1. Team members: Mohamad Faisal b. Mohamad Khairi Harith Fahmi b. Mazlan Mohd Amirul Asraf b. Abu Bakar Mohd Asraf b. Arbain Asraf b. Arsyad Mohd Hafiz b. Haja Kamal Abdul Rahim b. Yusup

2. INTRODUCTION Non- Traditional Machining Conventional Machining Non traditional involve; Mechanical Energy Process Ultrasonic Machining (USM) Abrasive Jet Machining (AJM) WJM & AWJM Thermal Process Electrical Process Chemical Process

3. WATER JET AND ABRASIVE WATER-JET MACHINING

4. WATER JET MACHINING  Typically use to cut the “softer” and “easy to machine” material such as;  thin sheets and foils  non-ferrous metallic alloys  wood, textiles, honeycomb and etc.  Applied high pressure as up to 1400MP  Diameter nozzle around 0.05 mm and 1.0 mm

5. WATER JET MACHINING Product Water Jet Machine

6. ABRASIVE WATER-JET MACHINING  Same with water jet machining  The water jet contains or add with abrasive particle  With abrasive particle, increase the material removal rate compare to water jet machining.

7. ABRASIVE WATER-JET MACHINING  Additional process parameters: abrasive type, grit size, and flow rate  Abrasives: aluminum oxide, silicon dioxide, and garnet (a silicate mineral)  Grit sizes range between 60 and 120  Grits added to water stream at about 0.25 kg/min (0.5 lb/min) after it exits nozzle

8. ABRASIVE WATER-JET MACHINING application  Paint removal  Cleaning  Cutting soft material  Drilling  Textile and leather industry material  Steel  Ti alloys,NI-alloy  Metal matrix composite  Metal polymers Laminates  Ceramic matric composite

9. ABRASIVE WATER-JET MACHINING Advantages  Extremely fast set-up and programming  No heat generated on workpiece  Cut be started at any location without predrilled hole  Very little fixturing for most parts  Machine thick plate

10. ABRASIVE JET MACHINING (AJM)

11.  AJM a focused stream of abrasive grains of Al 2 O 3 or SiC carried by high-pressure gas or air at the high velocity.  The process differs from sandblasting (SB) in that AJM has smaller diameter abrasive and a more finely controlled delivery system.  The work piece material is removed by the mechanical abrasion (MA) action of the high-velocity abrasive particles. ABRASIVE JET MACHINING (AJM)

12.  Suited for machining holes in super hard materials.  AJM are quick to set up, and offer quick turn-around on the machine.  They complement existing tools used for either primary or secondary operations and could make parts quickly out of virtually out of any material.  All sorts of intricate shapes are easy to make. ABRASIVE JET MACHINING (AJM)

13. AJM SYSTEM

14. AJM TERMINOLOGY

15.  Drilling holes, cutting slots, cleaning hard surfaces, deburring, polishing and radiusing  Machining intricate shapes or holes in sensitive, brittle, thin, or difficult-to-machine materials  Insulation stripping and wire cleaning without affecting the conductor  Micro-deburring of hypodermic needles APPLICATIONS

16.  It is best suited for machining brittle and heat-sensitive materials like glass, quartz, sapphire, and ceramics  The process is used for machining super alloys and refractory materials  It is not reactive with any work piece material.  No tool changes are required  Intricate parts of sharp corners can be machined ADVANTAGES

17.  The removal rate is slow  Stray cutting can’t be avoided (low accuracy of ±0.1mm)  The tapering effect may occur especially when drilling in metals.  The abrasive may get impeded in the work surface.  Suitable dust-collecting systems should be provided. LIMITATIONS

18. ULTRASONIC MACHINING (USM)

19.  USM is abrasives contained in a slurry are driven at high velocity against work by a tool vibrating at low amplitude and high frequency. USM is mainly used for machining brittle materials which are poor conductors of electricity  Example of hard and brittle materials including glass, alumina, ferrite and quartz ULTRASONIC MACHINING (USM)

21. Vibrates at an ultrasonic frequency (19 ~ 25 kHz) The tool is pressed downward with a feed force, F. Between the tool and workpiece, there will be a slurry of hard abrasive particles As the tool vibrates over the workpiece, the abrasive particles act as the indenters and indent both the work material and the tool. During indentation, cracks would propagate due to increase in stress and lead to brittle fracture of the work material. The tools are made of tough, strong and ductile materials like steel to avoid brittle failure of the tools. ULTRASONIC MACHINING (USM)

22. Applications: machining hard and brittle metallic alloys, semiconductors, glass, ceramics and carbides. machining round, square, irregular shaped holes and surface impressions. wire drawing, punching or small blanking dies APPLICATIONS

23. Advantages: the process is non-thermal, non-chemical, and non-electrical higher productivity high quality and low cost solution Limitations: low MRR (material removal rate) low depth of hole ADVANTAGES AND LIMITATIONS

24. THANK YOU…..