Module-1

NTM – Introduction

The conventional processes generally involve a wedge shaped

cutting tool to remove material in the form of chip by causing
plastic deformation and shear failure. The cutting tool has to be
harder than the work piece at room temperature as well as under
machining conditions.

Non-traditional manufacturing processes is defined as a process

to remove excess material by various techniques involving
mechanical, thermal, electrical or chemical energy or
combinations of these energies but not by the use of sharp
cutting tools.
 Module-1

Extremely hard and brittle materials are difficult to machine

by traditional machining processes such as turning, drilling,
shaping and milling.

Non traditional machining processes, also called advanced

manufacturing processes, are employed where traditional
machining processes are not feasible, satisfactory or
economical due to special reasons as outlined below.
 Module-1

Situations where traditional machining processes are

unsatisfactory or uneconomical:
1. Workpiece material is too hard, strong or tough.
2. Workpiece is too flexible to resist cutting forces or too
difficult to clamp.
3. Part shape is very complex with internal or external
profiles or small holes.
4. Requirements for surface finish and tolerances are very
high.
5. Temperature rise or residual stresses are undesirable or
unacceptable.
 Need for the development of NTM Processes

The strength of steel alloys has increased five folds due to

continuous R and D effort. In aero-space requirement of High
strength at elevated temperature with light weight led to
development and use of hard titanium alloys, nimonic alloys
(NIMONIC is a family of nickel-based alloys primarily
consisting of nickel and chromium), and other HSTR alloys. The
ultimate tensile strength has been improved by as much as 20
times. Development of cutting tools which has hardness of 80 to
85 HRC which cannot be machined economically in
conventional methods led to development of non –traditional
machining methods.
 Need for the development of NTM Processes

[Link] advanced industries like aerospace, nuclear

power, wafer fabrication (procedure composed of many repeated
sequential processes to produce complete electrical circuits. Examples
include production of radio frequency (RF) amplifiers, LEDs, optical
computer components, and CPUs for computers), automobiles has
ever increasing use of High –strength temperature resistant
(HSTR) alloys (having high strength to weight ratio) and other
difficult to machine materials like titanium, SST, nimonics,
ceramics and semiconductors. It is no longer possible to use
conventional process to machine these alloys.
[ To machine high strength alloys]
 Need for the development of NTM Processes

2. Production and processing parts of complicated shapes (in

HSTR and other hard to machine alloys) is difficult, time
consuming and uneconomical by conventional methods of
machining.
[ To produce complex shapes and surfaces]

3. Innovative geometric design of products and components

made of new exotic materials with desired tolerance, surface
finish cannot be produced economically by conventional
machining.
[ To machine exotic materials ]
 Need for the development of NTM Processes

4. High accuracy and surface finish in hard, brittle, fragile and

thin materials is not possible by conventional methods.
[ To obtain higher accuracy and surface finish]

5. The difficult geometry like dies, small holes less than 0.1 mm
and holes with aspect ratio of 100:1 etc., are impossible to
generate by conventional machining.
[ To produce difficult geometries ]
 Need for the development of NTM Processes

The following examples are provided where NTM processes are

preferred over the conventional machining process:
Intricate shaped blind hole – e.g. square hole of 15 mm x15
mm with a depth of 30 mm with a tolerance of 100 microns
Difficult to machine material – e.g. Inconel, Ti-alloys or
carbides, Ceramics, composites , HSTR alloys, satellites etc.,
Low Stress Grinding – Electrochemical Grinding is preferred
as compared to conventional grinding
Deep hole with small hole diameter – e.g. φ 1.5 mm hole with
l/d = 20
 NTM-Characteristics

• Material removal occurs with micro chip formation or even no

chip formation. For example in AJM, chips are of microscopic
size and in case of Electrochemical machining material (no
chips) removal occurs due to electrochemical dissolution at
atomic level.

• In NTM, there may not be a physical tool present. For example

in laser jet machining, machining is carried out by laser beam.
Energy in its direct form is used. However in Electrochemical
Machining there is a physical tool that is very much required for
machining
 NTM-Characteristics

• In NTM, the tool need not be harder than the work piece
material. For example, in EDM, copper is used as the tool
material to machine hardened steels.

