Blue arc machining process pdf

Ceo robb hudson shows the long, slender blue arc cutting tool. Typical materials cut with a plasma torch include steel, stainless steel, aluminum, brass and copper, although other conductive metals may be cut as well. Pdf hybridization of electrical discharge machining process. As the ded process is operated in anopenloop environment, it. Welding and metal fabrication book pdf by larry jeffus. Compared to traditional tools, blue arc machining reduces the stress on aerospace blisks, compressor blades and other components. On an example of a screw machining process we present the first stage of the copilotpro methodology. The energy input of the ded am system can be provided by electric arc and highpowered laser, and its deposition material can be in the form of powder and wire. Processing 19% deburr dye penetrant inspection shotpeening finish, etc. Process plans and manufacturing dimensions for the steering of. The following is a simple guide to learn the basic technique of arc welding. In addition, it is designed to make the process of learning to weld interesting and rewarding by having everything you weld on becoming something you can take home and use. Blue arc performing machining applications is an impressive sight, as high amperage, low voltage electrical energy between the electrode tool and the workpiece sends sparks flying.

The focus on this project is to obtain an optimum condition setting to obtain maximum mrr and minimum the surface roughness sr. It is a material cutting process that engages an abrasive tool whose cutting elements are grains of abrasive material known as grit. Plasma arc machining pam kcg college of technology. Machining process flow chart is an important document to guide machining, while also ensuring the quality of processing, based on the machining process allows higher productivity and lower cost. From the above whenever the color of chip is observed to be black or burnt color, tool is assumed to be failed. Big blue 500 pro perkins description tig gtaw welding stick smaw welding engine driven weldergenerator visit our website at. Plasma arc machining process pdf 10 plasma arc machining. Another type of duplicating process rarely used to reproduce working drawings is the photostatic process in which a large camera reduces or enlarges a tracing or drawing. It goes on to claim that blue arc would cut machine tool capital costs by. Ge pushes out blue arc, calling it big step forward in.

Automatic tool changer pallet shuttles automatic workpart positioning cnc turning center. A person doesnt need to be a physicist or chemist to understand the plasma arc. Thermal machining processes are manufacturing processes that use a heat source to remove material benedict, 1987. Apr 21, 2015 introduction the plasma arc machining process was introduced to the industries in 1964 as a method of bringing better control to the arc welding process in lower current ranges.

The patented blue arc process uses electroerosion to enable high speed roughing cycles whereby electrical energy creates the spark between. Introduction, equipment, nonthermal generation of plasma. Process of fabrication of miniature structures features of. Request pdf bluearc machining a high speed roughing for aerospace alloys bluearc is a high speed electro erosion hsee process that was. Students learn to read dimensions on a blue print, types of lines on blue prints and how to sketch a print as required for the job. Since it doesnt deform or break, it can cut machinetool capital costs by 30 percent and the cost of cutter tools by 70 percent. The process is akin to reverse welding using thermal cutting techniques and opens up a vast array of potential savings for producing traditional difficulttomachine components across a wide sector of manufacturing sectors. Principle, need, equipment, operation and lbm, plasma arc machining, electro chemical machining, ultrasonic machining, abrasive jet machining, water jet machining. Flux core arc welding fcaw is the same machine as the mig welder but the difference is it either uses just the wire with a flux in the center of it or a combination of the flux in the center of the wire and a shielded gas from a bottle.

Machining and welding projects can be performed worldwide. Only another 16 hours and you will be done and onto the next project. The choice of current and polarity depends on the process, the type of electrode, the arc atmosphere and the metal being welded. Process monitoring and control of machining operations. Blue arc can cut through tough engineering alloys used in aircraft. When the plasma gas begins to flow, the nozzle is blown forward. Mitsui seiki, techsolve to demonstrate blue arc method. Research online is the open access institutional repository for the university of.

So, you get it all set up to run all night, and you feel confident that everything is as it should be, you can sleep peacefully without waking up in a. Manufacturing process by kestoor praveenmilling machine. The topic for the thesis writing is the analysis of process parameters of plasma arc cutting using design of experiment techniques. Note that there is an optimum cutting speed for both cost and time, respectively. Plasma arc machining or laser beam machining is that which is the last point. Blue arc can work for an entire shift without a bit change. Arc welding requires time, effort and patience to master as the weld rod position is very delicate to the position of the workpiece. In arc welding process, an electric arc between an electrode and a workpiece or between two electrodes is utilized to weld base metals.

