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Introduction-

Want to know about LaMont Boiler?

Then, you landed on the right place, Here, you will get a complete knowledge of Lamont Boiler, From start to end.

So, come with me and feel comfortable while I start the engine of this knowledgeable journey with you.

LaMont Boiler Definition-

Lamont boiler is high pressure, forced circulation, water tube boiler with an internally fired furnace.

A forced circulation boiler was introduced by La-Mont in the year of 1925 which is used in Europe and America and this boiler was invented to use in ships.

Working Principle of LaMont Boiler-

This modern high-pressure LaMont boiler works on the forced circulation system and the Lamont boiler is a pressure water tube steam boiler working on forced circulation.

In which the boiler water is circulated through an external pump through long closely spaced tubes of small diameter.

The mechanical pump is employed in order to have adequate and positive circulation in steam and hot water boilers.

Here is the systematic and simple diagram of this boiler.

Parts and Construction-

There are several parts used in this boiler. Here are its parts and construction of Lamont boiler are given below-

Feed Pump

Economizer

Air Pre-Heater

Steam Outlet

Steam Separating Drum

Circulating Pump

Radiant Evaporator

Convective Evaporator

Superheater

Want to know about the major Difference between condenser coil and evaporator coil?

Then you landed at the right destination. Here you will get a complete knowledge of condenser coil vs evaporator coil, from scratch to end.

Before I start, let’s know about the basics of these terms, It will further help you to understand more clearly deep down into this article.

Now, Let’s dwell in-

What is Condenser Coil?

A condenser coil is used in the refrigeration system to condense the vapour into the liquid state via condensing coil, known as the condenser coil.

The main function of the condenser coil is to release heat to outdoor air.

What is Evaporator Coil?

The evaporator coil is the main part of Air-conditioning system and it is used to absorb heat from the air inside and vent it outside, known as the evaporator coil.

The evaporator coil is located inside the air handler.

After knowing the basics of these devices, Let’s move to the mainstream of the article, value the purpose of your landing at Engineers Rail.

Difference between Condenser coil and Evaporator coil-

Here are some basic differences of these devices given in the tabular form down below-

To read difference, go here- https://www.engineersrail.com/difference-between-condenser-coil-and-evaporator-coil/

That’s it for now, I hope you liked spending time here in the short type of article.

If so, consider sharing with your friends and colleagues or needy ones to spread valuable knowledge out. Sharing links are down below.

Want to read more? Here are some suggested articles to consider-

Condenser: Definition, Principle, Types, Advantages, Disadvantages

What’s the Difference between condenser and Evaporator?

Difference between orificemeter and venturimeter

Thank you for being with me. I hope to see you in the next session.

Don’t forget to bookmark Engineers Rail for further reading with convenience.

Before you go, here is the Q&A session, you should attain for while.

FAQs-

Is an evaporator coil the same as a cooling coil?

The evaporator coil is also known as an indoor coil or cooling coil. These both terms are the name of the same coil, ie, Evaporator coil.

Can you use evaporator coil cleaner on condenser coils?

No, it should not be recommended because of specification. The evaporator cleaners are designed to clean evaporators coil heavy dust.

How long does the evaporator coil last?

Want to know about the difference between condenser and Evaporator?

So, you landed on the right place, here you will know about condenser vs evaporator, from scratch to end.

Hence, I invited you to come with me and join the journey with me.

Before I start, It would be nice to get some briefs about these terms. so, here we go…

What are Condensers?

A condenser is a cooling device that either releases heat or collect heat. It is also a form of heat exchanger device.

In general, Condensing gas in liquid and vice versa is the main work of the condenser and this state of changing the form of fluid, known as condensation.

To know more-

Condenser: Definition, Principle, Types, Advantages, Disadvantages

Now, let’s move to the next term of this journey, which is-

What is Evaporator?

The evaporator converts the liquid refrigerant into the vapour state by absorbing heat from the surrounding, known as the evaporator.

This is the main part of the refrigeration system used in various industries as well as in-home refrigeration and air conditioning.

Although, These devices condenser and evaporator used in the refrigeration system and evaporator and condenser are one type of heat exchanger in general.

Now, let’s move on to the mainstream of the article, which is-

Difference between condenser and Evaporator-

Here are some major differences between condenser and evaporator in tabular form-

To read difference, go here- https://www.engineersrail.com/difference-between-condenser-and-evaporator/

These were some major points differences between condensers and evaporators concluded in tabular form for easy understanding.

That’s it for now.

I hope, you liked spending time here and get some valuable knowledge and it added some value to you. If so. consider, sharing with your friends and colleagues or needy ones, sharing links are down below.

Read more-

Difference between orificemeter and venturimeter

Difference Between Conventional and Non-Conventional Machining Processes

Thank you for being with me and I hope to see you in the next session.

Don’t forget to bookmark Engineers Rail for further readings with convenience.

Before you go, Here are some Q&A sessions, you should look at-

FAQs-

Can a condenser be used as an evaporator?

No, both have different properties in terms of working. Hence they can not be replaced with one another.

Can condenser be bigger than evaporator?

Want to know about the Difference between orificemeter and venturimeter?

Then you are on the right path. Here you will know the detailed comparison between these two devices.

So, I invite you to come with me and feel comfortable while I start the engine of this knowledgeable journey.

So, Without further delay, Let’s dive in.

Before jumping in the title of the article, It would be nice to know about these devices briefly.

What is an Orifice meter?

Basically, an Orifice meter is referred as a type of flow meter that uses differential pressure measurement techniques and this helps to get discharge rate as well as calculate the flow rate.

