MOTDUL E -1

TNTRODUCTTON

A
D
induei
Flistovy om +h bast euw detodes, Engiveerirg

AD
m +ho dveloprmont
hawe
hawe oith nessed ol opid gouoh
machine
matexials Zih:
dilliault to
harden cnd

U
Aaiule
as nitrallay Onspalley
ninmonis , Car<biddes,

VT
and
other h
teels eat 'Kesising els many

r e n g t h - Tumperatuae
Resistavt HTR allas

M aexe8pace, u d e a r ,
Thse moderfals nd ofde appicotion
- 2tveno
ktrurqh
high-
oHhey mdusties Ouoing to heix
engineexrig, aand

qualtres.
o
ocight Aatio, hardness, aund A
heat Aesistvg
D
ool mchnig,
fov uch matevials he onvertional edged
AD

in pik of hecent technological adwncememt s ignyE

neconomical ond R degree o accur acy and
aunc &udace
D
U

mataals
Besides, machinina, hese
VT

s h aMained as oo
&onetre
into Conpler &aps s d:iut, ime Consumiva ond
mpo6i bk.
Thseroccss ave non - todtional or un conventional m

enseenge hot *hey do not ennploy a Convensional or

toeliional tool ko metal Aennoval msfed desecty
utiige sme orrn qnexg1 metal machinvg.
 A
crpo1
trudoialk

D
LETR
000

AD
7000 T H a n i u m

U
VT
3500

L400

700

250

1115 30
A
1945 60 160
D
Yees o4 Developrmont
AD

Need or Non- 4radedional machiniq ocess

U

mochivning
VT

new
e insbances
ces lecd tohe development
method- NTM are
. hard oorpicc natxíals ke
maw Caxbides
Machivigg q
Aainles Aeds heat resieitng teels ond inilar uch mat
Tool eax andailuve becors a evtaus broblen m moehinvo
uch mateials. Furthes, +ho high Oost d tools and the damo
aond +e damoqe
**
duing macining made A braticeully or econonically wipossible
macuine Auch watetals usirq Conventional machanirg p o s

. Machinina e s y r a l l diametr hdes , deep Cawi-tes a Connplex

geormedical ape
 3, Ooskpicce s c o e c ible or ender (thun)

A
dusing macining

D
A. A oy hh urlau nish cidh cose dimensianal acauray

AD
haroduot sequised.

U
traditonal and non-
twaditional mmachinia
onpoizon betuceen

VT
envntinal Machinln on- Convnainal Machini
.Hhee is divect Contact etuoeen hee ib no daxect Covtact T
lool and Oorkpie ce oetuoeen ool amnd ocspie co

Contast ketuem
.inca +hon is Contact betvoeen
cund voovepiece tamser medidtool and vooxtpteca, transe meclio
|4ool ,

is not nece86ary eceO A a

D
AD

3Hs dteult to peo machiniaplkeated Snapes Cambe

Opesations and Complicated hape easiy mauchined.

U

dos not e i g t &nce

VT

aut and tocl JkplToo

4 lool qes VOom Oeax

beuoeen ool ound

gos on Ae ductng d to Contact no Contat

betuoen kool ancl oorepfece OOrpfece

I i t a l mvestmnt r equpm
5Ttialinvestmnt o eopiprmunt
non-tracdtio is high
%less Canpove
machinina
*o
Kequived
k i l e d Jabour
are

not necoamy
6 Skued habo machinivg Opevations
opevakon|eyorrm
oedorm machining
Metalatt s kcss ,
whnen Compare
stmoval Ate is [Link]
T. Metal o Convensîonal vachanig
Convpored to NTM o
coss.
 Hakd motaTals ea o
8Hahcd matexials axe odicuA to orre

A
Machne im Convensional machininq machne m non- Convenstowa

D
broces. mouchinang oes.

AD
i m e equired oY nachinig opexcTime equixed r machiniq
Hian kess. MOYe .