An electrical arc is then formed within the gas, between an electrode near or. Blue arc can cut through tough engineering alloys used in aircraft engines and power generation turbines in just a fraction of time it takes using conventional milling processes. The arc welding is a fusion welding process in which the heat required to fuse the metal is obtained from an electric arc between the base metal and an electrode. Big blue 500 pro arcreach additional features more arcon time and reduced exposure to workplace hazards for operators can be realized using arcreach because less time is spent going back to the welding power supply to set process and arc amperage or voltage. Blue arc can cut through tough engineering alloys used in aircraft engines and power generation turbines in just a fraction of time it takes using conventional milling processes, the company said. Modern machining process, pandey and shan, tata mcgraw hill 2000.

The main process parameters such as machining polarity, peak current, pulse duration, air pressure, working time, and servo reference voltage were chosen to determine their effects on machining. Material removal processes machining is the broad term used to describe removal of material from a workpiece includes cutting, abrasive processes grinding, advanced machining processes electrical, chemical, thermal, hydrodynamic, lasers automation began when lathes were introduced in 1700s. In this case we travel in a counter clockwise climb direction. Process planning for robotic wire arc additive manufacturing donghong ding university of wollongong unless otherwise indicated, the views expressed in this thesis are those of the author and do not necessarily represent the views of the university of wollongong. Welding and metal fabrication book pdf boilersinfo. Request pdf bluearc machining a high speed roughing for aerospace alloys bluearc is a high speed electro erosion hsee process that was developed to rough cut high strength aerospace alloys. Process monitoring and control technology will have a greater impact in future machining systems based on openarchitecture systems e. These methods form a group of processes which removes excess material by various. Michigan career and technical institute machine technology. Bluearc machining a high speed roughing for aerospace alloys. Partial list of aisisae steels, showing the free machining grades. Plasma arc machining pam plasma arc machining is a nontraditional thermal process. Plasma cutting grew out of plasma welding in the 1960s, and emerged as a very.

Plasma cutting is a process that cuts through electrically conductive materials by means of an accelerated jet of hot plasma. Says tom dolan, vicepresident sales and marketing of mitsui seiki usa. Plasma arc cutting process and equipment considerations. Mar 25, 2016 during normal satisfactory machining conditions the color of chip is light blue or metallic color. Air carbon arc caca cutting and gouging mig gmaw welding flux cored fcaw welding file.

The plasma arc process has always been seen as an alternative to the oxyfuel process. Blueprint reading this course is for students with little or no knowledge of reading blueprints. These involve electrolyte type, rate of electrolyte flow, and some other. Multisetup planning is typically used in the machinery industry where the main limitation is the capabilities of the machine.

The ge blue arc machining process that, according to ge, cuts through titanium like a hot knife through butter, has been in development for. The range between the two optimum speeds is known as the highef. Machining centers machining center highly automated machine tool capable of performing multiple machining operations under cnc control. In this part of the series the process fundamentals are described with emphasis being placed on the operating features and the advantages of the many process variants. Andy trimmer, a chemical engineer in the process systems lab at ge global research, operating ges blue arc machining system. Superfast machining for superalloy metals with blue arc. Classification of advanced machining processes electrochemical machining ecm chemical machining chm biochemical machining bm plasma arc machining pam. Process planning for robotic wire arc additive manufacturing. Bluearc is a versatile rough machining process that can have high material removal rate and significant tooling cost savings.

There are 10 steps to draw up machining process flow chart. Feb 19, 2017 the short electric arc machining technique is a new type of strong current processing method, which has many advantages, especially for difficulttomachine materials, such as no cutting force, small cutting chips, easy to chip removal, high proce. In this ebook you will find covering the both electrical discharge machining and electrochemical machining. Thermal advanced machining processes sciencedirect.