In short, Orifice meters is a device to measure the flow rate or discharge rate of any fluid. Oficemeter is used mainly in robust applications and an Orifice meter works based on the differential measurement technique.

What is Venturimeter?

Volumatricmeter is the discharge measuring device and it measures volumetric flow.

Here, You may ask that what is volumetric flow?

So, volumetric flow is the amount of the fluid flowing or volume of fluid flowing through the media per unit of time. In short, the volume of the flowing fluid per unit time.

Difference between orificemeter and venturimeter-

Here is the side by side comparison of the orificemeter and venturimeter in the table down below-

To read difference, go here- https://www.engineersrail.com/difference-between-orificemeter-and-venturimeter/

These were the major differences between the orifice meter and venturimeter which is given in the table above.

I hope you enjoyed spending time here and this added some value to you. If so, consider sharing with your friend and colleagues or to the needy ones, because SHARING IS CARING and you should not miss this opportunity.

Read More-

Riveted Joints: Definition, Types, Uses, Efficiency, Advantages and More

I hope to see you in the next session. Thank you for being with me.

Before you go, here are some Q&A sections of this topic called ‘Difference between orificemeter and venturimeter’. You should not miss this.

FAQs-

Which is more accurate Venturi or orifice?

Venturi is more accurate than orifice.

Where is Venturimeter used?

Venturimeter is used to measure the flow rate of the fluid.

What is the basic principle of a Venturimeter?

Venturimeter works on the principle of Bernoulli’s equation.

Which is better Venturimeter and Orificemeter?

Want to know about Riveted Joints?

Then you landed on the right place, Here you will get complete information, from scratch to end.

So, Come and stay with me while I start the engine of this knowledgeable journey.

So, Without further delay, let’s dive in from the basics to advanced-

Definition of Riveted Joints-

Riveted joints are those that can not weld or join by any means other than using rivets causing permanent joints of two separated components, known as Rivets Joints.

This can be the basic definition of Rivet joints, now let’s move to the types of rivets joints. So, Here we go-

Types of Riveted Joints-

Mainly Two types of riveting joints are used while riveting any metal sheets-

(I) Lap Joint Rivet

(II) Butt Joint Rivet

Lap Joint Rivet-

Lap joint rivet is done by Overlapping metal sheets from the corner side.

When a Single straight line of rivets is used in the lap joint, then it is called a Single row lap joint.

When a Double straight line is used to join two metal sheet corners in a lap joint, Known as a Double-row lap joint.

When a Double line of rivets is placed in the zig-zag dimension, then it is called a Double-row zig-zag lap joint.

Butt Joint Rivet-

When two metal sheet joints side by side together facing in the same direction, Knowm as Butt Joint.

When the jointing side of metal sheets comes together, then riveting is done by placing a piece of the sheet above the metal sheet.

This piece of sheet is known as Strap.

If a Single strap is used in butt riveting, then it is called a Single strap butt joint.

And, When a Double strip is used to riveting the butt joint, then it is called a Double strap butt joint.

When the single row of rivets and the single strap is used on both metal sheets i butt joint, then it is known as single-row single strap butt joint.

When the single row of rivets and two-strap is used on both metal sheets to fastening the butt joint, then it is known as the Single row double strap butt joint.

And, when two rows of rivets and the double strap is used on both metal sheets of butt joint, then it is called Double row double strap butt joint.

In special cases, Triple-riveted joints are used in both types of joints.

Failure of Riveted joint-

Here are some types of failure in riveted joints, This will help you to understand the possible cause of riveted joint failure.

Bearing failure

Net-tension failure

shear-out failure

Cleavage Failure

Cleavage-tension failure

Bolt Failure

Fastener Failure

Pull-through Failure

Above mentioned reasons are the main sources of Riveted joint failure.

Now, I am going to discuss the equation of Efficiency of the Riveted joint, So, it will be easy to calculate efficiency, If needed.

Want to know about Types of rivets?

Then you landed in the right place. Here you will get a complete guide on types of rivets and their uses, from scratch to end.

⇒Here are some basics of Rivets, Have a look first-

Rivets are fasteners used for joining metal sheets and plates in fabrication work such as bridges, ships, cranes, structural steelwork, boilers, aircraft etc.

The rivet is often inserted and close by force so that it completely fills the holes and forms rigid rivets joint.

And, Riveting is the method of making permanent joints for riveting the plates to be joined are drilled or punched.

Now, let’s dig into the mainstream of the article, Where you will know types of rivets with diagram–

Types of Rivets-

Here are the most common 11 types of rivets-

Solid rivets

Split rivets

Blind rivets

Tubular rivets

Snap head rivets

Pan head rivets

Mushroom head rivets

Countersunk rivets

Flathead

Conical head rivets

Pan head with tapered neck rivets

Solid Rivet-

Solid rivet’s shank is solid and is used for general purposes. This rivet is the strongest of all kinds.

It is the simplest and reliable rivet founded in the Bronze age and can be fitted through a hammer or rivet gun.

The material used in manufacturing can be aluminium, brass, copper, stainless steel etc and comes in many colours and sizes.

Split Rivet-

Split’s shank is divided into parts and identified by pairs of legs on their tails which are folded back on themselves after installation.

it is used in small and light works like tin plates, textiles, leather, plastics and use in bicycle seats.

As the name suggests, It is split into two parts from the body side and having a single head at the top. It is also known as a Bifurcated rivet.

