What Is Hybrid Manufacturing and Classification of hybrid machining process
Technological improvement of machining processes can be achieved by combining different machining actions or phases to be used on the material being removed. A mechanical conventional single cutting or MA action process can be combined with the respective machining phases of electrodischarge (ED) in electrodischarge machining (EDM) or ECD in ECM. The reason for such a combination and the development of a hybrid machining process is mainly to make use of the combined advantages and to avoid or reduce some adverse effects the constituent processes produce when they are individually applied. The performance characteristics of a hybrid process are considerably different from those of the single-phase processes in terms of productivity, accuracy, and surface quality Depending on the major machining phase involved in the material removal, hybrid machining can be classified into hybrid chemical and electrochemical processes and hybrid thermal machining.
|Classification Of hybrid machining|
Hybrid chemical and electrochemical processes.
In this family of hybrid machining processes, the major material removal phase is either CD or ECD. Such a machining action can be combined with the thermal assistance by local heating in case of laser-assisted electrochemical machining (ECML). In other words, the introduction of the mechanical abrasion action assists the ECD machining phase during electrochemical grinding (ECG) and electrochemical superfinishing (ECS).
Ultrasonic-assisted electrochemical machining (USMEC) employs an USM component with ECM. The mechanical action of the fluid jet assists the process of chemical dissolution in electrochemical buffing (ECB). Kozak and Rajurkar (2000) reported that the mechanical interaction with workpiece material changes the conditions for a better anodic dissolution process through mechanical depassivation of the surface. Under such conditions, removing thin layers of oxides and other compounds from the anode surface makes the dissolution and smoothing processes more intensive. Significant effects of the mechanical machining action have been observed with ultrasonic waves. The cavitations generated by such vibrations enhance the ECM by improving electrolyte flushing and hence the material removal from the machined surface.
Hybrid thermal machining.
In this case the main material removal mechanism is a thermal one. The combination of this phase with the ECD phase, MA action, and ultrasonic (US) vibration generates a family of double action processes. The triplex hybrid machining is also achievable by combining the electrodischarge erosion (EDE) phase, the ECD action, and the MA in grinding (G). Such a combination enhance the rate of material removal and surface quality in electrochemical discharge grinding (ECDG) and the other hybrid processes.