MOTDUL E -1

TNTRODUCTTON
crpo1

LETR
trudoialk

om +h bast euw detodes, Engiveerirg induei 000

Flistovy
m +ho dveloprmont
hawe
hawe oith nessed ol opid gouoh
machine
matexials Zih:
dilliault to
harden cnd 7000 T H a n i u m

Aaiule
as nitrallay Onspalley
ninmonis , Car<biddes,
other h
teels eat 'Kesising els and many 3500

r e n g t h - Tumperatuae
Resistavt HTR allas
L400

M aexe8pace, u d e a r ,
Thse moderfals nd ofde appicotion
700
- 2tveno
ktrurqh
heix high-
oHhey mdusties Ouoing to
engineexrig, aand 250
qualtres.
aund heat Aesistvg
o
ocight Aatio, hardness, 1115 30 1945 60 160

ool mchnig, Yees o4 Developrmont

fov uch matevials he onvertional edged
in pik of hecent technological adwncememt s ignyE
neconomical ond R degree o accur acy and
aunc &udace
D Need or Non- 4radedional machiniq ocess
mataals
s h aMained as oo Besides, machinina, hese e insbances
ces lecd tohe development new mochivning

into ond &onetre

Conpler &aps s d:iut, ime Consumiva
method- NTM are
mpo6i bk. Caxbides
oorpicc natxíals ke
maw
. Machivigg q hard
Thseroccss ave non - todtional or un conventional m
Aainles Aeds heat resieitng teels ond inilar uch mat
enseenge hot *hey do not ennploy a Convensional or Tool eax andailuve becors a evtaus broblen m moehin vo
toeliional tool ko metal Aennoval msfed desecty uch mateials. Furthes, +ho high Oost d tools and the damo
aond +e damoqe
utiige sme orrn qnexg1 metal machinvg. made A braticeully econonically wipossible **
duing macining or

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)
8Hahcd matexials axe odicuA to Hakd motaTals orre ea o

dusing macining Machne im Convensional machininq machne m non- Convenstowa

A. A oy hh urlau nish cidh cose dimensianal acauray broces. mouchinang oes.

haroduot sequised. i m e equired oY nachinig opexcTime equixed r machiniq
Hian kess. MOYe .
traditonal and non-
twaditional mmachinia
onpoizon betuceen
nish is pov susface niah is qcod (Sum)

envntinal Machinln
etuoeen
on- Convnainal Machini
T t Cast oroduetron is koss Cest o production is more
.Hhee is divect Contact hee ib no daxect Covtact

lool and Oorkpie ce oetuoeen ool amnd ocspie co kaste orocuction s more ohe Rat of recdukron is Ress
Contast ketuem Covpane to NTM onen anpani to lonvensional
.inca +hon is Contact betvoeen
and vooxtpteca, transe meclio
machini
|4ool cund voovepiece , tamser medidtool
is not nece86ary eceO a 13 cononical Un- economical.

J4tress induced on orkpiece machi trem ee machini possidk

3Hs dteult to peo machiniaplkeated Snapes Cambe
- núg
Opesations and Complicated hape easiy mauchined.
15 eczion mochiniq s not pe3si bl gn pveczíon mmatloinig a
by Convenbional whachinin oRsibu by non- Convnstonak
and tocl dos not e i g t &nce
4 lool qes VOom aut JkplToo Oeax

mahining .
beuoeen ool ound
gos on Ae ductng d to Contact no Contat

betuoen kool ancl oorepfece OOrpfece Non-tadilional Machinirq rocess

Gheneral Classicoeion
I i t a l mvestmnt r equpm h e nov-4vadiionod mmacdini nqa ouss ve classilied on he.
5Ttialinvestmnt o eopiprmunt
non-tracdtio is high bass
%less Canpove
machinina sed
*o
exa
Kequived onvoval
k i l e d Jabour
are
Methaniam o matuiol
not necoamy .
6 Skued habo machinivg Opevations
opevakon|eyorrm OY enexa4 tYonser
oedorm machining 3. Medc

Metalatt s kcss ,
whnen Compare
stmoval Ate is [Link]
T. Metal o Convensîonal vachanig
Convpored to NTM o
coss.
 ne qy d.
Based On

Mechouiem o Frcec
Ene
T neq
V
metal sernovc mec

Thyef ca Cutting tool Convunional

heax Contact macniwvg

Mechantcal Hyohaubie Ipmu- uSM, OTM
s o s t on Hign Ve loa
Partcles
maeprUnw ATM

lectvo Jon Displacmt

High urent ECM EC G

chemical
Electroy

Ablatove Reactive
Chemical Fusior Coreesue CHM
laton envrommunt mt

Radiation Amplked lzght teM, PAM

Classification of Non Traditional Machining Process
ThexmO Vouporiscion ion 8t ecn inibed matata
Mechanical Metal removal Processes
lectrtc. dontsed matetalTBM, DAM
Hot g abis It is characterized by the fact that the material removal is due to the
Fusion Eleckrons g Votoqe EDM. application of mechanical energy in the form of high frequency vibrations or
kinetic energy of an abrasive jet.
Based on Mechonism o Materal Kenmoval 1. Ultra sonic Machining (USM).
2. Abrasive Jet Machining (AJM).
) . Erasion- Mechanical Enexqy based procss. 3. Water Jet Machining (WJM).