Blind Rivet-

As the name suggests, Blind rivets are actually used where you can not access the other side of the surface like something hollow.

Metal sheets and other hard materials are fastening through blind rivets with the help of the rivet-gun.

The common uses of these rivets refer to brittle and soft materials, electrical parts, automobiles, hand tools, locks, and home appliances etc.

Commonly, It is also known as POP and Break stem rivet.

Tubular Rivet-

Tubular’s shank is hollow in nature and the rest is just similar to the solid rivet. It is used to drill in shoes and file covers etc.

This can also be used to fastening aluminium, thin metals sheets, plastics, leather and on the pivot points where movement is required.

This is also known as Hollow rivet, due to the hollow shape at the body end.

This is classified into two categories-

(I) Full Tubular

(II) Semi Tubular

Snap Head Rivet-

Snap head or cup head rivet is the most commonly used rivet and it gives a very strong joint.

These rivets are widely used and meet the requirement of various industries like the manufacturing and construction industries to provide maximum strength in general.

The diameter of Shank is approx 1.6d and the length of the head is 0.7d.

Pan Head Rivet-

It has the unique design of a slightly rounded head and slopping down from the top of the head(see diagram) to provide a tighter grip during the fastening process.

This can be made up of carbon steel, brass, copper, aluminium and stainless steel with a length range from 6mm to 100mm in general.

Pan heads are used in Heavy structural work to provide maximum strength and grip.

Mushroom Head Rivets-

A mushroom head is used to deduce the rivet head height on the metal surface and provides the locking needed for maximum strength.

As the name suggests, these rivets are mushroom-like heads and have a lower profile than standard rivets.

Materials are used to manufacture these rivets aluminium alloys, titanium, and nickel alloys.

Introduction-

Want to know about Electron beam machining?

Then you landed in the right place. Here you will know the Electron beam machining process, From scratch to end.

I will cover topics like- basic definition, principle, various equipment and its construction and further working, advantages, disadvantages, application and so on.

So, stay with me while I start this knowledgeable journey with you.

So, let’s dive in...

What is Electron Beam?

The Electron Beam is a stream of negatively charged particles that are generated, accelerated, and some extent, focussed inside a device called an ” Electron Gun”.

What is Electron Beam Machining?

Electron Beam machining or EBM is a non-conventional machining process, Where the electrons are focused and concentrated on the small spot on the metal, the kinetic energy of the electrons is converted into heat energy which is sufficient to melt the workpiece, Known as Electron beam machining or EBM.

It is just similar to laser beam machining and electron beam machining is most appropriate for machine very hard and brittle materials that cannot be machined using a conventional process.

Working principle of Electron beam Machining-

EBM machining process works on the principle of the high-velocity beam of the electron is focused on the workpiece, the electrons strike on the workpiece and their kinetic energy is converted into heat energy.

This results in the removal of material from the workpiece by vaporization and melting.

Fig. Electron beam machining diagram-

Types of Electron Beam Machining-

There is two types of EBM machining process

Thermal EBM-

The Beam is used to heat the material up to the point where it is selectively vaporized.

Non-Thermal EBM-

This utilizes the beam to cause a chemical reaction.

Construction of Electron Beam Machining-

Here are some equipment and construction of EBM machining-

Electron Gun

Magnetic lens

Electronic lens

Magnetic deflection coil

Optical viewing system

Vacuum chamber

Electronic system

Movable table

Electron Gun-

Electron gun which generates and directs a controlled beam of electrons of high energy density on the workpiece to change it chemically and physically.

Magnetic Lens-

The magnetic lens is provided which shape the beam and doesn’t allow to diverge electron or reduce the divergence of the beam.

Electromagnetic lens-

An electronic lens is used to focus the electron beam at a spot.

Magnetic deflection coil-

The Magnetic deflecting coil does not allow to beam deflect and take care of all the electron movements.

Optical viewing system-

It is a system to check whether the process is under control or not.

Vacuum chamber-

EBM process is done in the vacuum chamber to avoid any air entering probability so Electron Beam Machining is required to be carried out in the vacuum. Because air can decrease the velocity of the electron beam, hence electron beam machining requires a vacuum during the entire operation.

Electronic system-

An electronic system that controls the size and movement of the beam.

Movable table-

The workpiece is mounted on the movable table fixture that is mostly operated with CNC. The table can be move in all three directions.

Working-

The EBM works the same as laser beam machining. Here electron beam machining working can be summarized into the following points-

Electron gun produces high-velocity electrons particles.

Then, This high-velocity electrons particle moves towards the Anode.

Here from the Anode, It gets concentrated and moves towards the magnetic lens.

Here in the magnetic lens, the convergent electrons pass through it and all divergent and low energy electrons are absorbed by it, resulting in high-quality electron beam production.

After passing through the magnetic lens, High-quality electrons move to the deflection coil which focuses the electron beam at the single spot point.

Hence High-intensity electron beam is ready to bombard the surface of the workpiece.

Here kinetic energy of electrons converts into thermal energy.

And due to the thermal energy, the material is removed from the contact surface by melting and vaporizing.

Introduction-

Want to know about Laser beam machining?

Then you landed in the right place. Here you will get a complete and detailed article on the laser beam machining process, from scratch to end.

What is laser?

The laser is a device for producing a very narrow beam of highly intensive monochromatic coherent light.

By the way, The word LASER basically stands for-

L→ Light

A→ Amplification by

S→ Stimulated

E→ Emission of

R→ Radiation

Laser is produced when electrons and atoms of special crystals are energize using electric current.

