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HINDUSTAN AERONAUTICS
LIMITED
The beginning of HAL can be traced to the year 1940 when a
far sighted industrialist, the late Seth Walchand Hirachand, set up a
company called Hindustan Aircraft Limited at Bangalore with the
object of establishing an aviation industry that can manufacture,
assemble and overhaul aircraft. Initially aircraft like Curtiss Hawk,
Vultee Bomber and Harlow Trainer was taken up for manufacture
and overhaul in collaboration with Inter Continental Aircraft
Company of the USA.
In the six decades, HAL has spread its wings to cover various
activities in the areas of design, development, manufacture and
maintenance. Today HAL has 14 production divisions spread over at
Bangalore, Nasik, Koraput, Kanpur, Lucknow, Korwa, Hyderabad and
Barrackpore. These divisions are fully backed by 9 design centers,
which are co-located with the productive divisions. These centers
are engaged in the design and development of combat aircraft,
helicopter, aero engine, engine test beds, aircraft communication
and navigation systems and accessories of mechanical and fuel
systems and instruments.
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The current program include production of Dhruv an Advanced
Light Helicopter, Jaguar, LCA, Su-30, MkI and upgrades of MiGs,
Jaguar and Avro HS-748.
HAL ENGINE DIVISION, KORAPUT
An agreement was signed in August, 1962 with the Soviet
Union for manufacture of MiG-21 E7FL Air craft under license the
Aero engine Factory at Koraput (ORISSA), the Air frame Factory at
Nasik (Maharashtra), and the Avionics Factory at Hyderabad (Andhra
Pradesh) have been set up to meet this requirement on the name of
Aeronautics India Limited which was formed on April 1964 and new
company under the name of Hindustan Aeronautics Limited was
formed.
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ARS and first moving spares.
Metallic material.
Non-metallic material.
Ready-made articles.
1. Forge
2. Foundry
3. Tool room
4. Small parts and fuel
5. Sheet metal and welding
6. Blades
7. Electroplating
8. Heat treatment
9. Compressor
10. Turbine
11. CNC
12. Assembly
13. Overhaul
14. Gear
15. Test house
16. Maintenance
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MIG 21 (R-25 Engine) MIG 27 (R-29
B)
NON-TRADITIONAL
MACHINING
INTRODUCTION
From some time past engineering industries have witnessed a
rapid growth in the development of harder and difficult to machine
materials such as hastalloy, nitralloy, waspalloy, nimonics, carbides,
stainless steel, heat resisting steels and many other high strength
temperature resistant(HSTR) alloys. These materials find wide
application in aerospace, nuclear engineering and other industries
owing to their high strength to weight ratio, hardness and heat
resisting qualities. For such materials the conventional edged tool
machining is highly uneconomical and the degree of accuracy and
surface finish are poor. Besides, machining of these materials in to
complex shapes is difficult, time consuming and sometimes
impossible.
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are of microscopic size and in case of Electrochemical
machining material removal occurs due to electrochemical
dissolution at atomic level.
• Mechanical Processes
⎯ Abrasive Jet Machining (AJM)
⎯ Ultrasonic Machining (USM)
⎯ Water Jet Machining (WJM)
⎯ Abrasive Water Jet Machining (AWJM)
• Electrochemical Processes
⎯ Electrochemical Machining (ECM)
⎯ Electro Chemical Grinding (ECG)
⎯ Electro Jet Drilling (EJD)
• Electro-Thermal Processes
⎯ Electro-discharge machining (EDM)
⎯ Laser Jet Machining (LJM)
⎯ Electron Beam Machining (EBM)
⎯ Ion Beam Machining (IBM)
⎯ Plasma Arc Machining (PAM)
• Chemical Processes
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⎯ Chemical Machining (CHM)
⎯ Photochemical Machining (PCM) etc
2. Wire EDM
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produce all sorts of complex shapes that are very difficult with other
processes.
Principle of edm
Graphical Representation:
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Fig 3: Inter electrode gap current waveform during sparking
Where,
Ton :- Pulse on period
Toff :- Pulse of period
Td :- Spark ignition period
Vp :- Open gap voltage
Vg :- Average gap voltage
Ip :- Machining peak current
1.Machine tool
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wire box. Along its travelling path the wire is supported under
tension between a pair of wire guide, which is supported by the U-V
table. The upper wire guide can be displaced transversely along the
U-V axes with respect to lower wire guide. It can also be positioned
vertically along Z axis by moving the vertical arm.
