Nonconventional Processes
What is the nonconventional process?
Unconventional machining processes were developed initially to
machine very hard materials that are almost impossible to be machined
economically by conventional methods. Conventional machining processes
require that the cutting tool materials is harder than the work piece material.
As a result, these processes are termed as Unconventional or nontraditional
machining methods.
Applications for the non-conventional machining processes:
- For complex shape which are difficult to to machine by conventional
method
- For hard and brittle materials
- For work that requires high accuracy
- For difficult geometries
Comparison
CONVENTIONAL MACHINING PROCESSES
1. Direct contact of Tool and Work piece.
2. Cutting tools are always harder than work piece.
[Link] life is due to high wear.
4. Generally microscopic chip formation.
5. Material removal takes place due to application of cutting
force.
6. Suitable for all material.
7. It cannot be used to make prototype parts very effectively.
NON-CONVENTIONAL MACHINING PROCESSES
1. Tools are non convectional techniques like laser beam, electric
arc etc.
[Link] may not be harder, and it may not be physical presence.
3. Tool life is more.
[Link] removal occurs with or without chip formation.
[Link] uses different energy sources like electrical, thermo-chemical
etc. to provide machining.
6. Not suitable for all material.
7. It can be used to produce prototype parts very effectively.
TYPE OF NON-CONVENTIONAL PROCESSES
1. Electric Discharge Machining (EDM)
2. Electro-Chemical Machining (ECM)
3. Electro-Chemical Grinding (ECG)
4. Ultrasonic Machining (USM)
5. Laser Beam Machining (LBM)
6. Chemical Machining (CHM)
7. Abrasive Water Jet Machining (AWJM)
8. Water Jet Machining (WJM)
9. Plasma Arc Machining (PAM)
1. Electric Discharge Machining (EDM)
EDM is a nonconventional machining technique uniquely used for cutting
metals which are not possible to cut with traditional methods. EDM only
works with materials which are electrically conductive. The cutting tool for
EDM may be made of hardened tool steel, titanium carbide or inconel or
Kovar.
Principle of EDM
The main attraction of EDM over conventional machining is that this
technique use thermoelectric process to erode undesired material from the
w/p.
2. Electro-Chemical Machining (ECM)
ECM removes material through an electrochemical reaction, using a tool and
an electrolyte solution. It’s non-contact and produces no thermal or
mechanical stress, making it ideal for producing complex geometries in hard
or heat-resistant metals. However, it requires the workpiece to be
conductive.
3. Electro-Chemical Grinding (ECG)
ECG combines ECM with grinding. A rotating grinding wheel acts as the
cathode, while the workpiece is the anode. The process removes material
through electrochemical action and mechanical grinding. This is useful for
machining difficult-to-grind materials, offering higher precision and reduced
tool wear.
4. Ultrasonic Machining (USM)
USM employs high-frequency vibrations to remove material with the help of
an abrasive slurry. It’s primarily used for brittle materials like ceramics or
glass, where conventional methods might cause cracking or chipping. This
process is non-thermal and non-chemical.
5. Laser Beam Machining (LBM)
LBM uses a focused laser beam to melt, vaporize, or remove material. It
offers extreme precision and is widely used for cutting, engraving, or drilling
in industries requiring minimal thermal distortion. It works on a variety of
materials, including metals, ceramics, and plastics.
6. Chemical Machining (CHM)
CHM removes material through controlled chemical reactions. A chemical
etchant dissolves portions of the workpiece, typically protected by a resist
coating. This method is used for thin sheets or delicate parts, with
applications in aerospace and electronics.
7. Abrasive Water Jet Machining (AWJM)
AWJM uses a high-pressure stream of water mixed with abrasives to cut
through materials. It can machine a wide range of materials, including
metals, glass, and stone, without generating heat or altering material
properties.
8. Water Jet Machining (WJM)
Like AWJM, but without abrasives, WJM uses a pure high-pressure water jet to
cut softer materials like plastics, rubber, and wood. It’s often used in
industries where environmental impact and minimal waste are prioritized.
9. Plasma Arc Machining (PAM)
PAM uses a plasma jet (ionized gas) to cut through electrically conductive
materials like metals. The plasma reaches extremely high temperatures,
melting and vaporizing the workpiece. PAM is used for fast cutting of thick
materials, such as steel and aluminum.
These processes provide alternatives to traditional machining, allowing for
high precision, reduced tool wear, and the ability to machine hard-to-cut
materials.