U
nish is pov susface niah is qcod (Sum)

VT
t Cast oroduetron is koss Cest o production is more

kaste orocuction s more ohe Rat of recdukron is Ress

Covpane to NTM onen anpani to lonvensional
machini

A
13 cononical D Un- economical.

J4tress induced on orkpiece machi trem ee machini possidk

AD

- núg

15 eczion mochiniq s not pe3si bl gn pveczíon mmatloinig a

U

by Convenbional whachinin oRsibu by non- Convnstonak

VT

mahining .

Non-tadilional Machinirq rocess

Gheneral Classicoeion
h e nov-4vadiionod mmacdini nqa ouss ve classilied on he.

bass
sed
exa
matuiol onvoval
. Methaniam o
3. Medc OY enexa4 tYonser
 ne qy d.
Based On

A
Mechouiem o Frcec

D
Ene
T neq
V
metal sernovc mec

AD
Cutting tool Convunional
Thyef ca
heax Contact macniwvg
Mechantcal Hyohaubie Ipmu- uSM, OTM
s o s t on Hign Ve loa

U
Partcles
maeprUnw ATM

VT
lectvo Jon Displacmt
High urent ECM EC G

chemical
Electroy

Ablatove Reactive
Chemical Fusior Coreesue CHM
laton envrommunt mt

Amplked lzght teM, PAM

Radiation
ThexmO Vouporiscion ion 8t ecn inibed matata
lectrtc.
Fusion
Hot g abis
Eleckrons Adontsed matetalTBM, DAM
g Votoqe EDM.
D
AD

Based on Mechonism o Materal Kenmoval

Enexqy based procss.

U

Mechanical
) . Erasion-
VT

Eletic Diedhage - Rleckrtaal Enevg based proces3es

Acherical 5tching - Chericol Enevg based rocesses

i) Melting and Vapoigation - hermal based rocesses

Ton Displaceeunt themal kased proceKses.

Based onhe media or enexqx trosjer

)Etectvons EBM
renouzed gas -ATM

TM
ooctex
oaNe USMM
iv uttrasonic
 A
D
Classification of Non Traditional Machining Process

AD
Mechanical Metal removal Processes

U
It is characterized by the fact that the material removal is due to the

VT
A
application of mechanical energy in the form of high frequency vibrations or

D
kinetic energy of an abrasive jet.

AD
1. Ultra sonic Machining (USM).
2. Abrasive Jet Machining (AJM).

U
3. Water Jet Machining (WJM).

VT
 A
Electro-Chemical

D
It is based on electro-chemical dissolution of materials by an electrolyte

AD
under the influence of an externally applied electrical potential.

U
1. Electro-Chemical Machining (ECM).

VT
A
2. Electro-Chemical Grinding (ECG)

D
3. Electro-Chemical Drilling (ECD)

AD
Thermal Method
The material is removed due to controlled, localized heating of the work

U
piece. It result into material removal by melting and evaporation. The source of

VT
heat generation in such cases can be widely different.
1. Electric Discharge Machining (EDM).
2. Plasma Arc Machining (PAM).
3. Electron Beam Machining (EBM)
4. Laser Beam Machining (LBM0
 PAM, BM.
[Link] hoss

A
v chervical Reoqent -
CHM , ECM

D
AD
USM ultrasonicMachining
OJM oater jeb Machinte

U
AJM Abrastlve det Machini va

VT
ECM Rlecbro chermical Machintvg
ECG
Electo chericol
Grinding
CHM cheuicoul Machining
IBM Ton Beam Machining
PAM Plasma Are Machinig
BDM Electren Dischorcge Machinang A
D
LB M k a s e r BeamMadhinin
AD

EBM Bleeron Bearn Machint na

Sleckon Wonodstional mackaniq oesscs
U

In ordes o
t
roke he won-sadotonal
VT

use
madhinna pocU
ctnt ,4 is neeessay hat *he eceet natk o h ichi
ning
oblem ust be Pnauon
*he poins ohich hould be Dooked t o love. ha
Kdeetton hese
oco3es ave
1Phystcal ranmet
opeties h e oevk motertals andha ghape to be
Maahne
nRocse Capakabi lity (o) machinig oharactentgttcs.
Bconende Considexatrons
 e