These excited electrons emit photons and these emitted photons from a concentrated beam of light, forming a laser.

Generally, garnet crystal is commonly used in solid-state lasers.

This laser is discovered by Dr T.H. Maiman in 1960.

Now, let’s dig into the mainstream of the article, where I will explain the laser beam machining process. So, let’s jump in-

What is Laser beam machining?

Laser beam machining(LBM) is a non-conventional process in which material is removed using the laser beam to produce heat and due to that heat, metal is removed from the surface of the workpiece, due to vaporization.

The laser beam machining process is used for machining brittle materials with low conductivity, But it can be used on almost every material.

Laser beam machining working principle-

LBM machining works on the basis of laser properties in which a laser is directed towards the workpiece for machining.

This process uses thermal energy to remove materials from metallic or non-metallic surfaces.

In this process, a monochromatic laser beam is made to focus on the workpiece to be machined by a lens to give extremely high energy density to melt and vaporize any material.

Fig.- laser beam machining diagram-

Parts of Laser beam machining-

Here are some equipment or components used in the LBM process–

Power Supply-

It provides the energy for the excitation of electrons from lower energy levels to higher energy levels.

Flash lamp-

The power supply is connected to the flash lamp to expose laser material through emitted light by the flash lamp.

Basically, the flash lamp is used to get energize the laser material.

Laser Discharge Tube-

A laser tube is used to fill laser material inside including a mirror on both sides of the tube. One side mirror is partially reflective and the other side includes totally reflective.

Laser materials-

Laser material plays a key role in this process.

where Co2(pulsed or continuous waves) and Nd: YAG is used as laser material.

Co2 emits light in the infrared region and it can provide up to 25KW power in continuous mode.

And, Neodymium Doped Yttrium Aluminium Garnet(Nd: YAG) is a solid-state laser and it can deliver light through optical fibre and it can provide 50KW in the form of Pulsed mode and 1KW in the form of continuous mode.

Lens-

A convex lens is used to focus on the workpiece. The main function of the lens is to focus the laser beam in the single-pointed direction directly on the workpiece.

Construction of Laser beam machining-

Firstly, there is the power supply as you can see in the diagram above.

And, two flash lamp has installed both sides of the laser discharge tube.

Again, two reflecting mirror is installed both sides of the laser tube on the top and bottom position.

Here, at the top of the laser tube, a 100% reflective mirror is installed and the bottom of the tube partially reflective mirror is mounted.

After the mirror, a lens is mounted to focus the laser rays on the workpiece.

Working-

Here is the working of LBM-

When the switch is turned on, a High voltage power supply applies to cross the flashlight or flash tube and the flashlight gives energy to the laser material in the laser discharge tube.

When the light is turned on laser tube emits the high energy photons and hence these high energy photons are absorbed by the laser material.

This absorbed energy causes most of the electrons contains in the atom of the laser material to be excited at the high energy level from its ground state.

After a short duration, The electrons of the high energy level comes to the ground state, they emit photons.

These emitted photons stimulate the excited electrons to returns to their ground state. Thus, producing more photons.

As the Photon concentration increases, the laser is formed.

A 100% reflective mirror is used to reflect all the photons back to the laser material and a semi-reflective mirror reflects some of the photons back and escaping photons through a semi-reflective mirror forms a high energy laser beam.

Then a lens is used to focus the laser beam on the workpiece to be machined.

Interaction of laser and workpiece produces a large amount of heat and thus vaporizing the surface of the workpiece.

And hence laser beam machining process can be used for removing materials from the workpiece through this process.

Introduction-

Want to know about Plasma Arc Machining?

Then you landed in the right place. Here you will know about the plasma arc machining process, from scratch to end.

Welcome to Engineers Rail, Grab your seat and be comfortable, while I start the engine of the knowledge.

So, let’s get started…

First, I would like to tell you about What is plasma, to clear your basics. So, here it is-

What is Plasma?

Plasma is often called the fourth state of the matter. The first three are-

Solid

Liquid

Gas

So, If you first start with solid, let’s say-Ice.

When you put energy into ice, it will start melting.

Again if you put further energy into the melted ice (Liquid), it will start to evaporate and converts into Gas.

Now, if you put even more energy into the gas, it gets ionized and this ionized gas is called Plasma.

So, Plasma is essentially an ionized gas that has some interesting properties like it conducts electricity and emits light.

Now, Let’s drive into the mainstream of the article, Starting with- What is plasma arc machining and later on working principle.

What is Plasma Arc Machining?

When gas is heated to a temperature of about 5500C to ionize the gas, when gas is completely ionized, then the temperature of the central part of the plasma is between 11000°C to 28000°C.

When such an ionized gas is directed on the workpiece through a high-velocity jet, the metal is removed by melting.

This high velocity of hot gas is known as plasma jet and this process is known as plasma arc machining(PAM).

Working Principle of Plasma arc machining-

Here is the principle of plasma arc machining-

In PAM Machining, constricting an electric arc through a nozzle generates the basic plasma jet. Instead of diverging into an open arc, the nozzle constricts the arc into a small cross-section.

This action greatly increases the power of the arc so that both temperature and voltage are raised.

After passing through the nozzle, the arc exists in the form of a high-velocity, well-illuminated and intensity hot plasma jet.

The basic heating phenomenon that takes place at the workpiece is a combination of heating due to the energy transfer of electrons

Recombination of dissociated molecules on the workpiece, and the convective heating from the high-temperature plasma that accompanies the arc.

Once the material has been raised to the molten point, the high-velocity gas stream effectively blows the material away.