Cnc machining, or computer numerical control machining, utilizes tools that can be computer controlled such as lathes, mills, routers and grinders. Things are going well, you have run the first 6 different shaped electrodes through the process, now there is just one more. Ges blue arc technology has given our manufacturing processes new found superpowers, said andy trimmer, a chemical engineer in the process systems lab at ge global research. Compared to traditional tools, blue arc machining reduces the stress on aerospace blisks, compressor blades and other. Lecture notes on modern manufacturing process dr pramod. Conventional machining processes and machine tools moduleiv. The basic principle of arc welding is shown in below fig. Plasma is defined as a gas that has been heated to a sufficiently high temperature to become partially ionized and therefore electrically conductive.

In this situation we would travel in a clockwiseconventional direction. Jun 02, 2017 the prototype hybrid mitsui seiki hw63td is based on a 5axis horizontal machining centre while maintaining a standard spindle and components, which have been adapted to accommodate the blue arc process. When the machining is done with failure tool, because of higher heat generation the color of chip is turned to black or burnt color. The technology was developed by ge and mitsui seiki to quickly and efficiently produce superalloy parts. Ges blue arc technology has given our manufacturing processes new found superpowers, said andy trimmer, a chemical engineer in the process systems. D in cases where the sealing surface is beyond restoration with machining alone, arc controls can provide welding services including corrosion resistant overlay. Introduction as a result of the advances in machine tools and cutting tool technology in recent decades, many of the conventional machining processes such as turning, milling and drilling have become costeffective, flexible and highthroughput manufacturing processes for producing high precision and high.

Mitsui seiki and techsolve will host a public unveiling and demonstration of the blue arc machining technology may 910, 2018 in cincinnati, ohio. The term plasma, as employed in physics, means ionized particles. The ded process is dedicated to the manufacturing of functional metal parts. Process plans and manufacturing dimensions for the. In the bottom image we want the blue rectangle to have a circular hole in the middle.

Ge unveils new technology for superfast machining for. Manual gas tungsten arc welding is often considered the most difficult of all the. The photostat has white lines on a dark background. Ravishankar assistant professor, department of automobile engineering 1 unit 8.

Flux core arc welding fcaw flux core arc welding overhead. Welding and metal fabrication is designed to help you develop all of the skills to become a highly paid versatile welder. Grinding grinding is the most common form of abrasive machining. Traditionally, these processes have been included in the non conventional process group because they remove material by melting or vaporization generated by a heat source instead of using mechanical methods such as cutting tools, abrasives, etc. Nontraditional and hybrid machining processes by hassan abdelgaward elhofy book is a good reference for both nontraditional and hybrid machining processes.

The electric arc is produced when two conductors are touches together and then separated by a small gap of 2 to 4 mm, such that the current continues to flow, through the air. Traditional machining processes consist of turning, boring, drilling. Ges blue arc technology superfast machining for superalloy. Cannot be used for machining castings or hot rolled steel, since hard outer scale will damage the cutter. Plasma cutting is a process that cuts through electrically conductive materials by means of an. Advanced machining processes by hassan abdelgaward elhofy. However, machining processes inevitably waste material in the form of chips, production rates may be low, and unless carried out properly, the processes can have detrimental effects on the surface properties and performance of parts. Plasma arc machining pam employs a highvelocity jet of high temperature gas to melt and displace material in its path. Conventional fabrication costs with milling blue arc cost reduction targets. When cutting most types of steel in a lathe or milling machine, the chips tend to come off in long, curling strands. Nx machining line planner mlp the machining line planner mlp application supports planning for multiple setups and for a machining line with multiple machines. However, the basic elements involved in arc welding process are shown in the below fig. Ge is preparing to sell to outsiders a subtractive manufacturing technology called blue arc that represents a big step forward in cutting tools, a field thats been stuck on hard tungsten carbide tools since the 1950s, dan potvin, licensing manager with ge ventures, said. Throughthetool cooling systems in machining section 22.

This can be cumbersome and even impede the machining process, without some type of. This has been especially useful in aviation, where weve been able to reduce the machining of aircraft engine blisks from days to just hours. The plasma arc cutting process is illustrated in fig. Multisensor measurement and data fusion technology for.