MODULE-1
NON-TRADITIONAL MACHINING
(NTM)
1. Introduction to Non-Traditional Machining
Non-Traditional Machining (NTM) processes are machining methods used to remove
material without direct mechanical contact between tool and workpiece.
These processes are used when conventional machining (turning, milling, drilling) cannot
machine hard, brittle, or complex materials .
Need for NTM
Machining very hard materials like ceramics, carbides.
Producing complex shapes and micro holes.
Machining brittle materials like glass.
Achieving high precision and surface finish.
Examples of NTM Processes
Ultrasonic Machining (USM)
Electro Chemical Machining (ECM)
Electrical Discharge Machining (EDM)
Electron Beam Machining (EBM)
Laser Beam Machining (LBM)
2. Ultrasonic Machining (USM)
Definition
Ultrasonic Machining is a mechanical non-traditional machining process in which material is
removed by abrasive particles vibrating at ultrasonic frequency.
Typical vibration frequency: 20 – 40 kHz
Main Components of USM
1. Power Supply
Converts normal electrical frequency 50–60 Hz into high frequency (20–40 kHz)
electrical energy.
2. Transducer
Converts electrical energy into mechanical vibrations.
Magnetostrictive type is commonly used.
3. Tool Horn
Amplifies vibrations from the transducer.
Focuses the vibration energy to the tool.
4. Tool
Made of tough and ductile material.
Performs hammering action on abrasive particles.
5. Abrasive Slurry
Mixture of:
Water
Abrasive particles
Common abrasives:
Silicon carbide
Aluminium oxide
Boron carbide
Sand
Working Principle of USM
1. Power supply produces high frequency electrical energy.
2. Transducer converts it into vibrations.
3. Tool vibrates at 20–40 kHz frequency.
4. Abrasive slurry flows between tool and workpiece.
5. Abrasive particles strike the work surface.
6. Material is removed by brittle fracture .
Material Removal Mechanism
Material removal occurs due to:
Impact of abrasive particles
Micro chipping
Brittle fracture
Applications of USM
Machining glass and ceramics
Producing precision holes
Machining semiconductors
Machining hard and brittle materials
3. Electrochemical Machining (ECM)
Definition
Electrochemical Machining is a machining process in which metal is removed by
electrolysis.
It is the reverse process of electroplating.
Basic Principle
Workpiece acts as Anode (+)
Tool acts as Cathode (−)
Electrolyte flows between them
Material removal occurs due to electrochemical reaction
Working of ECM
1. Tool and workpiece are kept at a small gap (0.05 – 0.7 mm).
2. Electrolyte flows through the gap at high velocity (30–60 m/s).
3. DC power supply is applied.
4. Electrochemical reactions occur.
5. Metal from the workpiece dissolves into electrolyte.
Example electrolyte:
Sodium Chloride (NaCl)
The ionic dissociation of NaCl and Water takes place in electrolytes shown below:
As the potential difference is applied across the electrode ,the movement of ions starts in
between the tool and workpiece. The positive ions moves towards the tool (cathode) and
negative ions move towards the workpiece.
At cathode the hydrogen ions takes electrons and gets converted into hydrogen gas
In the same way,the iron atoms comes out from the anode(workpiece) as Fe++ ions
Components of ECM
1. Electrolyte
Conductive liquid used to carry ions.
Examples:
NaCl solution
NaNO₃ solution
2. Tool (Cathode)
Properties:
Good electrical conductor
Chemically inert
High dimensional accuracy
Tool materials:
Aluminium
Titanium
Stainless steel
Bronze
3. Workpiece (Anode)
Material from which metal is removed.
4. DC Power Supply
Voltage range: 3 – 30 V
5. Pump
Circulates electrolyte.
6. Filters
Remove impurities from electrolyte.
7. Pressure Gauge
Measures pressure of electrolyte.
8. Flow Meter
Measures electrolyte flow rate.
Advantages of ECM
No tool wear
High surface finish
No heat affected zone
Can machine very hard materials
Disadvantages
High power consumption
Electrolyte handling problems
Limited to conductive materials
4. Electrical Discharge Machining (EDM)
Definition
Electrical Discharge Machining is a thermal machining process in which material is
removed by electric sparks .
Also called:
Spark machining
Spark erosion
Electro-erosion
Principle of EDM
EDM works on the principle that:
Heat generated by electrical sparks melts and vaporizes the material.
Spark gap: 0.01 – 0.5 mm
Working of EDM
1. Tool and workpiece are placed in dielectric fluid.
2. Small gap is maintained between them.
3. High voltage is applied.
4. Thousands of sparks occur per second.
5. Each spark melts a small portion of metal.
6. Molten material is removed by dielectric fluid.
Types of EDM
1. Die sinking EDM
2. Wire cut EDM
3. Hole drilling EDM
Advantages of EDM
Can machine very hard materials
Produces complex shapes
Burr-free machining
Suitable for thin and fragile parts
Disadvantages
Low material removal rate
High power consumption
Tool wear occurs
Only conductive materials can be machined
Applications of EDM
Die and mould manufacturing
Fuel injector holes
Aircraft components
Tool sharpening
Small precision holes
5. Electron Beam Machining (EBM)
Principle
In EBM, high velocity electrons strike the workpiece surface , converting kinetic energy
into heat and causing melting and vaporization of material.
The process occurs in a vacuum chamber.
Working
1. Tungsten filament emits electrons.
2. Electrons are accelerated by high voltage.
3. Magnetic lenses focus the electron beam.
4. Beam strikes workpiece.
5. Heat generated removes material.
Advantages
High precision machining
Can machine hard materials
Minimal distortion
No filler material required
Disadvantages
High equipment cost
Vacuum chamber required
Limited workpiece size
Requires skilled operator
6. Laser Beam Machining (LBM)
Definition
Laser Beam Machining uses a high energy concentrated laser beam to melt and vaporize
material.
Working Principle
1. Laser beam is generated in ruby crystal.
2. Xenon flash lamp excites chromium atoms.
3. Laser beam is amplified between reflective mirrors.
4. Beam exits through a small opening.
5. Optical lens focuses the beam on the workpiece.
6. Heat melts the material.
Advantages
High precision
Very small heat affected zone
Can weld thin materials
No tool wear
Limitations
Slow welding speed
Expensive equipment
Not suitable for mass production
Limited depth of machining