• Most NTM processes do not use mechanical energy to provide

material removal. They use different energy domains to provide
machining. For example, USM, AJM, WJM uses mechanical
energy where as ECM uses electrochemical dissolution
constitutes material removal.
 NTM-Characteristics

• Tool wear is negligible in most processes. No burr is left on the

workpiece.

• Entire complicated shapes can be produced in one machine

setting like EDM

•Extremely good surface finish and surface integrity is possible.

•NTM processes are versatile and productive processes and can

be integrated easily with NC, CNC etc
Sl. Traditional Machining Non-traditional Machining
No
01 The cutting tool and work piece There is no physical contact
are always in physical contact between the tool and work piece,
with relative motion with each In some non traditional process
other, which results in friction tool wear exists.
and tool wear.
02 Material removal rate is limited
NTM can machine difficult to cut
by mechanical properties of and hard to cut materials like
work material. titanium, ceramics, nimonics,
SST, composites, semiconducting
materials
03 Machining of small cavities, Machining of small cavities, slits
slits, blind holes or through and Production of non-circular,
holes are Difficult micro sized, large aspect ratio,
holes are easy using NTM
Sl. Traditional Machining Non-traditional Machining
No
04 Relative motion between the tool Many NTM processes are
and work is typically rotary or capable of producing complex
reciprocating. Thus the shape of 3D shapes and cavities.
work is limited to circular or flat
shapes. In spite of CNC systems,
production of 3D surfaces is still
a difficult task.
05 Use relative simple and Non traditional processes
inexpensive machinery and requires expensive tools and
readily available cutting tools equipment as well as skilled
labour, which increase the
production cost significantly
06 Capital cost and maintenance Capital cost and maintenance
cost is low cost is high
Sl. Traditional Machining Non-traditional Machining
No
07 Traditional processes are well Mechanics of Material removal
established and physics of of Some of NTM process are
process is well understood still under research

08 Conventional process mostly Most NTM uses energy in

uses mechanical energy direct form For example : laser,
Electron beam in its direct
forms are used in LBM and
EBM respectively
09 Surface finish and tolerances High surface finish (up to 0.1
are limited by machining micron) and tolerances (25
inaccuracies Microns) can be Achieved
10 High metal removal rate. Low material removal rate.
 Comparison between traditional & NTM processes in terms of
cost, applications, scope, machine time and limitations

Factors Traditional Machining Non-traditional Machining

Cost Initial cost & tool and Initial capital investment &
fixture cost of conventional tool cost are higher
equipment is low compared to conventional
process
Applicat It cannot be used to cut high It can be used to cut high
ions strength, high toughness and strength & high temperature
high temperature materials resistant materials
Scope Complicated geometry Thin, fragile, brittle and
cannot be produced. Thin refractory materials of
fragile materials are difficult complicated geometry can e
to machine cut
 Comparison between traditional & NTM processes in terms of
cost, applications, scope, machine time and limitations

Factors Traditional Machining Non-traditional Machining

Machine Parts can be produced MRR for most of the NTM
time faster. MRR is high. It is processes is low and hence
suitable for mass machining time is low. It is
production suitable for batch production.
Limitation Tool must be harder NTM can machine difficult –
than the WP. MRR is to-cut and hard –to –cut
limited by mechanical materials like titanium,
properties of the work ceramics, nimonics, SST,
material semiconducting materials and
composites.
 CLASSIFICATION OF NTM

NTM processes can be classified into categories:

(a) Based on fundamental energy used
(b) Based on the mechanism, transfer media and
energy source
(a) Based on fundamental energy used
(i) Mechanical energy
(ii) Electrochemical energy (Ion displacement)
(iii) Electro thermal energy (Thin intense local heat)
(iv) Chemical energy (application of acidic or
alkaline in nature)
 CLASSIFICATION OF NTM
1. Mechanical Processes
(a) Abrasive Jet Machining (AJM)
(b) Ultrasonic Machining (USM)
2. Electrochemical Processes
(a) Electrochemical Machining (ECM)
(b) Electro Chemical Grinding (ECG)
(c) Electro Jet Drilling (EJD)
3. Electro-Thermal Processes
(a) Electri-discharge machining (EDM)
(b) Laser Jet Machining (LJM)
(c) Electron Beam Machining (EBM)
4. Chemical Processes
(a) Chemical Machining (CHM)
(b) Photochemical Machining (PCM)
 CLASSIFICATION OF NTM

