Mechanism 27
2.2.4 Advantages, Limitations and Applications 28
2.3 Electrochemical Buffing (ECB) 29
2.3.1 Introduction 29
2.3.2 Equipment and Process Mechanism 29
2.3.3 Applications 30
2.4 Electrochemical Deburring (ECDe) 31
2.4.1 Introduction 31
2.4.2 Process Details 31
2.4.3 Advantages and Applications 32
2.5 Electrochemical Superfinishing (ECSF) 32
2.5.1 Introduction 32
2.5.2 Equipment and Working Principle 33
2.5.3 Process Mechanism and Parameters 34
2.5.4 Applications 34
2.6 Electrochemical-Type Advanced Drilling Processes 35
2.6.1 Electrochemical Drilling (ECD) 35
2.6.2 Shaped Tube Electrodrilling (STED) 37
2.6.3 Capillary Drilling (CD) 38
2.6.4 Electrolytic Stream or Jet Drilling (ESD or EJD) 38
References 39
3 Thermal Hybrid Machining Processes 41
Abstract 41
3.1 EDM Combined with Conventional Machining 41
3.1.1 Electric Discharge Grinding (EDG) 41
3.1.1.1 Introduction 41
3.1.1.2 Equipment and Working Principle 42
3.1.1.3 Process Mechanism and Parameters 43
3.1.1.4 Applications 43
3.1.2 Electric Discharge Abrasive or Diamond Grinding (EDAG or EDDG) 43
3.1.2.1 Process Details 43
3.1.2.2 Applications 45
3.2 EDM Combined with ECM 45
3.2.1 Electrochemical Discharge Machining (ECDM) 45
3.2.1.1 Introduction 45
3.2.1.2 Equipment and Working Principle 46
3.2.1.3 Process Mechanism and Parameters 47
3.2.1.4 Applications 48
3.2.2 Electrochemical Discharge Grinding (ECDG) 49
3.2.2.1 Process Details 49
3.2.2.2 Applications 50
References 51
4 Assisted Hybrid Machining Processes 53
Abstract 53
4.1 Vibration-Assisted HMPs 54
4.1.1 Ultrasonic-Assisted ECM (USECM) 55
4.1.1.1 Introduction 55
4.1.1.2 Equipment and Working Principle 55
4.1.1.3 Process Mechanism and Parameters 56
4.1.1.4 Applications 57
4.1.2 Ultrasonic-Assisted EDM (USEDM) 57
4.1.2.1 Introduction 57
4.1.2.2 Equipment and Working Principle 58
4.1.2.3 Process Mechanism and Parameters 59
4.1.2.4 Applications 59
4.2 Heat-Assisted HMPs 60
4.2.1 Laser-Assisted ECM (LAECM) 60
4.2.1.1 Introduction 60
4.2.1.2 Equipment and Working Principle 61
4.2.1.3 Process Mechanism and Parameters 62
4.2.1.4 Applications 63
4.2.2 Laser-Assisted EDM (LAEDM) 63
4.2.2.1 Introduction 63
4.2.2.2 Working Principle and Applications 63
4.3 Abrasive-Assisted HMPs 64
4.3.1 Abrasive-Assisted ECM (AECM) 65
4.3.1.1 Process Details 65
4.3.1.2 Applications 66
4.3.2 Abrasive-Assisted EDM (AEDM) 66
4.3.2.1 Process Details 66
4.3.2.2 Applications 68
4.4 Magnetic Field-Assisted HMPs 68
4.4.1 Magnetic Field-Assisted EDM (MAEDM) 68
4.4.2 Magnetic Field-Assisted Abrasive Flow Machining (MAAFM) 69
4.4.2.1 Introduction and Limitations of AFM 70
4.4.2.2 Details of MAAFM 70
References 72
Index 74