A
tdaisivq

D
ton+tns .rot d

AD
cotron, drr Aine
appli
1ter(o

U
VT
hcal axametev
b en
(uwent
oe, Ooltoae o l u t f a l ,
oie a w
Conm ba
oevkpiecematerial
-ool ard bDH
[Link]
USM aud
[Link]
p o c s kke
machining a bateclov
proimatly anne boucao
a
Compoantotig
t e i a l vohile BCM a d CM onaume

tecito arvount o o Puvdtn, A oth Yespect

ot ta jp
D
a nal! gap
results w
qqreate
AD

copiece,
btsemtool and
hanevs one r o e r
m ll
meta emoval rom ho okpieck, cheia has
Tstvict +ha qap ard henee a brop chci
U

ndtiras

o he rmad haein,
VT

mctatal
opedios d ooxk Con

ropats .1he
o s piecc mcteri alg osses doent ductrk
or

Conductvg,
hand ot Conductivg ov On
or
ranmitcS
macuinavng
e-tc USM proce qood CM
othev hand
Conductve n he
and qlcuses ATe on -
pa alla
alla
and M gcod ov madhinig t e and *pa
no oith USM.

a) ocs_Capabalihe
soces (opabiits
TM c e s welnde, Melai
atever ltrd
Kirvoval scete Eurlace onigh,tlevones
 rcute Conm
orameter, PAM as a
htgna meal, *emoval
e sul m eccullet
eccllot

A
Scsultp
-bocuss ,BCM
a e d o USM and BDM

D
haoevh It Causes erclensive udoce donnse.
sla nish,

AD
to ATM or SM proces8
kohen Connpaned

U
iv) 5cononnec_ Conaiderabtons
Copital

VT
sdeted o
fattos mcude csts
Bconeical eoclsememb
and

investment,ookng axd t n s ouoe

P o C e s 8 , A J M , USM
other mcured or maehining proeens , AJM
O epuses
Capitod investnneent,
aund PAM procio segudre Nary
BBM, EOM BM. and LB Mphsouss. lbeira
Compaxed o
BCM [Link] u-
Cests xe
hrgh or BDM and
-mptron s Vey hooor USM and
ALBM brocess. Bonav
D
Cnslderobon i a Veu wportamb aspet os & detenvines
AD

heno Coeb to machang a paocttoloe Co pouemb

Advandcgs
U

Malral temoval ofhout nechantcal l

VT

oork OOrlc p iece.

Malkalal emovat ale fadepnd R o0nkpi
handne
3 Cung ones &dpendus oenkpRe harolne
H Too mahwufa need no be hander
ho0xkpfeu makrlal,
5
Tool oea h onoa pxoblem
6 Abreh mahlne Quy makrtal
SIreu u malutnfug
XumovaL
3 norm makrfal Ove euh CUa
nultane ouly
Superfo Aurlas Rkgntly poutble
 Jule Coualely Ahapecd
hand ad_agle malial
to machlnrd.
be

A
mftro- machlufug poub
uFiuely oued

D
eulsants amgla au

doallang

AD
42Mtoo hole a fhallow

PonR 16le

U
iMI TA TIONS:

VT
Pl modexn maclintug mehod au geon eally cely
Corl
2 het 4pec powoe COnRumphon plhe uea
ufle
eleckrtcally Couduclive
Conduchve

33 ADOnk pYece and dool mul be

Recosl 0 hea alleceod 2one 0Y turau pxoduus may

MOwlea Ome o u purpore Hu Compahlby

Daou oih
uoikhku Mehallurglcal lak o Hu oorlcpYus
A be/os uiag a
Makrta Can be Akadtel
o produchin woc
D
pankalax NTM pHO
5The deph
AD

Cus mited hola .ov Cauhe

6 Thexe May be vaype kPe uoalle
&
U

nnllahons cau be Ovexcome

MO hhire
Cau be
VT

Conlxolleod #o hal dhe ackvautagu

oblatned uoth producs gualrly
aluanle