UNCONVENTIONAL

MACHINING
PROCESS

UNIT 1:INTRODUCTION

CONVENTIONAL PROCESS

Machining process where metal is removed using

direct contact with the tool and the work piece.

There will be a wear in the tool when the work

piece is harder.
This process is also called as traditional process

UNCONVENTIONAL
PROCESS
There will be no physical contact

between the tool and the work piece

during the machining process.
Machining will be done utilizing some
form of energy for the metal removal
There will no wear and tear of the tool
piece
This process is also called as Non
traditional process

Why need of UCMP ?

Metals which has the high temperature

resistant, strength are difficult to machine

using traditional method.
And many applications need high yield
strength. temperature resistant alloys in the
fields like aero space, nuclear engineering etc
So these metals cannot be easily machine
during Conventional process and the
machining finish will not be perfect
To get rid of these errors UMP is needed.

CLASSIFICATION OF UCMP
1.Shape of material
Electrical
Electro
chemical
Chemical
Mechanical
Thermal

CLASSIFICATION OF UCMP
2.MECHANISM INVOLVED
EROSION

IONIC DISSOLUTION

VAPORISATION

CLASSIFICATION OF UCMP
3.MATERIAL REMOVAL
Hydrostatic
pressure
High current
density
High voltage

Ionised material

CLASSIFICATION OF UCMP
4.Medium of energy transfer
High voltage
particles
Electroyte
Electron
Hot gases

MECHANICAL ENERGY METHOD

ELECTRICAL ENERGY METHOD

ELECTRO CHEMICAL ENERGY METHOD

CHEMICAL ENERGY METHOD

Thermal Energy method

LASER BEAM
MACHINING(LBM)
PLASMA ARC
MACHINING(PAM)
ELECTRON BEAM
MACHINING(EBM
)
ION BEAM
MACHINING(IBM)

PROCESS SELECTION PARAMETERS

Some of the process parameters to be
seen in UMP are
PROCESS PARAMETERS SELECTION

PHYSICAL

SHAPES TO BE
MACHINED
Machining
characteristics
Economic
Considerations

1.PHYSICAL
PARAMETERS
Some of the physical parameters of UCMP are listed in the
table

2.SHAPES TO BE
MACHINED
UCMP applications are also been seen in the size
and shape of the materials

3.MACHINING CHARACTERISTICS
or Process CAPABILITIES
Process capabilities
are analyzed on the
following aspects
Metal removal rate

obtained
Tolerance maintained
Surface finish obtained
Depth of surface

damage
Power required for

machining

4.PROCESS ECONOMY

LIMITATIONS OF UCMP
Some of the limitations of UMP are
UCMP are more expensive
Metal removal rate is slow
AJM,CHM,PAM,EBM are not commercially

economical process

ADVNTAGES OF UCMP
It increases productivity
Reduces No of rejected components
Close tolerance is possible
Harder and difficult to machine materials can

be machined by this process

The machined surface do not have any
residual stresses.
The tool material need not be harder than
work piece material as in conventional
process.

UNIT 2
MECHANICAL ENERGY BASED PROCESS

In this methods, the material is removed by

mechanical
erosion of the work piece material.

1. Abrasive jet machining AJM

2. Water jet machining - WJM
3. Ultrasonic machining -USM

Abrasive Jet Machining (AJM)

In AJM ,a high speed stream of abrasive particles

mixed with high pressure air or gas are injected

through a nozzle on the work piece to be
machined.

The impact of the particles produce sufficient

force to cut small hole or slots, deburring,

trimming and removing oxides and other surface
films.

Principle of AJM
High velocity abrasive gas jet
(150 ~ 300 m/s)

nozzle
Stand off
distance (0.5
~15 mm)

work piece

ABRASIVE JET MACHINING

AJM PROCESS
Work material - hard and brittle

(glass,quartz,ceramics,mica,etc.,)
Abrasive
- Al2O3,SiC,glass
powder,dolomite
Size
- around 25 um
Flow rate
- 2-20 g/min
Medium
- N2 or Co2 or Air
Velocity
-125-300m/s
Pressure
- 2 to 8 kg/cm2
Nozzle mtrl - tungsten carbide or synthatic
sapphire

Life of nozzle

- Tungesten carbide 12 to 20

hrs
Nozzle tip clearance - 0.25 to 15 mm
Tolerance

- 0.05 mm

m/c operation - drilling,cutting,deburring

cleaning,etc..,

MRR PROCESS
PARAMETERS
Mass flow rate
Abrasive grain size
Gas pressure
Velocity of abrasive particles
Mixing ratio
Nozzle tip clearance.

Abrasive Grain size

Mixing ratio

Mixing ratio = mass flow rate of

abrasive/mass flow

rate of

Gas pressure

GAS PRESSURE

Stand Of Distance

Advantages of AJM
Suitable for cutting all materials
There is no direct contact between the tool

and work piece.

Very thin and brittle materials can be cut
without any risk of breaking
Thermal damage is avoided
Low initial investment
Good surface finish

Disadvantages of AJM
Material removable rate is slow
Soft material cannot be machined
Machining accuracy is poor
Nozzle wear rate is high
Abrasive powder cannot be reused
Requires some kind of dust collection system.

Applications of AJM
m/cing of hard and brittle materials
Fine drilling and micro welding
m/cing of semiconductors
Cleaning and polishing of plastics, nylon and

Teflon components
Surface etching and surface preparation

WATER JET MACHINING

Water jet machining (WJT)

Water jet acts like a saw and cuts a narrow groove

in the material.
Pressure level of the jet is about 400MPa.
Advantages
- no heat produced
- cut can be started anywhere without the need
for predrilled holes
- burr produced is minimum
- environmentally safe and friendly
manufacturing.
Application used for cutting composites, plastics,
fabrics, rubber, wood products etc. Also used in
food processing industry.

ULTRASONIC MACHINING

ULTRASONIC MACHINING (UM)

In UM the tip of the tool vibrates at low amplitude

and at high frequency. This vibration transmits a

high velocity to fine abrasive grains between tool
and the surface of the work piece.
material removed by erosion with abrasive
particles.
The abrasive grains are usually boron carbides.
This technique is used to cut hard and brittle
materials like ceramics, carbides, glass, precious
stones and hardened steel.

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