ABSTRACT
Chapter 2 deals with the mechanical non-traditional machining operations and their relevant machine tools. It includes jet machines and operations, ultrasonic machining, and abrasive flow machining. In jet machining, high-velocity stream of water (WJM) or water mixed with abrasive materials (AWJM) is directed to the workpiece to cut the material. If a mixture of gas and abrasive particles is used, the process is referred to as abrasive jet machining (AJM).
Ultrasonic machining (UM) is an economically viable operation by which a hole or cavity can be pierced in hard and brittle materials, whether electric conductive or not, using an axially oscillating tool, which oscillates with a small amplitude of 10 to 50 µm at high frequencies of 18 to 40 kHz. During tool oscillation, abrasive slurry is continuously fed into the working gap between the oscillating tool and the stationary workpiece, to abrade the material of the workpiece into a conjugate image of the tool form. This chapter provides the design of acoustic horns (tool carrier) necessary for US equipment.
Abrasive flow machining (AFM) is a process that finishes surfaces and edges by extruding a viscous abrasive media flowing, under pressure, through or across a workpiece. This process provides a high level of surface finish and close tolerances with an economically acceptable rate of surface generation for a wide range of components.