Components & construction of Plasma arc machining-

Here are the plasma arc cutting equipment and construction, given below-

Power supply

Gas supply

Cooling water system

Electrode & nozzle

Workpiece

Power supply-

Electricity supply is needed to turn the gas into plasma, the greater the current, the harder the plasma.

Gas Supply-

Compressed air, nitrogen and other gas provide a source for the plasma. In this example, a second inert sealed gas is used to protect the workpiece and blow off melted metal.

Cooling water system-

A cooling water system is used to provide the cooling effect to the plasma torch, mounted in the other body of the plasma cutter.

Electrode & Nozzle-

Special engineered electrodes and nozzles constrict and maintain the plasma jet concentrating it into the small area so it can be used for cutting.

Workpiece-

The workpiece is positioned below the plasma gun in pam machining. Materials like magnesium, carbon, stainless steel, aluminium and steel alloys can be cut using this process.

Now, let’s discuss the working of the same.

Working-

When the operator is ready to cut, a start signal is sent to the DC power supply.

A circuit temporarily connects the nozzle to the positive side of the power supply with the electrode on the negative side.

Next, the high-frequency spark ionizes the gas and makes it electrically conductive.

This creates a current path between the electrode and nozzle and forms a Pilot arc plasma.

When the pilot arc contacts the workpiece, the plasma arc transfers to the workpiece melting the metal.

Then, the high-velocity gas blows the molten material away.

And that’s the end of the working of PAM.

Hence, let’s look out further the Advantages, disadvantages and applications of this process in this journey.

Advantages of plasma arc machining-

Here are some advantages of the PAM machining process-

The main advantage of PAM is the suitability for any materials irrespective of hardness or heat resistant characteristics.

PAM allows high material removal rate(up to 10000 cm3/hr) and Material removal rate(MRR) for high strength materials are comparable with conventional turning.

Ferrous and non-ferrous materials up to 150 mm thick can be cut.

Plasma arc methods are also employed in special applications to replace conventional machining operations such as lathe turning, milling and planning, heat treatment and metal deposition operation, and plasma arc welding.

The plasma arc, as an industrial tool, is the heaviest employed in sheet and plate cutting operations as an alternative to more conventional oxy-fuel torches or cutting tools.

Introduction-

Want to know about the Electrical discharge machining?

Then you landed in the right place. Here you will get complete details about the electro-discharge machining process, from scratch to end.

So, I invite you to come along the board and stay with me while I take you on the journey of knowledge, here in Engineers Rail.

So, Shall we start?

What is Electrical Discharge Machining?

Electric discharge machining is a non-conventional machining process that uses an electric spark to remove metal from the workpiece.

This process is done by applying high-frequency current through electrodes and Workpiece emerging in the dielectric fluid.

It is also known as Spark erosion, Electro-erosion or spark machining.

Electrical discharge machining(EDM) is used to machine very hard materials.

Working Principle of electrical discharge machining-

Here is the working principle of EDM machining-

EDM works on the principle of Heat energy generated by a spark is used to remove the material from the workpiece.

The tool and workpiece are separated by a small gap called a spark gap. The gap is varied from 0.01mm to 0.5mm.

When supply is ON, thousands of sparks are produced per second.

When the spark comes in the contact with the dielectric fluid in the spark gap, the fluid gets ionized. It allows current to flow between the tool and workpiece.

Types of Electrical discharge machining-

Die sinking EDM process

Wire cut EDM process

Hole drilling EDM process

Die Sinking EDM process-

When two metals parts are placed in the dielectric fluid and connected to the source power supply, erosion of material takes place due to spark energy generated by electric tension between two metals parts, ie, anode and cathode. It is also known as the sinker EDM process.

In this case, the metal removal is affected by non-stationary electrical discharges which are separated from each other both spatially and temporarily.

Wire Cut EDM Process-

The fundamental principle of metal removal in wire cut EDM is the same as EDM. It is also known as WEDM.

It employs electrical energy to remove metal from the workpiece without touching it.

The maximum depth of the workpiece is to be 90mm, wire dia is to be 0.3mm and speed should be 2.5 to 150mm/sec.

Here in WEDM wire acts as a tool and EDM wire is made of copper or a mixture of copper graphite.

Hole Drilling EDM Process-

Here in hole drill EDM, High-pressure dielectric fluid enters through the rotating electrode to produce fast and accurate drills.

hole drill EDM is just similar to die sink EDM, But there is a number of differences.

Hole drilling EDM is used to drill holes where difficult to machine materials is to drill.

To drill, different types of electrodes are used in different materials, from small as 0.3mm diameter to 6mm diameter.

After knowing the types of EDM, Now let’s move to the various parts and construction of the EDM machines.

Parts of Electric discharge machining-

Here are the principal components of the EDM process-

DC pulse generator

workpiece and tool

Servo control unit

Pinion

Dielectric Medium

Dielectric fluid

DC pulse generator-

This converts the AC power supply into a high pulse DC supply, responsible for generating spark between the tool in the workpiece.

The negative terminal sets to the tool and the positive terminal is supplied to the workpiece.

Workpiece and tool-

Here workpiece acts as Anode and the tool acts as a cathode.

Servo control unit-

A servo control unit controls the spark gap between the tool and workpiece.

Pinion-

The pinion is used to controlling the motion of the tool directed by the servo control unit

Dielectric Medium-

Dielectric medium is consist of dielectric fluid, fixture, and workpiece itself.

