Quality

Difference Between USM and EDM - Ultrasonic Machining & Electric Discharge Machining
NTM

NTM

Machining is one type of subtractive manufacturing processes where excess material is removed from the workpiece to produce intended feature. Conventional machining processes (such as turning, threading, facing, milling, shaping, drilling, hobbing, etc.) employ a wedge-shaped cutting tool to shear off the workpiece material in the form of chips. Such processes always utilize mechanical energy in order to remove material by shearing. Several non-conventional machining processes have also emerged over

Difference Between PAM and IBM - Plasma Arc Machining and Ion Beam Machining
NTM

NTM

Different forms of energy (such as mechanical, thermal, electrical, chemical, electro-chemical, light, etc.) are directly utilized in advanced machining processes to realize material removal from the workpiece for fabricating intended 3-D feature following the subtractive manufacturing approach. Plasma Arc Machining (PAM) is one such advanced machining process where thermal energy (heat) is primarily used to melt down and vaporize material from the workpiece. A high temperature jet of thermal plasma

Difference between EBM and IBM
NTM

NTM

Non-traditional machining (NTM) processes can directly utilize different forms of energy (like mechanical, thermal, chemical, electric, light, etc.) to selectively remove material from the workpiece in order to fabricate intended 3-D feature. These processes eliminate the barrier imposed by mechanical strength and hardness of the workpiece for processing by a conventional metal cutting process. Several NTM processes have emerged over the last few decades, which include AJM, USM, CHM, ECM,

Difference between LBM and IBM
NTM

NTM

Several advanced machining processes have been developed over the last few decades to cater the evergrowing demand of high quality small-scale products made of a wide variety materials with highly finished surfaces and close tolerance. Laser beam machining and ion beam machining are two such processes that follow subtractive manufacturing approach to fabricate intended features with improved accuracy and tight tolerance. However, their working principle and extent of capability are

Difference between coated and uncoated cutting tools
Machining

Machining

Cutting tool is a part and parcel in every conventional machining process. Tool material and geometry are two active parameters that influence process capability and machinability. For uninterrupted material removal, the tool material should be harder than the workpiece material. In addition to the hardness, tool material should ideally possess certain common properties, such as high strength, high toughness, high fatigue strength, shape retention capability at high temperature, high thermal

Difference Between EDM and EBM
NTM

NTM

Non-Traditional machining (NTM) processes directly utilize different forms of energy (mechanical, electrical, chemical, thermal, etc.) to remove material from the workpiece following the subtractive manufacturing approach. Among thermal energy based NTM processes, EDM, EBM, LBM and PAM are common. In all these processes the workpiece material is locally heated to a very high temperature in order to melt and vaporize it. However, the source of heat is different for each

Difference between EBM and LBM
NTM

NTM

There exist four basic non-traditional machining processes (EDM, LBM, EBM, and PAM) where thermal energy is utilized to melt and vaporize a tiny volume of material from the workpiece. Although mechanism of material removal is same in all four processes, the source of heat is different. In Electron Beam Machining (EBM), a concentrated beam of electrons is used as heat source. Here ample electrons are first generated using an electron

Differences between WJM and AWJM
NTM

NTM

Among the mechanical energy based non-traditional machining processes, water jet machining (WJM) and abrasive water jet machining (AWJM) are two common processes that have wide variety of applications, starting from metallic industry to textile and lather industries. In water jet machining, clean water is pumped to a high pressure (2500 – 4000 bar) with the help of intensifier and the pressurized water is delivered to the work surface in the

Differences between AJM and WJM
NTM

NTM

Mechanical energy based non-traditional machining (NTM) processes directly utilize mechanical energy to gradually remove material from the workpiece primarily by erosion. Examples of such processes include abrasive jet machining (AJM), water jet machining (WJM), abrasive water jet machining (AWJM) and ultrasonic machining (USM). In abrasive jet machining, abrasive particles are first mixed with the compressed gas at a pre-defined mixing ratio. This mixture is then directed towards the workpiece in

