Proses Pemesinan Non Tradisional part 2

Summary

This video script delves into non-traditional machining processes, specifically focusing on chemical machining. It explains key steps such as surface cleaning, applying masking materials like Cut and Pill or photoresist, and using chemical etching to achieve precise cuts and features. The script highlights the advantages of these methods in producing parts with fine tolerances and minimal defects, especially in industries like aerospace. Non-traditional techniques are especially valuable when traditional methods fail, offering improved precision and surface finish for complex or hard-to-machine components.

Takeaways

• 😀 Non-traditional machining processes using chemical energy can achieve high precision and handle complex shapes.
• 😀 Surface cleaning is the first step, ensuring proper adhesion of masking materials to the workpiece.
• 😀 Masking materials like stickers (Cut and Pill) and photoresist films are used to protect areas that won’t be machined.
• 😀 The 'Cut and Pill' method involves sticking material onto the surface to mark areas for machining, while photoresist provides finer control.
• 😀 Once masked, the workpiece is submerged in a chemical solution that reacts with the unmasked areas, eroding them.
• 😀 After machining, masking material is removed, and the workpiece undergoes a final cleaning process.
• 😀 Chemical machining provides finer tolerances than traditional methods like blanking, with a precision of up to 1/100th.
• 😀 Using chemical reactions for machining reduces material stress and risk of metallurgical defects compared to traditional subtractive methods.
• 😀 Non-traditional machining is ideal for materials that are too hard for traditional tools or when high precision is needed.
• 😀 This process is useful for creating complex features, such as small holes, deep holes, or non-circular shapes that are difficult to achieve with conventional machining.
• 😀 Non-traditional machining processes are compared with conventional methods like milling and grinding in terms of material removal rate, dimensional control, surface finish, and defect minimization.

Q & A

What are the general stages of a non-traditional machining process using chemical energy?

The process consists of four main stages: 1) Cleaning the material surface to be cut. 2) Applying a coating to mark areas that will be affected by the chemical process. 3) Submerging the material in a solution to dissolve the uncoated areas. 4) Cleaning the surface after the chemical reaction and removing any masking.

What is the difference between the Cut and Pill method and the photoresist method?

The Cut and Pill method involves applying a sticker-like mask to the material's surface to protect certain areas during the chemical reaction, resulting in a larger tolerance of up to 0.1. The photoresist method uses a negative film to apply a mask, allowing for much finer tolerances, around 1/100 of the Cut and Pill method.

How does the masking process influence the machining tolerance?

The masking process determines the precision of the cut. For example, the Cut and Pill method provides a larger tolerance, while the photoresist method offers significantly finer tolerances, resulting in a more accurate product with minimal material removal.

Why is non-traditional machining, especially using chemical energy, preferred in certain applications?

Non-traditional machining with chemical energy is preferred for processes that require very fine tolerances and minimal material loss, such as when making parts for aerospace. This method helps avoid the metallurgical defects commonly found in traditional subtractive machining.

What is the advantage of using chemical energy-based machining for surface quality?

Chemical energy-based machining provides superior surface finishes, especially for materials like magnesium. The process can result in smooth surfaces without significant roughness, which is a challenge in traditional machining methods.

How does chemical blanking compare to traditional blanking in terms of hole spacing?

Chemical blanking allows for much smaller hole spacing compared to traditional blanking. This method prevents adjacent holes from affecting each other, which is a common issue in conventional methods where holes might degrade or overlap.

How does the thickness of the masking layer affect the final tolerance in photoresist machining?

The thinner the masking layer, the finer the tolerance in photoresist machining. This allows for very precise cutting, as the masking layer can be applied with great accuracy, leading to smaller variations in the final product.

What materials are most suited for non-traditional machining processes?

Non-traditional machining processes using chemical energy are particularly suitable for hard materials that are difficult to machine with traditional methods. These include high-strength alloys and aerospace-grade materials.

What are some limitations of traditional drilling methods compared to non-traditional machining?

Traditional drilling methods can struggle with materials that are too hard, resulting in tool breakage. Additionally, deep or narrow holes can be problematic, as longer drills may deflect, causing vibrations and tool failure. Non-traditional machining can overcome these limitations by using chemical reactions for more precise and efficient cutting.

What types of components are typically manufactured using non-traditional machining techniques?

Non-traditional machining techniques are often used to manufacture components with complex geometries, such as thin walls, freeform shapes, and intricate holes. These include parts for aerospace, medical devices, and other high-precision industries.