Dielectric fluid-

It works to maintain the gap between workpiece and tool, acting as a non-conductor. Mostly, Deionized water, silicon oil, glycol, kerosene oil is used as dielectric in ed machining.

How does it work?

Here is a working explanation of electric discharge machining, step by step-

As the pulse of DC electricity reaches the electrode and applies an intense electrical field develops in the gap.

Microscopic contaminants suspended in the dielectric fluid are attracted by the field contrasted in the field’s strongest point.

These contaminants build a high conductive bridge across the gap.

As the field’s voltage increases, the material of the conductive bridge heats up.

Some pieces are ionized to form a spark channel between the electrode and the workpiece.

At this point, Both the temperature and pressure in the channel rapidly increase, generating a spark.

A small amount of material is melt and vaporized from the electrode and the workpiece at the point of spark contact.

Hence, metal removal in electric discharge machining takes place through Spark erosion.

Introduction-

Electrochemical machining(ECM) is developed by W. Gussef in 1929. In this process, the material removal takes place using an Electrochemical process.

This machining process is usually used to remove metal from extremely hard materials or materials that are difficult to machine using conventional processes.

Want to know about the electrochemical machining process, from scratch to end?

Then, you landed in the right place.

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Table of Contents

What is Electrochemical machining?-

It is the method of removing metal from the electrochemical process, where DC current is passed between the tool(cathode) and workpiece(Anode) through an electrolyte is known as ECM machining.

In this process, a combination of electrical energy and chemical energy is used to remove materials from the workpiece.

Working Principle-

Electrochemical machining works based on Faraday’s laws of electrolysis.

The amount of metal removed by machining or deposited is calculated from faraday’s laws of electrolysis, Which states that-

The amount of mass removed by machining, m, is directly proportional to the amount of electricity.

m ∝ It

The amount of different substances dissolved, m, by the same quantity of electricity(It) is proportional to the substances chemical equivalent weight.

m ∝ ∈

Where ∈ = Chemical equivalent weight.

Here,

ECM uses s direct current at a high density of 0.5 to 5 A/mm² and a low voltage of 10 to 30V.

The machining current passes through the electrolytic solution that fills the gap between an anodic workpiece and a pre-shaped cathodic tool.

The electrolyte is forced to flow through the interelectrode gap at high velocity, usually more than 5m/s to intensify the mass and charge transfer through the sublayer near the anode.

The electrolyte removes the dissolution products, such as metal hydroxide, heat, and gas bubbles, generated in the interelectrode gap.

The example of the dissolution reaction of iron in sodium chloride(NaCl) water solution as an electrolyte.

The result of electrolyte dissolution and Nacl dissolution leads to-

The negative charge anions OH– and Cl– moved towards the anode and positively charged cations of H+ and Na+ are directed to the cathode. At the anode, Fe changes to Fe++ by losing two electrons.

Fe→ Fe++ + 2e

At the cathode, the reaction involves the generation of hydrogen gas and hydroxyl ions.

2H2O+2e→H2 +2(OH)–

The outcome of these electrochemical reactions is that iron ions combine with other ones to precipitate out as iron hydroxide, Fe(OH)2

Fe+2H2O→Fe(OH)2+H2

The ferrous hydroxide may react further with water and oxygen to form the ferric hydroxide, Fe(OH)3

4Fe(OH)2+2H2O+O2→4Fe(OH)3

With this metal electrolyte combination, electrolysis has involved the dissolution of iron, from the anode and the generation of hydrogen, at the cathode.

Electrochemical Machining Equipment & Construction-

There are several electrochemical machining equipment used to construct the electrochemical machine in the electrochemical machining process-

Dc power supply

Table

Workpiece

Tool

Feed Unit

Electrolyte

Pump

Filter

Pressure gauge

Flow Meter

Dc power supply-

The DC power supply used in this process is from 3 to 30V. The DC power supply is used to create a potential difference between the workpiece and the tool and make them act as anode and cathode respectively.

Table-

The table used to hold the workpiece on the top of it.

Workpiece-

This the object from which material is to be removed. The workpiece is connected to the positive terminal of the DC power supply and acts as an anode.

Tool-

This tool is connected to the negative terminal and acts as a cathode.

The too(cathode) should have good thermal conductivity and electrical conductivity and also should be corrosion proof.

The most commonly used tools in the ECM machining process are stainless steel, brass, copper, etc.

Feed Unit-

It is used to constantly move the tool downward towards the workpiece.

Electrolyte-

The electrolyte is used to establish an electrical connection between the anode and the cathode so that positive and negative ions flow from these two.

The electrolyte is used to remove the heat produced from the passage of the current.

The most commonly used electrolyte used in the ECM process is salt electrolytes like sodium chloride and sodium nitrate.

Pump-

This pump is used to pump the electrolyte towards the gap between the cathode and anode.

Filter-

The filter is used to filter the electrolyte and remove the unwanted particles from the electrolyte.

Pressure gauge-

The pressure gauge is used to control the pressure at which the electrolyte is supplied to the system of electrochemical machining.

Introduction-

Using Water Jet Machining, A jet of water to cut a sheet of metal may sound impossible, but it is actually based on the principle we learn early in our lives.

A simple example is of Water Jet is- When a finger is put over part of the tap, the stream of water flows with higher pressure so that it washes away mud far more effectively, giving a jet-cleaned item.

Welcome to Engineers Rail, the ultimate source for all the engineering queries.

In this article, you will know all about water jet machining, From scratch to end. So, grab your seat and get relaxed while I start the Engine of the Knowledge.

Now, I am heading you the main-stream of the article. So, here we go…

What is Water Jet Machining?

