Abstract
Advanced engineering materials, including inter alia fiber-reinforced composites, super alloys, and ceramics, offer superior thermal, physical, chemical, and mechanical properties in the form of better strength, higher weight-to-volume ratio, improved corrosion, and wear resistance, to name a few. These properties have permitted the design of products with better properties, but they have also made these advanced materials difficult to machine by conventional machining processes thus making them unsuitable and uneconomical. Complex 3-D forms, tight tolerances, acute surface finishes, and stringent design constraints have necessitated research of new machining methods capable of processing the difficult-to-machine advanced materials economically and accurately. The basic idea behind a hybrid machining process is the synergistic combination of constituent machining processes in order to overcome their individual shortcomings and achieve effective material removal. This chapter has summarized some important aspects of the literature on hybrid machining processes. Machining processes in general are categorized into mechanical, thermal, chemical, and electrochemical processes based on their dominant material removal mechanism. Working principles and mechanisms material removal of existing hybrid processes and their capabilities have been discussed. It is noted that the complex physicochemical, electrical, thermal, and mechanical interactions associated with hybrid machining processes are yet to be fully understood, and there exists a knowledge gap due to the unresolved issues.
Similar content being viewed by others
References
Aspinwall DK et al (2001) Hybrid high speed machining (HSM): system design and experimental results for grinding/HSM and EDM/HSM. Ann CIRP 50(1):145–148
Basak I, Ghosh A (1996) Mechanism of spark generation during electrochemical discharge machining: a theoretical model and experimental verification. J Mater Process Technol 62(1–3):46–53
Basak I, Ghosh A (1997) Mechanism of material removal in electrochemical discharge machining: a theoretical model and experimental verification. J Mater Process Technol 71(3):350–359
Bhattacharyya B, Doloi BN, Sorkhel SK (1999) Experimental investigations into electrochemical discharge machining (ECDM) of non-conductive ceramic materials. J Mater Process Technol 95(1–3):145–154
Brehl DE, Dow TA (2008) Review of vibration-assisted machining. Precis Eng 32(3):153–172
Cao XD, Kim BH, Chu CN (2009) Micro-structuring of glass with features less than 100 μm by electrochemical discharge machining. Precis Eng 33(4):459–465
Cook NH, Foote GB, Jordan P, Kalyani BN (1973) Experimental studies in electro-machining. Trans ASME J Eng Indus 95(4):945–950
Curodeau A et al (2008) Ultrasonic abrasive μ-machining with thermoplastic tooling. Int J Mach Tool Manuf 48(14):1553–1561
Curtis DT et al (2009) Electrochemical superabrasive machining of a nickel-based aeroengine alloy using mounted grinding points. CIRP Ann Manuf Technol 58(1):173–176
Dabrowski L, Marciniak M, Szewczyk T (2006) Analysis of abrasive flow machining with an electrochemical process aid. J Eng Manuf 220(3):397–403
De Silva AKM et al (2011) Thermal effects in laser assisted jet electrochemical machining. CIRP Ann Manuf Technol 60(1):243–246
Endo T, Tsujimoto T, Mitsui K (2008) Study of vibration-assisted micro-EDM – the effect of vibration on machining time and stability of discharge. Precis Eng 32(4):269–277
Huang H et al (2003) Ultrasonic vibration assisted electro-discharge machining of microholes in Nitinol. J Micromech Microeng 13(5):693
Hur J et al (2002) Hybrid rapid prototyping system using machining and deposition. CAD Comput Aid Des 34(10):741–754