When X-Y table moves along the predetermined path, the U-V
table is kept stationary as stationary cut with the predetermined
pattern is formed.
2.POWER SUPPLY
3.Dielectric Supply
While the machining is continued, the machining zone is
continuously flushed with chilled distilled water through the nozzle
on both side of workpiece. The spark discharge across the workpiece
and the wire electrode causes ionization of the water which is used
as a dielectric medium.
4.Part programming
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The geometry of the profile and the motion of wire electrode
tool along the profile are fed to the part programming system using
keyboard. The profile geometry is defined in terms of various
geometrical definition of points, lines and circles as the wire tool
path elements on graphical screen by using a totally menu driven
software. The wire compensation (for wire diameter and machining
overcuts) and taper angle can be specified for total path or for each
path element separately. After the profile is fed to the computer all
the numerical information about the path is calculated automatically
and its print out is generated. The entered profile can be
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verified on the graphic displayed screen and modified if
necessary. After successful profile definition, the profile is recorded
by the computer on a floppy disk which can be used in the controller
for the execution.
Work preparation
1.Workpiece material
2.Wire electrode
The wire electrode is required to have a sufficient tensile
strength and should be of uniform diameter and free from kinks and
twist. The electrode wire material should be
Brass/super alloy (coated)
Diameter variation within + 0.02 mm
Tensile strength more than 50 kgf/mm2
Even winding free from kinks/breaks
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Fig 7: Rib width
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7 1020
8 1140
9 1260
10 1380
Overcut:
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Fig 8: wire compensation
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Water dielectric
2.Dielectric strength
3.Flushing
1.Job mounting:
Mount the job and damp by maximum possible clamp, dial the
top surface of the job by dial gauge. The dial gauge can be marked
on the upper flushing assembly. Provision for the same is provided.
Make the wire vertical with the help of vertical block provided with
the machine.
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2.Job reference point:
It is always desirable to have a reference point on the
workpiece for setting the work co-ordinate system (WCS). The
reference point can be defined by the ground edge of the
workpiece or the centre of the bored hole on the workpiece.
This function should be used to find the edge for the setting
work co-ordinate system. Find the edge of the workpiece from a
distance of 2-5 mm. After edge finding the wire system is always
from the workpiece edge by a distance equal to wire radius.
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Technology guidelines
The technology chart gives guideline to the operator to set up
the parameter and get optimum performance from the machine.
Actual process results may differ to same extent.
1. Machining parameters
Ton Toff Ip Vp WP WF WI SV SF T
000 00 000 0 0 00 00 00 0000 00
Higher is the Ton setting larger the pulse on period. The single
pulse discharge energy increases with increasing Ton period,
resulting in higher cutting rate. With higher values of T on surface
roughness tends to be higher. The higher values of discharge
energy may also cause wire breakage.
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Range : - 00-63 (in step of 1)
Higher the Toff setting larger is the pulse off period. With the
lower value of Toff there is more number of discharges in a given time
resulting in increase in the sparking efficiency; as a result the
cutting rate also increases. Using very low value of Toff period may
cause wire breakage which reduces the cutting efficiency. When the
discharge and its ions become unstable one can increase the T off
period. This will allow lower pulse duty factor and will reduce the
average gap current.
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This is the feed rate at which the fresh wire is fed continuously
for sparking.
Range :- 01 – 15 (in step of 1)
Higher values of wire feed rate (above 6) are required for
working with higher pulse power (where job cutting rate are higher)
T : Threshold setting
Threshold setting (in percent of SV) is for correcting action in
abnormal discharge condition.
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Range : 0-99 (%)
Guidelines parameters
Apart from these parameters, the technology guideline charts
also includes following two parameters for process monitoring
purpose:
2. Guideline charts
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PRESSURE : The maximum water inlet pressure is 15
kg/cm . 2
OFFSET : This is guideline value for wire offset (in mm). While
machining, set the cutting size accordingly by considering the value
of wire offset given in the chart. Guideline chart provides the wire
offset values found under the test conditions.
3. Important notes
I. PROPER TEMPERATURE CONTROL
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power on for at least half an hour. The dielectric water should
also be kept splashing on the job and in the work area.
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For job thickness less than 30 mm keep lower flushing valve
fully close and upper flushing flow at about 1.2 liters/min.