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
 PAM, BM.
[Link] hoss
v chervical Reoqent -
CHM , ECM

USM ultrasonicMachining
OJM oater jeb Machinte

AJM Abrastlve det Machini va

ECM Rlecbro chermical Machintvg
ECG
Electo chericol
Grinding
CHM cheuicoul Machining
Electro-Chemical IBM Ton Beam Machining
It is based on electro-chemical dissolution of materials by an electrolyte PAM Plasma Are Machinig
under the influence of an externally applied electrical potential.
1. Electro-Chemical Machining (ECM).
BDM Electren Dischorcge Machinang
2. Electro-Chemical Grinding (ECG) LB M k a s e r BeamMadhinin
3. Electro-Chemical Drilling (ECD) EBM Bleeron Bearn Machint na
Thermal Method
The material is removed due to controlled, localized heating of the work
piece. It result into material removal by melting and evaporation. The source of
Sleckon Wonodstional mackaniq oesscs
heat generation in such cases can be widely different. In ordes o
t
roke use he won-sadotonal
madhinna pocU
1. Electric Discharge Machining (EDM).
ctnt ,4 is neeessay hat *he eceet natk
o h ichi ning
2. Plasma Arc Machining (PAM).
oblem ust be Pnauon
3. Electron Beam Machining (EBM)
4. Laser Beam Machining (LBM0 *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
 rcute Conm
orameter, PAM as a
htgna meal, *emoval
e e sul m
Scsultp eccullet
eccllot
and BDM -bocuss ,BCM
tdaisivq a e d o USM
ton+tns .rot d haoevh It Causes erclensive udoce donnse.
cotron, drr Aine sla nish,
appli ATM or SM proces8
to
kohen Connpaned
1ter(o
iv) 5cononnec_ Conaiderabtons

sdeted o Copital
hcal axametev
fattos mcude csts
b en Bconeical eoclsememb
and

(uwent investment,ookng axd t n s ouoe

oe, Ooltoae o l u t f a l , P o C e s 8 , A J M , USM

w
Conm ba mcured or maehining proeens , AJM
oie Oother epuses
a
oevkpiecematerial
-ool ard bDH
[Link] Capitod investnneent,
p o c s kke USM aud aund PAM procio segudre Nary
LB Mphsouss. lbeira
[Link]
machining a bateclov BM. and
Compaxed o BBM, EOM
proimatly anne boucao
BCM [Link] u-
t e i a l vohile BCM a d CM onaume a
Compoantotig Cests xe
hrgh or BDM and
oth Yespect
ot ta jp -mptron s Vey hooor USM and LBM brocess. Bonav
tecito arvount o o Puvdtn,
qreate Cnslderobon i a Veu wportamb aspet os & detenvines
a n a l ! gap
results w q
btsemtool and copiece,
heno Coeb to machang a paocttoloe Co pouemb
hanevs one r o e r
m ll
meta emoval rom ho okpieck, cheia has
henee a brop chci
ndtiras Tstvict +ha qap ard Advandcgs
o he rmad haein, Malral temoval ofhout nechantcal l
mctatal oork OOrlc p iece.
opedios d ooxk Con

ropats .1he Malkalal emovat ale fadepnd R o0nkpi

o s piecc mcteri alg osses doent or

Conductvg,
ductrk
handne
hand or
ot Conductivg ov On 3 Cung ones
e-tc USM proce qood
macuinavng ranmitcS &dpendus oenkpRe harolne
Conductve n he othev hand
CM
H Too mahwufa need no be hander
and qlcuses ATe on -
alla
pa alla
*pa ho0xkpfeu makrlal,
and M gcod ov madhinig t e and 5
Tool h onoa
no oith USM.
oea
pxoblem
6 Abreh mahlne Quy makrtal

a) ocs_Capabalihe SIreu u malutnfug

soces (opabiits
TM c e s welnde, Melai 3 norm makrfal XumovaL Ove euh CUa
atever ltrd
nultane ouly
Kirvoval scete Eurlace onigh,tlevones Superfo Aurlas Rkgntly poutble
 Jule Coualely Ahapecd
hand ad_agle malial
to machlnrd.
be
mftro- machlufug poub
uFiuely oued
amgla
doallang
au
a fhallow eulsants
42Mtoo hole
PonR 16le

iMI TA TIONS:
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
be/os uiag a
Makrta Can be Akadtel
o produchin woc
pankalax NTM pHO
5The deph Cus mited hola .ov Cauhe
6 Thexe May be vaype kPe uoalle
be Ovexcome &
MO hhire nnllahons cau

Cau be
Conlxolleod #o hal dhe ackvautagu
oblatned uoth producs gualrly
aluanle