Definition- A Non-conventional machining process In which a high-velocity water jet is used to remove materials from the surface of the workpiece.

Water jet machining(WJM) is a mechanical energy based non-traditional machining process used to cut and machine soft and non-metallic materials.

It uses the high-velocity water jet to cut a non-metallic workpiece smoothly.

However, It is just similar to Abrasive jet machining.

Working Principle of water jet machining-

It works on the principle of water erosion.

When a high-velocity water jet strikes the surface, the removal of metal takes place.

Types of water jet machining-

There are basically two types of water jet machining-

Water Jet cutting

Abrasive Jet Cutting

(I) Water Jet Cutting–

It is the type of machining that uses only water jet force to cut soft or non-metallic materials like wood and plastics. Rubber, foam, paper, cloths and foods.

Here is the Water jet cutting thickness, which can be considered during operation-

MaterialsThicknessRubber15mmFoam15mmPlastic8 mmPaper3mm

(II) Abrasive water jet machining–

Abrasive water jet cutting is the type of machining where abrasives are used to increase the cutting power of machining.

Adding abrasives with a water jet gives the ability to cut hard materials.

Through this abrasive water jet machining process, Hard materials like- titanium, steel, aluminium can be easily cut down.

Abrasive materials used-

The abrasives used in abrasive water jet machines are- Garnet, aluminium oxide(Al₂O₃), glass, sand.

This raises the force to cut and makes it able to cut harder materials.

Parts and construction-

Various part is used to construct the Water jet machine-

Storage tank

Pump

Intensifier

Tubing

Accumulator

Control valve

Nozzle

Regulator

Drain System

(I) Storage Tank-

The storage tank is also called a reservoir, which stores the water inside it and acts as permanent water storage.

(II) Pump-

The pump is used to connect the storage tank to the intensifier.

(III) Intensifier-

An intensifier is used to intensify the liquid pressure. In general, It increases the pressure of water and gives a high-pressure water jet.

Water pressure is used for cutting is- 200–400mPa or can be varied according to the workpiece.

(IV) Tubing-

High-pressure tubing is used to transport fluid from one system component to another system component.

The tubing may be made from a solid stainless steel wall or composite wall with stainless steel inside and carbon steel as a jacket.

Tubing may be used to pressurize fluids at a pressure greater than the yield stress of the tube material.

(V) Accumulator-

The accumulator is the support system of the reservoir, Where water is stored in the accumulator temporarily.

This temporary water may be used, in case of reservoir failure.

(VI) Control valve-

a control valve is used to control the flow and direction of the water jet.

(VII) Nozzle-

Nozzle meant to convert the high-pressure liquid to a high-velocity jet. Hence, pressure energy is converted into kinetic energy through the nozzle and water hits the workpiece with intensify pressure.

For the minimum erosion, the Material should be extremely hard. Nozzle made of sintered diamond or sapphire is used.

Diamond, tungsten carbide and special steel are also used to make nozzles.

The diameter of a nozzle is usually 0.05–0.35mm.

Fig- Systematic diagram of Nozzle

(VIII) Regulator-

The flow regulator is used to regulate the flow of the water jet.

(IX) Drain System-

When the water jet goes through cutting, it mixed up some wear and tear particles into the water, makes it unable to reuse. Then, the Drain system comes into play. It cleans the water and makes it reusable and sends it to the storage tank.

Working of Water Jet Machining-

Initially, water from the reservoir is pumped to the intensifier using a hydraulic pump.

Instifier increases the pressure of water up to 200–400mPa.

An excess supply of water sends to the accumulator for temporary storage.

Then the required quantity of pressurized water enters the nozzle through a control valve and flow regulator.

In case you missed it, the Control valve controls the direction of the water. flow regulator controls and regulate the flow of water and the nozzle converts the pressure energy of water into kinetic energy of water having very high velocity, approx 900m/s.

When a water jet strikes with very high velocity, it induces a trace on the workpiece.

These induced traces further intensify, causing the removal of material for the workpiece.

Fig.- Systematic diagram of Water machining process-

Process Parameters-

Various water jet machining process parameters are given below-

Standoff distance

Fluid pressure

Feed rate

Jet fluid

Nozzle diameter

Standoff distance-

It is the gap between the jet nozzle and the workpiece.

Material removal increases with the increase of stand-off distance up to a certain limit and then falls gradually.

Its values normally lie between 3–25mm.

Fluid pressure-

Cutting at a higher water jet is faster and increased pressure increasing the depth of the cut.

Feed rate-

Thick materials can be machined without difficulty at high jet pressure and low feed rate.

Jet fluid-

It must have low viscosity, minimized energy use, common and inexpensive.

Nozzle diameter-

The internal diameter of the nozzle ranges from 0.07–0.50mm.

Nozzle material should be wear-resistant and easily maintain.

Abrasive Jet Machining Definition-

Abrasive jet machining(AJM) uses a stream of fine-grained abrasive mixed with air or some other carrier gas at high pressure directed by nozzle on the work surface, where metal removal occurs due to erosion caused by the abrasive particle impacting the work surface at the high speed.

Principle-

In abrasive jet machining, the material is removed by the erosive action of a high-velocity stream of fine abrasive particles transmit on the work surface.

Parts and construction-

Here are several parts and construction of the Abrasive Jet Machining-

Air compressor

Air Filter

Pressure Gauge

Flow Regulator Valve

Mixing Chamber

Hoper

Vibrator

Nozzle

Working principle of Abrasive Jet Machining-

Step by Step guide of abrasive jet machining working-

Firstly, Air is drawn to the air compressor, where the air is pressurized in between 25-130psig.