(a) Based on Mechanism, Transfer media and energy

source
(i) Basic mechanism involved in the processes like shear,
erosion, ionic dissolution, vaporization, chemical
ablation, thermal ablation etc
(ii) Source of immediate energy required for material
removal, namely hydrostatic pressure, high current
density, high voltage, ionized material, chemical energy
etc.
(iii) Medium for transfer of those energies like high
velocity particles, electrolyte, electron, hot gases,
radiation etc
 SELECTION OF NTM
The correct selection of non-traditional machining methods must
be based on the following aspects.
1. Physical parameters of the process
2. Shapes to be machined
3. Materials applications
4. Metal removal rate (MRR) (Process capability)
i. Tolerance
ii. Surface finish
iii. Surface damage depth
iv. Specific power
5. Process economy
 SELECTION OF NTM
1. Physical parameters of the process
The following table gives the physical parameters of some
modern machining processes.
Parame Unit ECM EDM EBM LBM PAM USM AJM
ters s
Potential Volts 5-30 DC 50 200000 4500 250 220 220
Current Amp 10000 DC 15-300 0.001 2 600 12 AC 1.5
ere pulsed DC pulsed DC
Power Watt 100000 2700 150 Avg 2000 50000 2400 250
s 2000 Peak
Gap mm 0.25 0.025 100 150 7.5 0.25 0.75
Medium - Liquid Liquid Vacuum Air, Argon, Abrasive Argon,
electrolyte dielectric Hydro Nitrogen, grain and Nitroge
gen Hydrogen water n, Co2
Work - Conductive Conductive All All Conducti Hard, Hard,
Material , Difficult , Difficult materials materi ve brittle brittle
to machine to machine als materials and and
fragile fragile
 SELECTION OF NTM

1. Physical parameter of the process

From the physical parameters of the different NTM processes.

PAM and ECM require high power for fast machining.
EBM and LBM require high voltages and require careful
handling of equipment.
EDM and USM require medium power.
EBM can be used in vacuum and
PAM uses oxygen and hydrogen gas.
 SELECTION OF NTM
2. Shapes to be machined
The following table gives shape application of some modern machining processes.

NTM Hole making Cavity sinking Pocketing Cutting

Proces
s Precision holes Standard holes Precisi Standard Shall Deep Shallo Deep
on cavity ow pocket w cut cut
D<0.25 D>0.25 L/d<20 L/d>20 cavity pocke
mm mm t

USM Good Poor Good Good Poor Poor Poor

AJM Fair Poor Poor Fair Good

ECM Good Good Fair Good Good Good Good Good

CHM Poor Fair Good Poor Good
EDM Good Fair Good Good Good Good Poor
LBM Good Good Fair Poor Poor Poor Good Fair
PAM Fair Poor Poor Good Good
 SELECTION OF NTM
3. Materials applications
The following table gives summery of various NTM processes.
 SELECTION OF NTM
4. Metal removal rate (MRR)
The process capability criterion is mainly associated with the
ability of the NTM processes to achieve the desired material
removal rate, tolerance, surface finish, etc. on the work
material. The followings are the different sub-criteria as
considered under the process capability criterion:
(a) Material removal rate (b) Tolerance
(c) Surface finish (d) Surface damage depth
(e) Corner radii.
 SELECTION OF NTM
4. Metal removal rate (MRR)
The following table gives summery of various process capabilities of NTM processes.
 SELECTION OF NTM
5. Process economy

This is directly related to the economical aspects of the NTM

processes and helps in making decisions on the basis of the
following sub-criteria:
(a) Capital investment (b) Tooling and fixtures
(c) Power requirement (d) Efficiency
(e) Tool consumption.
 SELECTION OF NTM
5. Process economy
The following table gives summery of various process capabilities of NTM processes.
 Advantages of NTM
1. There is no mechanical or physical contact between
the WP & tool. (EDM, ECM, CHM, LBM)

2. MRR is independent of hardness of materials & other

properties like brittleness, toughness, strength etc.,

3. NTM can be used to machine any class of material.

4. Hardness of the WP does not affect the cutting forces

generated since there is no physical WP & tool
interaction. (EDM, ECM, CHM, USM)

5. Quieter operations (EDM, CHM)

 Advantages of NTM
6. The tool wear is negligible and for most of the NTM,
tool wear is zero. (ECM, LBM, CHM)