Jain VK, Chak SK (2000) Electrochemical spark trepanning of alumina and quartz. Mach Sci Technol 4(2):277–290
Jain VK, Rao PS, Choudhury SK, Rajurkar KP (1991) Experimental investigations into travelling wire electrochemical spark machining (TW-ECSM) of composites. J Eng Ind 113:75–84
Jain VK, Choudhury SK, Ramesh KM (2002) On the machining of alumina and glass. Int J Mach Tool Manuf 42(11):1269–1276
Jui SK, Kamaraj AB, Sundaram MM (2013) Fabrication of high aspect ratio micro holes in glass by micro electrochemical discharge machining. Submitted to NAMRI/SME, vol 41
Kasashima N, Kurita T (2012) Laser and electrochemical complex machining of micro-stent with on-machine three-dimensional measurement. Opt Lasers Eng 50(3):354–358
Kim J-D, Choi M-S (1995) Simulation for the prediction of surface-accuracy in magnetic abrasive machining. J Mater Process Technol 53(3–4):630–642
Kim S et al (2010) Hybrid micromachining using a nanosecond pulsed laser and micro EDM. J Micromech Microeng 20:015037
Knights M (2005) Hybrid prototyping process combines casting and machining. Plast Technol 51(10):45–51
Komanduri R, Lucca DA, Tani Y (1997) Technological advances in fine abrasive processes. Ann CIRP 46(2):545–596
Kozak J (1996) The analysis of the interactions of mechanical abrasion and electrochemical dissolution processes in AECG. In: Proceedings of the 19th Science Symposium on Abrasive Machining, Łódź, pp 275–282 (in Polish)
Kozak J, Oczos KE (2001) Selected problems of abrasive hybrid machining. J Mater Process Technol 109(3):360–366
Kozak J, Rajurkar KP (2000) Hybrid machining processes evaluation and development. In: Proceedings of the second international conference on machining and measurements of sculptured surfaces, Kraków, Poland, pp 501–536
Kuo C-L, Huang J-D, Liang H-Y (2003) Fabrication of 3D metal microstructures using a hybrid process of micro-EDM and laser assembly. Int J Adv Manuf Technol 21(10–11):796–800
Kurita T, Watanabe S, Hattori M (2001) Development of hybrid micro machine tool. In: Proceedings of the second international symposium on environmentally conscious design and inverse manufacturing, Kraków, Poland, pp 797–802
Lauwers B (2011) Surface integrity in hybrid machining processes. Proc Eng 19:241–251
Lee SJ (2005) Micro/meso-scale shapes machining by micro EDM process. Int J Kor Soc Precis Eng 6(2):5–11
Lim H, Kumar AS, Rahman M (2002) Improvement of form accuracy in hybrid machining of microstructures. J Electron Mater 31(10):1032–1038
Liu HS et al (2006) Application of micro-EDM combined with high-frequency dither grinding to micro-hole machining. Int J Mach Tool Manuf 46(1):80–87
McGeough JA (2002) Micromachining of engineering materials. Marcel Dekker, New York, 397
Mediliyegedara TKKR et al (2005) New developments in the process control of the hybrid electro chemical discharge machining (ECDM) process. J Mater Process Technol 167:338–343
Mognol P et al (2006) High speed milling, electro discharge machining and direct metal laser sintering: a method to optimize these processes in hybrid rapid tooling. Int J Adv Manuf Technol 29(1–2):35–40
Murti V, Philip P (1987) An analysis of the debris in ultrasonic-assisted electrical discharge machining. Wear 117(2):241–250
Pa PS (2007) Electrode form design of large holes of die material in ultrasonic electrochemical finishing. J Mater Process Technol 192–193:470–477
Pa PS (2009) Super finishing with ultrasonic and magnetic assistance in electrochemical micro-machining. Electrochim Acta 54(25):6022–6027
Pajak PT et al (2006) Precision and efficiency of laser assisted jet electrochemical machining. Precis Eng 30(3):288–298