After the compressor, pressurized air goes to the filter, Where the air is filtered from any atmospheric impurities in the air.

Now, Pressure is monitored with the help of a Pressure gauge and the next Abrasive jet flow is regulated through a regulator valve. And then, Air passes to the mixing chamber, where the abrasive particle is fed with the help of hoper to the mixing chamber.

Read in-depth working Here

Process Parameters-

The parameters that influence the rate of metal removal rate(MRR) and accuracy of the machining in this process are-

Carrier gas

Types of abrasive

Size of abrasive grain

The velocity of abrasive jet

Work material

Nozzle design

I hope you liked it.

The present trend is towards the development of material removal processes that employ primarily non-mechanical energy.

‘Abrasive Jet’ and ‘Ultrasonic machining’ methods are important because of certain special characteristics with which electrochemical, chemical or thermal processes can not compete.

Welcome to Engineers Rail, Here you are going to get complete information about the Ultrasonic machining process, from scratch to end.

So, Grab your seat and feel comfortable, while I am connecting you to the mainstream of the article.

So, without further delays, let’s Get Started…

Before I start, It would be nice to have a brief overview of Ultrasonic sound and waves, So, you can connect more easily later on. So, here it is-

The term ‘Ultrasonic’ is used to describe a vibratory wave of a frequency above that of the upper-frequency limit of the human ear.

It generally embraces all frequencies above about 16kc/s.

There are two types of waves, Namely-

(I) Shear Waves

(ii) Longitudinal Waves

Where Longitudinal waves are mostly used in ultrasonic applications since they are easily generated. They can be propagated in solids, liquids and gases and can travel at a high velocity So that their wavelength is short in most media.

Now, Move to the mainstream of the article-

Table of Contents

What is Ultrasonic Machining?-

Ultrasonic machining(USM) is a process of Non-conventional machining process, In which material is removed due to the action of Abrasive Grains.

The abrasive particles are driven in the work surface by the tool oscillating normal to the work surface at a high frequency.

Principle-

As you know, Ultrasonic is a high-frequency sound wave. Where A receiver generates high-voltage electrical pulses and a transducer converts those electrical pulses to high-frequency ultrasonic waves.

Types of Ultrasonic Machining-

There are two types of USM–

Rotary Ultrasonic Machining(RUM)

Chemical assisted ultrasonic machining(CUSM)

(I) Rotary Ultrasonic Machining(RUM)-

It is the mixer of both unconventional ultrasonic machining and conventional Diamond grinding process get together to produce Higher metal removal rate(MRR), enhanced hole accuracy with improved surface finish.

RUM can easily remove metals even from difficult to machine materials like- Ductile materials, Hard and brittle materials, ceramics and composites materials etc.

(II) Chemical Assisted Ultrasonic Machining(CUSM)-

This machining process is the same as USM, the only difference is the Liquid media used, CUSM uses chemicals like hydrofluoric acid instead of water used in USM.

This change in phenomena helps to improve metal removing rate and overall surface finishing in general.

Introduction-

There has been a rapid growth in the development of harder to machine metals and alloys during the last two decades.

Here, you will know about the Conventional and Non-Conventional machining processes and their differences.

So, grab your seat in Engineers Rail and relax, while I start the engine and take you to the Knowleable journey.

So, Let’s get started…

Before I jump to the topic of the article, It would be nice to let get an overview of these terms before. What do you say?

♦There is two types of Metal removal process–

Conventional Machining Process

Un-Conventional Machining Process

Conventional Machining Process-

As the name suggests, the Conventional Machining process is- Where the metal removing process is done manually or physically. This machining process is also known as the Traditional Machining process.

Conventional machining is uneconomical for such materials and the degree of accuracy and surface finish attainable is poor.

These are some examples of the same.

Example of Conventional machining process–

Turning

Boring

Drilling

Milling

Shaping

Sawing

Planing

Broaching

Slotting

Reaming

Grinding

Tapping

These were some examples of the Traditional machining process, Now let’s talk about some advantages of the Traditional machining process.

Advantages of Conventional Machining Process–

Here are some advantages-

The complex specimen can be machined

Easy setup

Economical

Non-Conventional Machining Process-

Non-conventional machining processes are those- where the metal removal process is done through mechanical, electrochemical, chemical, thermoelectric and without involving conventional tools. It is also known as the Modern Machining process or Un-Traditional Machining process.

Merchant(1960) emphasized the need for the development of newer concepts in metal machining. By adopting a unified programme and utilizing the result of basic and applied research.

The newer machining processes are often called ‘modern machining process’ or ‘Unconventional machining process methods’. These are unconventional in the sense that conventional tools are not employed for metal cutting, instead energy.

Example of Un-conventional machining process-

Ultrasonic Machining(USM)

Abrasive Jet Machining(AJM)

Water Jet Machining(WJM)

Electrochemical Machining(ECM)

Electrochemical Grinding(ECG)

Electrochemical Deburring(ECD)

Electrochemical Honing(ECH)

Chemical Machining(CHM)

Electric Discharge Machining(EDM)

Plasma Arc Machining(PAM)

Electron Beam Machining(EBM)

Neutral Particle Etching(NPE)

Laser Beam Machining(LBM)

Hot Machining(HM)

Classification of Un-conventional Machining Process-

The classification of modern machining processes is based on the type of energy used, the metal removal mechanism, and the source of energy requirement.