7. NTM can produce burr-free surfaces. (ECM, EDM,

CHM)

8. Uniform metal removal over the entire surface area is

possible. (CHM, ECM)

9. NTM produces good surface finish. (ECM, ECG,

CHM)
10. NTM processes are capable of producing residual
stress-free surfaces. (ECM, CHM, ECG)
 Advantages of NTM

11. Complex shapes, hard and fragile materials can be

machined.
(Roof lights, Fibre cement sheets, Corroded metal sheets, Glass,
Wood wool slabs)

12. Most of NTM processes can be integrated easily with

NC, CNC, DNC (Direct numerical control) and FMS.
(Flexible manufacturing system is a manufacturing system in which
there is some amount of flexibility that allows the system to react in
case of changes, whether predicted or unpredicted)
 Advantages of NTM

13. Micromachining of complex parts is possible. (EDM,

ECM, LBM, EBM)
(Micromachining is the basic technology for fabrication of micro-
components of size in the range of 1 to 500 micrometers. Their need
arises from miniaturization of various devices in science and
engineering, calling for ultra-precision manufacturing and micro-
fabrication)

14. NTM can maintain productivity with the desired

shape, accuracy and surface finish.
 Disadvantages of NTM
1. The NTM are quite expensive & initial investment is
high. (LBM, EBM, PAM, EDM)

2. Their specific power consumption is high. (EDM,

ECM)

3. Process performance depends on thermal, electrical

and chemical properties of WP.

4. MRR is low. (LBM, EBM)

5. It is not possible to produce perfect holes and cavities.

(EDM, LBM – produces side wall taper)
 Disadvantages of NTM

6. Heat affected zones (HAZs) produced by some NTM

processes may alter surface metallurgical properties
which may affect functioning of parts (LBM, EBM)

7. Highly skilled machine operators are required. (LBM,

EDM, EBM)

8. In some NTM processes, depth of penetration is low.

(LBM)
 Applications of NTM

1. Cutting of titanium foil, drilling of glass wafers,

engraving of registration numbers on toughened glass
of automobiles (AJM)

1. Drilling holes in non-conductive ceramics, drilling of

multiple holes (upto 930 holes of 0.32 mm dia) at the
same time, fabrication of turbine blades made of
silicon nitride (USM)
 Applications of NTM

3. Finishing of extrusion dies, nozzle of flame cutting

torch, airfoil surfaces of impellers, deburring of
aircraft valve bodies. (Metal extrusion is a metal forming
process in which a work piece, of a certain length and cross
section, is forced to flow through a die of a smaller cross sectional
area, thus forming the work to the new cross section)

4. Cutting of asbestos in aerospace industries, fiber glass

& polyethylene automotive parts (WJM)
 Applications of NTM

5. Machining of sandwiched honeycomb structures.

(sandwich structure consists of two relatively thin, stiff and strong
faces separated by a relatively thick lightweight core, (honeycomb)

6. Manufacture of hardened dies, plastic injection molding

dies, tiny holes of 10 microns in fragile & thin materials,
removal of broken taps, square holes, narrow slots &
blended features (EDM)
 Applications of NTM

7. Fabrication of press tools & dies (WEDM)

(Press tools are commonly used in hydraulic, pneumatic, and

mechanical presses to produce components at high volumes.
Generally press tools are categorized by the types of operation
performed using the tool, such as blanking, piercing, bending,
forming, forging, trimming etc.)

8. Cutting difficult – to – machine materials such as

composites, ceramics, micromachining of holes (LBM)
 Applications of NTM

9. Turning of difficult –to- machine materials,

simultaneous cutting of varieties of shapes, cutting of
thick materials (PAM)

10. Drilling of thousands of holes (less than mm) in very

thin plates used in turbine engine combustion domes,
holes in filters and screens in food processing
industries. Fine gas orifices in nuclear reactors, cooling
holes in turbine blades
 Applications of NTM

11. Cutting of HSTR alloys, cutting of curvilinear slots,

production of long curved profiles, production of
satellite rings and connecting rods, machining of gears,
machining of thin large diameter diaphragms (ECM)

12. Grinding of carbide cutting tools, reprofiling of worn

locomotive traction motor gears, sharpening of
hypodermic needles (ECG)

13. Removal of material in aircraft wing panel to reduce

weight (CHM)