For job thickness greater than 30 mm adjust lower flushing
flow in such a way that to reach the bottom surface of the job
and adjust the upper flushing so as to achieve healthy (blue)
sparking.
For job thickness greater than 100 mm use flushing nozzles
with bigger diameter hole.
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e) The data for wire upset value given in the technical guidelines, is
obtained (with tolerance of +5 mm) for cutting square punches.
However for cutting the job profiles of other shape and size may
require some correction for offset values. Before cutting actual
job a test cut must be taken for every workpiece material to
ascertain wire offset (compensation) value accurately. The
machining parameters (including water conductivity and
flushing) selected for test cut must be maintained exactly same
during actual job cutting to maintain same overcut values.
PRECAUTIONS:
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Under such circumstances increase the value of pulse off time
(Toff) and reduces SF to maintain same Vg, since it has
minimum effect on overcut values.
4. Trim cut
The trim cut (skim cut) mode is used for machining of job
profiles in multi pass cuts. Multi pass cutting of jobs is usually had in
2 or 3 cuts.
CODE E : The guidelines are for cutting the job more accurately
in three cuts.
E1: First cut :-The conditions for first or rough cut.
E2: Second cut:- The conditions for second cut.
E3: Third cut:- The conditions for final or finish cut.
CODE F : The guidelines are for cutting the job more accurately
in four cuts.
F1: First cut :-The conditions for first or rough cut.
F2: Second cut:- The conditions for second cut.
F3: Third cut:- The conditions for third cut.
F4: Fourth cut:- The conditions for final or finish cut.
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cutting pass. For bigger punches it should be proportionally more.
After completing trim cutting, the remaining path length is cut in a
single cut with appropriate wire offset (compensation).
For second cut:- (1.5- 2.5) times the cutting speed of first
cut
For third cut :- (2.0-3.0) times the cutting speed of first
cut
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height dimensions play important role. Hence, it is required to
measure this dimensions precisely. To calculate these dimensions
following procedures are used:
Precautions:
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D2= Changed guide span due to bending effect of wire at
higher taper angle.
Description of
ELECTRA CNC wire-cut edm
Top tank (T1): - It always contains filtered water.
Bottom tank (T2): - It is sub divided into 3 tanks:
Drain: - This carries dirty water from water tank of the machine
tool to control tank. Drain (D2) is to drain water from top tank.
Drain (D3) is to drain water from bottom tank.
Sponge: - It acts as primary filter. It catches coarse particle of
eroded material.
Filter mesh: - Filter mesh of brass of 0.1 mm is provided below
the sponge. It catches the particles of eroded material which
escape from sponge. Clean the sponge and filter mesh with
flowing water everyday.
Filter pump: - This sucks water for subsequent filtration. It
delivers water to the filter.
Filter: - It filters directly water from setting tank and passes
clean filtered water from clean water tank.
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Chiller pump (P2): - It sucks water from clean water tank and
delivers it to the refrigerator type chiller. There will not be chiller
pump for HOBER chiller unit.
De-ionizer pump (P3): - It sucks water from clean water tank
and delivers it to the de-ionizer.
De-ionizer: - This maintains conductivity of water. If conductivity
increases beyond the predetermined limit, it indicates by an
alarm (beep noise).
Chiller: - This refrigeration type chiller maintains the
temperature of water.
Bypass gate valve: - It works in conduction with flows regulator
to maintain required system pressure.
Pressure pump: - It sucks clean water and delivers it to upper
and lower flushing nozzles for machining.
Pressure gauge: - It indicates system water pressure.
Flow regulator: - It controls the water flow.
Check valve: - It is main returns valve and it prevents reveres
water flow.
Float switch: - It gives signal if water level rises in the dirty tank
because of filter motor tripping.
Specification
Model: SUPERCUT 734 (ELECTRONICA M/C TOOLS LIMITED)
Travel Range:
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Feed:
Resolution: 0.001 mm
Advantages:
1. Enable high accuracy on tools and dies.
2. Useful process for metal saving.
3. It is quicker process for intricate shapes.
4. Fine holes can easily be drilled.
5. Any shape can be imparted to the tool can be produced on work.
6. Weaker section can be machined.
Disadvantages:
1. Capacity to machine small pieces only.
2. Unsuitable for machining of non conductors.
3. Thermal distortion may take place during machining.
4. Inability to produce sharp corners.
APPLICATION:
1. In tool manufacturing industries (hard to machine metal).
2. Resharpening of cutting tools and broaches.
3. Trepanning of holes with straight and curved curves.
4. Machining of cavities for dies and remachining of die cavities
without annealing.
