NMP 2.
Electrical Energy Based Processes
ASSIGNMENT • Material removed by sparks or electrochemical dissolution.
1. Define Non-Traditional machining and classify based on the energy • Examples:
used. o Electro Discharge Machining (EDM)
Definition o Electro Chemical Machining (ECM)
• Non-Traditional Machining (NTM) involves material removal without o Electro Chemical Grinding (ECG)
using conventional cutting tools. • Application: Conductive materials, dies, molds, turbine blades.
• Material is removed using mechanical, electrical, thermal, or 3. Thermal Energy Based Processes
chemical energy. • Material removed by melting, vaporization, or high-temperature
• Suitable for hard, brittle, heat-resistant, or complex-shaped jets.
materials. • Examples:
Need for NTM o Laser Beam Machining (LBM)
• To machine modern hard materials like ceramics, carbides, and o Electron Beam Machining (EBM)
superalloys. o Plasma Arc Machining (PAM)
• Required for intricate shapes and high precision. • Application: Aerospace alloys, thin sections, heat-resistant metals.
• To avoid mechanical stresses and tool wear. 4. Chemical Energy Based Processes
• Used in aerospace, nuclear, and electronics industries. • Material removed by chemical dissolution using etchants.
Classification of NTM Based on Energy Used • Examples:
1. Mechanical Energy Based Processes o Chemical Machining (CHM)
• Material removed by impact or erosion using high-velocity abrasives o Photochemical Machining (PCM)
or fluids.
• Application: Microelectronics, aerospace sheet components.
• Examples:
o Abrasive Jet Machining (AJM)
o Water Jet Machining (WJM)
o Abrasive Water Jet Machining (AWJM)
o Ultrasonic Machining (USM)
• Application: Glass, ceramics, hard brittle materials.
2. Explain the abrasive jet machining with a neat sketch and list • Controls the pressure of the compressed gas before it enters the
the advantages and disadvantages system.
Definition • Maintains a steady flow of gas.
• Abrasive Jet Machining (AJM) is a non-traditional machining process Abrasive Feeder
in which material is removed by the high-velocity stream of abrasive • Stores the abrasive particles (Al₂O₃, SiC, glass beads, etc.).
particles carried by compressed air or gas.
• Supplies abrasives in a controlled manner into the gas stream.
• The impact of abrasives on the work surface causes small fractures,
Mixing Chamber
erosion, and material removal.
• Place where the compressed gas and abrasives are properly mixed.
• Mostly used for hard, brittle, and heat-sensitive materials.
• Ensures uniform abrasive flow to the nozzle.
Nozzle
• Made of hard materials like tungsten carbide or sapphire to resist
wear.
• Converts the high-pressure mixture into a high-velocity jet.
• Directs the abrasive jet towards the workpiece.
Workpiece
• The target material to be machined (usually hard and brittle materials
like glass, ceramics, carbides).
Working Principle • Material removal takes place here by impact/erosion.
• High-pressure gas (air, CO₂, or nitrogen) is used as a carrier. Dust Collector / Enclosure (Optional)
• The gas passes through a nozzle, mixed with fine abrasive particles • Used to collect the spent abrasives and prevent air pollution.
(e.g., Al₂O₃, SiC). Process Parameters
• The high-velocity jet of abrasives strikes the workpiece. • Gas pressure: 2–10 bar.
• Material is removed due to impact and erosion. • Abrasive size: 10–50 microns.
Constructions • Jet velocity: 150–300 m/s.
Gas Supply Unit • Common abrasives: Aluminum oxide (Al₂O₃), Silicon carbide (SiC),
• A cylinder filled with compressed gas (air, nitrogen, or CO₂). Glass beads.
• Provides the carrier medium for abrasive particles. Applications of AJM
Pressure Regulator • hard and brittle materials
• Cutting & cleaning.
• Etching on glass and decorative work. 3. Discuss the ultrasonic machining with a neat sketch.
• Drilling fine holes in heat-sensitive materials. Definition
Advantages of AJM • Ultrasonic Machining (USM) is a non-traditional machining
• hard, brittle, and fragile materials process in which material is removed by high-frequency
vibrations (20–40 kHz) of a tool, assisted by an abrasive
• heat-sensitive materials.
slurry.
• fine holes, intricate shapes, and delicate machining.
• The vibrating tool impacts abrasive grains, and these
• High surface finish possible. abrasives strike the workpiece surface, causing erosion and
• Simple and low-cost setup. micro-chipping.
Disadvantages of AJM • Mainly used for hard, brittle, and non-conductive materials
• Low material removal rate (MRR) → not suitable for heavy machining. like glass, ceramics, carbides, and diamonds.
• Nozzle wear is high → frequent replacement needed.
• Accuracy depends on abrasive size and jet control.
• Dust produced → requires proper handling.
• Not suitable for soft and ductile materials.
Construction of USM
The main parts of an Ultrasonic Machining setup are:
• Power Supply
o Provides high-frequency electrical energy.
• Transducer
o Converts electrical energy into mechanical vibrations
(using magnetostrictive or piezoelectric effect).
• Booster / Horn
o Amplifies the vibrations from the transducer and
transmits them to the tool.
• Tool Holder and Tool
o Tool is shaped according to the desired cavity.
o Made of soft ductile materials (brass, mild steel) so it Disadvantages
doesn’t wear quickly. • Low material removal rate (MRR).
• Abrasive Slurry Circulation System • Tool wear is significant.
o Mixture of water and fine abrasives (Al₂O₃, SiC, • Not suitable for soft and ductile materials.
Boron carbide). • Equipment is costly and requires skilled operation.
o Continuously supplied to the machining zone.
• Workpiece
o Usually hard and brittle material (glass, ceramic,
tungsten carbide, diamond).
Working Principle
1. The transducer produces ultrasonic vibrations (20,000–
40,000 Hz).
2. Vibrations are transmitted through the booster/horn to the
tool.
3. The tool vibrates at ultrasonic frequency with small
amplitude (0.01–0.05 mm).
4. Abrasive slurry is fed into the machining gap between tool
and workpiece.
5. Abrasive particles, hammered by the vibrating tool, impact
the workpiece surface.
6. Material is removed by erosion and brittle fracture.
Applications of USM
• Drilling holes in glass, ceramics, carbides, diamonds.
• Machining intricate shapes in hard materials.
• Used in aerospace, electronics, and medical instruments.
• Etching and engraving on brittle materials.
Advantages
• Can machine hard, brittle, and non-conductive materials.
• Produces complex shapes and fine features.
• No thermal damage to workpiece (cold machining).
• Good surface finish.