Comparison among drilling, boring and reaming
Machining

Machining

Macro-scale hole fabrication on a solid surface requires several different metal cutting operations based on the size and accuracy requirement. One typical series for hole making can be— (i) Centering, (ii) Drilling, (iii) Boring, (iv) Reaming and (v) Honing. Centering is carried out to locate the hole for easy and accurate alignment of a drill. Although it is optional, but centering can improve precision. Drilling is a process of originating

Typical drills and reamers
Machining

Machining

In order to make a macro-scale hole on a solid surface, a series of different machining processes are carried out depending on the finish and tolerance level requirement. One typical series of hole production can be— (i) Centering, (ii) Drilling, (iii) Boring, (iv) Reaming, and (v) Honing. Centering is performed to locate the hole center, drilling is carried out to originate a hole and boring is carried out to enlarge

Difference Between Rake Surface and Flank Surface
Machining

Machining

During machining, excess material is sheared off from the workpiece in the form of chips. A cutting tool having one or more sharp cutting edge(s) compresses a thin layer of workpiece material for shearing. This cutting edge is obtained by the intersection of rake surface and flank surface. Rake surface of a cutting tool is the chip flowing surface. That means the chips that are produced due to shearing action

Rake angle and clearance angle in machining
Machining

Machining

In conventional machining, the cutting tool compresses a thin layer of work material to gradually shear it off in the from of chip. Cutting tool is basically a wedge shaped device that actually shears off material from the workpiece. This cutting tool as well as the workpiece is mounted on the machine tool maintaining proper orientation. Necessary relative velocities between workpiece and cutter (in the form of cutting velocity, feed

Differences between machining and grinding
Machining

Machining

Primary objective of any subtractive manufacturing process is to remove layer by layer material from a solid 3-D blank to achieve desired shape, size and finish. Achieving high dimensional accuracy, close tolerance and surface finish are usually not possible by conventional machining processes like turning, milling, shaping, planing, drilling, etc. Such processes are mainly applied for bulk removal (stock removal) of material with high material removal rate. In order to

Differences between coolant and lubricant
Machining

Machining

During conventional machining or metal cutting, excess material is gradually removed from the workpiece in the form of chips using a wedge shaped cutting tool. Primarily due to continuous rubbing between moving chips and rake surface of cutting tool, intense heat is generated at the cutting zone. In continuous machining, this cutting heat leads to increase in temperature at the cutting zone. Excessive cutting temperature has several detrimental effects on

Differences between dry machining and wet machining
Machining

Machining

Machining is one secondary manufacturing process that is performed to impart desired shape, size and surface finish by removing unwanted material from a solid 3-D blank. In conventional machining operations, the cutting tool compresses a thin layer of workpiece material to gradually shear it off in the form of chips. The primary shear zone exists surrounding the concentrated shear plane along which work material undergoes shearing to become chip. Initially

Differences between flood cooling and MQL
Machining

Machining

In conventional machining operations, the cutting tool comes in physical contact with the workpiece to remove material in the form of chips. This chips flow over the rake surface of the tool before leaving the cutting zone. Presence of relative velocity under high contact pressure between the flowing chips and rake surface of the tool leads to excessive rubbing and heat generation. Excessive cutting heat or temperature has several detrimental

Difference between surface roughness and surface finish
Machining

Machining

After processing the workpiece by any surface modification process (such as metal cutting, surface treatment, forming, etc.), quality of the final surface can be judged based on several aspects. All such aspects are integrated by the term Surface Integrity. It covers all primary, standard and extended data sets related to quality of a solid surface. Assessing quality of machined surface is important for judging machinability for a combination of work-tool

Difference between surface roughness and surface integrity
Machining

Machining

Primary objective of machining or metal cutting operation is to provide desired shape and quality to the workpiece by removing excess material with the help of a cutting tool. Assessing quality of a machined surface is important for judging machinability for a particular combination of work-tool material under a specific machining condition. In the context of manufacturing, three terms—surface roughness, surface finish and surface integrity are commonly used to characterize