Radhakrishnan G et al (2003) Hybrid pulsed laser deposition and Si-surface-micromachining process for integrated TiC coatings in moving MEMS. Appl Phys Mater Sci Process 77(2):175–184
Rajurkar KP et al (2006) Micro and nano machining by electro-physical and chemical processes. Ann CIRP 55(2):643–666
Reyntjens S, Puers R (2001) A review of focused ion beam applications in microsystem technology. J Micromech Microeng 11(4):287–300
Schuh G, Kreysa J, Orilski S (2009) Roadmap “Hybride Produktion”–Wie 1+ 1= 3-Effekte in der Produktion maximiert werden können. ZWF – Zeitschrift für wirtschaftlichen Fabrikbetrieb 104(5):385–391
Shabgard M, Sadizadeh B, Kakoulvand H (2009) The effect of ultrasonic vibration of work-piece in electrical discharge machining of AISIH13 tool steel. World Acad Sci Eng Technol 52:392–396
Skoczypiec S (2011) Research on ultrasonically assisted electrochemical machining process. Int J Adv Manuf Technol 52(5):565–574
Sommer C (2000) Non-traditional machining handbook. Advance Pub, Houston, 432
Srivastava V, Pandey PM (2012) Effect of process parameters on the performances of EDM process with ultrasonic assisted cryogenically cooled electrode. J Manuf Processes 14:393–402
Stephen A, Vollertsen F (2010) Mechanisms and processing limits in laser thermochemical machining. CIRP Ann Manuf Technol 59(1):251–254
Sugioka K et al (2002) Microprocessing of glass by hybrid laser processing. Proc SPIE 4760(I):230–238
Sundaram M, Pavalarajan G, Rajurkar K (2008) A study on process parameters of ultrasonic assisted micro EDM based on Taguchi method. J Mater Eng Perform 17(2):210–215
Tandon S et al (1990) Investigations into machining of composites. Precis Eng 12(4):227–238
Tong H, Li Y, Wang Y (2008) Experimental research on vibration assisted EDM of micro-structures with non-circular cross-section. J Mater Process Technol 208(1–3):289–298
Wang X, Ying B, Liu W (1996) EDM dressing of fine grain super abrasive grinding wheel. J Mater Process Technol 62(4):299–302
Wang ZY et al (2003) Hybrid machining of Inconel 718. Int J Mach Tool Manuf 43(13):1391–1396
Wang W et al (2011) Abrasive electrochemical multi-wire slicing of solar silicon ingots into wafers. CIRP Ann Manuf Technol 60(1):255–258
Wüthrich R, Fascio V (2005) Machining of non-conducting materials using electrochemical discharge phenomenon – an overview. Int J Mach Tool Manuf 45(9):1095–1108
Yan BH et al (2002) Study of precision micro-holes in borosilicate glass using micro EDM combined with micro ultrasonic vibration machining. Int J Mach Tool Manuf 42(10):1105–1112
Yang I, Park MS, Chu CN (2009) Micro ECM with ultrasonic vibrations using a semi-cylindrical tool. Int J Precis Eng Manuf 10(2):5–10
Yeo SH, Murali M, Cheah HT (2004) Magnetic field assisted micro electro-discharge machining. J Micromech Microeng 14(11):1526–1529
Zheng Z-P et al (2007) 3D microstructuring of Pyrex glass using the electrochemical discharge machining process. J Micromech Microeng 17(5):960
Zhu D et al (2011) Precision machining of small holes by the hybrid process of electrochemical removal and grinding. CIRP Ann Manuf Technol 60(1):247–250
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2014 Springer-Verlag London
About this entry
Cite this entry
Sundaram, M.M. (2014). Hybrid Machining Process . In: Nee, A. (eds) Handbook of Manufacturing Engineering and Technology. Springer, London. https://doi.org/10.1007/978-1-4471-4976-7_15-1
Download citation
DOI: https://doi.org/10.1007/978-1-4471-4976-7_15-1
Received:
Accepted:
Published:
Publisher Name: Springer, London
Online ISBN: 978-1-4471-4976-7
eBook Packages: Springer Reference EngineeringReference Module Computer Science and Engineering