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BMMP 3533 ADVANCED

MANUFACTURING PROCESSES

• zolkarnain@utem.edu.my
• 013-6666057
• Room : 1FL/R/BP55 or Fabrication Lab
CHAPTER
ONE Introduction to Advanced Manufacturing
Processes

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Processes

Terminology

MODERN MACHINING PROCESSES (MMP)

ADVANCED MACHINING PROCESSES

UNCONVENTIONAL MACHINING PROCESSES

NON-TRADITIONAL MACHINING PROCESSES

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Processes

Traditional vs. Non-traditional Processes

1. Unlimited capabilities compare to traditional processes i.e.

removal rates increase, cost effective of operations and greater
usage.

2. Mostly using computer control of the process parameters

ensures reliability and repeatability.

3. Capable of being adaptively-controlled through the use of vision

systems, laser gages, in process inspection systems etc.

4. Increase the demand of engineers.

Nontraditional Manufacturing Processes

By Gary F . Benedict
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CHAPTER
ONE Introduction to Advanced Manufacturing
Processes
A advanced manufacturing processes generally should be
employed when;
1. The strength and hardness of work piece materials are very
high, typically > 400HB.

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2. The material too brittle to be machined without damage to

the part, typically the case of highly treated alloys, glass, ceramics
and powder metallurgy parts.

3. The work piece too flexible or slender to withstand forces

involved in machining or grinding, or the parts difficult to clamp in
fixtures and work holding devices.

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ONE Introduction to Advanced Manufacturing
Processes

4. Special surface finish and dimensional tolerance

requirements that cannot be obtained by other manufacturing
process or are uneconomical.

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Processes

5. There is a need for unusual and complex shapes, which

cannot easily be machined or cannot at all be machined by
traditional processes.

6. The temperature rise during processing and residual stresses

developed in the work piece are not acceptable.

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Processes (non-traditional)
Classification of nontraditional manufacturing processes
by principle form of energy;

1. Mechanical processes - mechanical energy in some form

different from the action of a conventional cutting tool; erosion of
the work piece material is typical.
2. Electrical processes - electrochemical energy to remove
material.
3. Thermal energy processes - thermal energy generally applied
to a small portion of the work surface, causing removal by fusion
and/or vaporization; thermal energy is generated by conversion of
electrical energy.
4. Chemical machining processes - most materials are
susceptible to chemical attack by certain acids or other etchants;
chemicals selectively remove material from portions of the work
piece, while other portions of the surface are protected.

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Processes (non-traditional)

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Processes (non-traditional)
Available nontraditional material removal processes:

Mechanical;

1. AFM - abrasive flow machining.

2. AJM - abrasive jet machining.
3. HDM - hydrodynamic machining.
4. LSG - low stress grinding.
5. RUM - rotary ultrasonic machining.
6. TAM - thermally assisted machining.
7. TFM - total form machining.
8. USM - ultrasonic machining.
9. WJM - water jet machining.

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CHAPTER
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Processes (non-traditional)
Available nontraditional material removal processes:

Electrical;

1. ECD - electrochemical deburring.

2. ECDG - electrochemical discharge grinding.
3. ECG - electrochemical grinding.
4. ECH - electrochemical honing.
5. ECM - electrochemical machining.
6. ECP - electrochemical polishing.
7. ECS - electrochemical sharpening.
8. ECT - electrochemical turning.
9. ES - electro-stream.
10. STEM - shaped tube electrolytic machining.

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Processes (non-traditional)
Available nontraditional material removal processes:

Thermal;

1. EBM - electron beam machining

2. EDG - electrical discharge grinding
3. EDM - electrical discharge machining
4. EDS - electrical discharge sawing
5. EDWC - electrical discharge wire cutting
6. LBM - laser beam machining
7. LBT - laser beam torch
8. PBM - plasma beam machining

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Processes (non-traditional)
Available nontraditional material removal processes:

Chemical;

1. CHM - chemical machining.

2. ELP – electropolish.
3. PCM - photochemical machining.
4. TCM - thermochemical machining.
5. TEM - thermal energy machining.

While many processes are available, only the most commercially

important processes are discussed.

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Processes (non-traditional)
Ferrous & Non-Ferrous Metals and their Uses

Put in the simplest terms, ferrous metals are those which contain
iron, whilst non ferrous metals don’t have any iron content. There
are, however, other differences between the two types of metal
which have a strong bearing upon the tasks which they are usually
called upon to perform.

http://www.castlemetalsuk.com/blog/ferrous-nonferrous-metals-uses/

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Processes (non-traditional)
Ferrous Metals
The following are ferrous metals and the kind of uses to which they are
usually put:
1. Mild Steel – Carbon content of 0.1 to 0.3% and Iron content of 99.7 –
99.9%. Used for engineering purposes and in general, none specialised
metal products.
2. Carbon steel – Carbon content of 0.6 to 1.4% and Iron content of 98.6
to 99.4 %. Used to make cutting tools such as drill bits.
3. Stainless Steel– Made up of Iron, nickel and chromium. Resists staining
and corrosion and is therefore used for the likes of cutlery and surgical
instrumentation.
4. Cast Iron – carbon 2 – 6% and Iron at 94 to 98%. Very strong but
brittle. Used to manufacture items such as engine blocks and manhole
covers.
5. Wrought Iron – Composed of almost 100% iron. Used to make items
such as ornamental gates and fencing. Has fallen out of use somewhat
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Processes (non-traditional)
Non Ferrous Metals
These are the non ferrous metals and their uses:
1. Aluminum – An alloy of aluminum, copper and manganese. Very
lightweight and easily worked. Used in aircraft manufacture, window
frames and some kitchen ware.
2. Copper – Copper is a natural occurring substance. The fact that it
conducts heat and electricity means that it is used for wiring, tubing and
pipe work.
3. Brass – A combination of copper and zinc, usually in the proportions of
65% to 35% respectively. Is used for ornamental purposes and within
electrical fittings.
4. Silver – Mainly a natural substance, but mixing with copper creates
sterling silver. Used for decorative impact in jewelery and ornaments,
and also to solder different metals together.
5. Lead – Lead is a naturally occurring substance. It is heavy and very
soft and is often used in roofing, in batteries and to make pipes.
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Processes (non-traditional)

Work materials

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Processes (non-traditional)

Work materials

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Processes (non-traditional)
Comparison of the non-traditional machining process

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Economic comparison of unconventional processes

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Motivation to AMP

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