Non Traditional

Machining Processes
By
Mr. Ashish Umarkar
Advanced Manufacturing Processes
(AMP-12154)
Unit no:-1
Marks:- 30
Development
Development of harder and difficult to machine
materials such as hastalloy, nitra alloy, waspalloy,
nimonics, carbides, stainless steel, heat resisting steels
and many other HSTR alloys
Used in aerospace industry, nuclear engineering and
other industries owing to their high strength to weight
ratio, hardness and heat resisting quality.
CHIPS FORMATION IN CONVENTIONAL
MACHINING PROCESS
CHIP

TOO
L

WORKPIEC
E

Thus the major characteristics of conventional machining are:

Generally macroscopic chip formation by shear deformation
Material removal takes place due to application of cutting forces
energy domain can be classified as mechanical
Cutting tool is harder than work piece at room temperature as well as
under machining conditions TOOL WORKPIECE CHIP
Schematic representation of various metal cutting operations .
The broad classification is given as follows:

Thus classification of NTM processes is carried out

depending on the nature of energy used for material
removal.
Mechanical Processes
Abrasive Jet Machining (AJM)
Ultrasonic Machining (USM)
Abrasive Water Jet Machining (AWJM)
Electrochemical Processes
Electrochemical Machining (ECM)
Electro Chemical Grinding (ECG)
Electro Jet Drilling (EJD)
 Electro-Thermal Processes
Electro-discharge machining (EDM)
Laser Beam Machining (LBM)
Electron Beam Machining (EBM)
Chemical Processes
Chemical Milling (CHM)
Photochemical Milling (PCM) etc.
Abrasive Jet Machining (AJM)
Abrasive
Pressure control filter feeder
valve

exhaust

Mixing
Drier chamber

Nozzle
turn valve
Electro-magnetic
shaker work
Air
piece
compressor
Ultrasonic Machining (USM)
ELECTROCHEMICAL MACHINING (ECM)
Electrolyte
An electrolyte is any substance containing free ions that
make the substance electrically conductive. The most typical
electrolyte is an ionic solution, but molten electrolytes and
solid electrolytes are also possible.

Function of electrolyte-
Carrying current between tool and work peice
Remove products of machining and other insoluble products
from cutting region
Dissipate heat produced in the operation.
Characteristics of Electrolyte
Good electrical conductivity
Non toxicity and chemical stability
Non corrosive property
Low viscosity and high specific heat

Electrolyte used-
Sodium chloride
Electric Discharge Machining (EDM)
Wire-cut EDM (WEDM)
Dielectric Fluid
A dielectric is an electrical insulator that can be ionized by
an applied electric field. When a dielectric is placed in an
electric field, electric charges do not flow through the
material as they do in a conductor, but only slightly shift
from their average equilibrium positions causing dielectric
polarization.
Characteristic-
Low viscosity
High fluidity
Controlled level of toxicity
Cheap and easily available
Function of Dielectric Fluid
Insulation Until required breakdown voltage attained.
Should act as conductor after required breakdown voltage
attained.
Should demonize rapidly after the discharge has been
occurred.
Clean spark gap by carrying away the molten metal.
Should cool the tool work piece and spark region.

Dielectric Used:-
light hydro carbon oil, kerosene, paraffin, transformer oil,
try ethylene glycol.
LASER Beam Machining (LBM)
Electron Beam Machining (EBM)
Chemical Machining (CHM)
PAM
Difference between EDM & ECM
1. Uses dielectric fluid as a conducting 1. Using electrolyte as a conducting
medium between tool and work medium between tool and work
piece. piece.
2. Wear of tool takes place during the
2. No wear of tool during process so
process.
tool life is high.
3. Heat is generated during the process.
3. No heat is generated during the
4. Low metal removal rate.
process.
5. It works on the principle of spark
erosion. 4. Metal removal rate is high.
6. Metal is removed by melting and 5. It works on principle of Faradays
vaporization. law of electrolysis.
7. Tools used are oversize for machining 6. Metal is removed by
inside surfaces and undersize for electrochemical reaction.
machining outside surfaces.
7. Tool used are of required size of
the work piece.
Dielectric Electrolyte
1. It is used as conducting 1. It used as conducting
medium in EDM medium in ECM
process. process.
2. It act as conductor and 2. It always provide passage
insulator both. for supply of electricity.
3. Tool wear takes place in 3. The electrolyte selected
the dielectric fluid. is such that there is no
wear of tool.
4. It may or may not be
corrosive in nature. 4. It should be non
corrosive in nature.
EBM LBM
When excited atoms releases
1. When high velocity
electrons strikes the work
piece its kinetic energy
converted into heat energy.
2. Electron gun is used as a
tool.
3. Accuracy is good.
4. Metal removal rate is low.
5. The complete process
should kept in vacuum.
6. Usually only metals.
1.
photons in the form of chain, a
LASER beam is generated
which strikes on w/p & melts
it.
2. LASER material is used as tool.
3. Accuracy is comparatively
more.
4. Metal removal rate is high.
5. Vacuum is required between
flash lamp and ruby rod.
6. Any material but not only
suitable for plastic.
Questions
1. Which of the following process uses mechanical
energy as principle energy source
a. ECG
b. LBM
c. Conventional milling
d. USM
e. WJM
f. WEDM
2. Chemical milling is used in which of the
following application
a. Drilling holes with high depth.
b. Making intricate patterns on thin sheet metal
c. Removing material to make shallow pockets in
metal.
d. Removing metals from aircrafts wing panels.
e. Cutting of plastic sheets.
3. Which of the following process would be best
suited for cutting a hole of 0.003 inch dia?

a. AJM
b. CHM
c. EDM
d. LBM
e. WEDM
4. Ultra sonic machining can be used for
both metallic and non metallic materials?
True
False
5. Which of the following process could be
used to cut a large piece of 1/2inch thick?
a. AJM
b. CHM
c. EDM
d. LBM
e. WEDM