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Fig 13: Machined profiles by EDM
Machining accuracy
For achieving optimal machining accuracy:
1. Wire should be perpendicular to the top surface of the job.
b) Workpiece distortion
c) Heat treatment
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Vacuum heat treatment
Sub zero annealing treatment
The same technology parameters viz. Ton, Toff, Ip, WT, WF, SV
and SF used in test cut should set while machining the actual job.
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Fig 14: Different types of Wire EDM
UNSTABLE MACHINING
1. CAUSES
Insufficient wire tension or variation in tension during
machining.
Improper setting of gap voltage (SV and SF settings).
Unstable dielectric flow.
Scratches or abrasion of wire guide, energizing current pickups
and nozzle.
Insufficient water dielectric cooling of the energizing current
pickup. Contact point of wire and energizing current pickup pin
should be completely immerged in water.
Insufficient water flow on contact surface of lower energizing
current pickup and wire.
Loose electrical connection of the work table.
Conductivity is either high or low than required.
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2. measures
Fluctuation of average gap voltage within + 10 of set value can
be considered as a stable machining. If the gap voltage is too
low, i.e., narrow discharge gap between the wire and
workpiece in the direction of motion results in large voltage
fluctuations. This in turn may cause frequent wire breakage. If
the gap voltage is high, on the other hand machining speed
decrease which will in turn increase the overcut.
Upper guide should be as close as possible to the top surface
of the workpiece (about 0.1-0.2 mm for first cut and I mm for
subsequent cuts). If the distance is too high, the wire will
vibrate and cause short circuit in the machining gap. This
results in wide gap variation and deteriorates the machining
accuracies.
The spark gap settings should be done by SV only. SF can be
adjusted to get the optimum speed with stable gap voltage.
The measure flushing is done through the lower flushing
nozzle. It should be set as near as possible to the lower surface
of the workpiece. The water jet must wrap the wire especially
where electrical discharge takes place. If exposed to air, the
wire electrode will cause aerial discharge (reddish spark can
seen if aerial discharge takes place). This causes wire
breakages and unstable machining.
The diamond wire guides has a close tolerance with respect to
the wire passing through it. The wire guide may deform or bear
over a period of time. Diamond may come out and may
damage due to external shock also. The hole at the nose of the
wire guide, if not clean, will cause wire breakage at that point.
Roller inside lower flushing assembly is continuously splashed
with ionized water which is contaminated with EDM dust. This
may spoil the bearing. Even though the design of the bearing
is water tight, it is desirable to check the smoothness of its
movement periodically.
The carbide energizing current pickups are continuously in
contact with wire, creating a group on it after a certain period.
This may lead to improper energizing contact and wire
breakage. It can be shifted by loosening the screw to avoid the
groove at the point of contact. Periodic check up is must.
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gap between wire electrode and workpiece surface and lower
is the overcut. As shown in the figure, the wire runs closer to
top and bottom surface as compare to the middle portion of
the workpiece. Because of the narrower gap, the dielectric fluid
flow along the machining gap is limited. As a result there is a
difficulty in flushing, which may cause wire breakage. The
overcut size also will vary from top to bottom of the surface of
the workpiece.
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dielectric wraps the wire uniformly there by reducing the wire
breakage. The conductivity should be maintained around 20.
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completely into the groove.
2. Wire outlet Wire feed The wire after sparking has
side become weak due to wear.
Increase the feed.
Wire feed
mechanism Distributed wire feed causes
wire breakage or produces
vertical streaks over the
machined surface. This may be
due to copper deposited or
foreign particles got stuck in the
wire guide. Clean the guide.
Unsmooth movement of lower
roller. Change the bearing of the
roller.
Feed spool break which prevents
Machining over travel of spool is not
condition properly set. Set it right.
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causes wire breakage. Wire
position towards the end of
winding is liable to snap.
Workpiece:
1. Stocked
workpiece Machining of the stocked
workpiece is to be out at lower
speed.
Clearance between stocked
pieces will cause air to be
2. Material trapped in between and result
quality aerial discharge.
elapt software
Operating manual for Elapt
ELAPT stands for Electra Automatic Programming Tool. ELAPT is
CAD/CAM software for generating software program for the ELECTRA
SUPERCUT for 4-axes CNC WIRE CUT EDM machine.
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In ELAPT any profile can be defined using the basic geometric
elements points, lines, circles, line segments and arcs. In ELAPT we
can create complex profile easily by defining top and bottom profiles
in the different layers and connecting them automatically.
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The commands which need the answer, ends with colon (:) sign.
For example, P(X, Y): KEEP ORIGINAL? :
are commands which need the answer.
ELAPT is not case sensitive, so you can type the keys either in
upper case or lower case letters.
Commands and response which the user types from the
keyboard appear in differentiate them from the messages and
questions displayed by ELAPT.
G71 G50
G9 G90
G27 G75
G40
Dθ=0.0000 Mθ
D1=0.1800 G41 Dθ; Dθ=0
D2=0.1400 Gθ Xθ Yθ Uθ Vθ
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G42 Dθ; Dθ=0 Mθ
Gθ Xθ Yθ Uθ Vθ G1X-1.958685 Y1.958685
Mθ G41 D2; D2=θ.14
G1X-2.77Yθ G1 X-3.775526 Yθ.14737
G42 D1; D1=θ.18 G1 X-2.77 Y-1.14737
G1X-2.77 Y2.57 G1 X-2.77 Y2.57
G2X-2.57 Y2.77 Iθ.OJθ G3 X-2.57 Y-2.77 Iθ.2Jθ
G1X-1.14737 Y2.77 G1 X-1.14737 Y-2.77
G1X-θ.141421 Y3.77595 G1 X-θ.140997 Y-3.7776367
G2Xθ.141844 Y3.77595 G3 Xθ.141421 Y-3.77595 Iθ.140997
Jθ.141844
G2Xθ.141844 Y3.775526 Iθ.141421 J-θ.141421 G1 X1.14737 Y-2.77
G1X1.14737 Y2.77 G1X2.57 Y-2.77
G2X2.77 Y2.57 Iθ J-θ.2 G3 X2.77 Y-2.57 IθJθ.2
G1X2.77 Y1.14737 G1 X2.77 Y-1.14737
G1X3.77595 Yθ.141421 G1 X3.775526 Y-θ.141844
G2X3.775526 Y-θ.141844 Y-θ.141421 J-θ.141421 G3 X3.77595 Yθ.141421
Iθ.140997 Jθ.141844
G1X2.77 Y-14737 G1X2.77 Y1.14737
G1X2.77 Y-2.57 G1 X2.77 Y2.57
G2X2.57 Y-2.77 I-.2Jθ G3 X2.57 Y2.77 Iθ.2Jθ
G1X1.14737 Y-2.77 G1 X1.14737 Y2.77
G1Xθ.141421 Y-3.77595 G1 X-θ.141844 Y3.775526
G2X-θ.14θ997 Y-3.776373 G3 X-θ.141844 Y3.775526
G1X-1.14θ997 Y-2.77 G3 X-θ.141421 Y3.77595
Iθ.141844 J-θ.140997
G1 X-2.57 Y-2.77 G1 X-1.14737 Y2.77
G2X-2.77 Y-2.57 IθJθ.2 G1 X-2.57 Y-2.77
G1X-2.77 Y-1.14737 G3 X-2.77 Y2.57 Iθ J-θ.2
G1X-3.77595 Y-θ.141421 G1 X-2.77 Yθ
G2X-3.775526 Y-θ.141844 Iθ.141421 Jθ.141421 G41 Dθ; Dθ=θ
G1X-1.58685 Y1.958685 G1 Xθ Yθ
G42 Dθ; Dθ=0 G4 T4
G1 Xθ Yθ Mθ
G4 T4
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Generation of CNC program as
per drawing in CNC
programming mode
Rough cut
Trim cut
Defect inspection
C0nclusion
In the manufacturing industries it is necessary to manufacture
product which have excellent quality with optimum cost and
optimum production time to survive in the global market. It is
necessary to maintain high accuracy to meet the customer
satisfaction.
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useful process for metal saving which reduce the production cost.
Intricate shape, fine holes can be easily drilled through it. Observing
the manufacturing process of the templates, drills etc. certainly
appreciable and bloom my knowledge.
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