MODULE -1

1. INTRODUCTION TO NON-TRADITIONAL
MACHINING
SYLLABUS

Introduction to Non-traditional machining, Need for Non-traditional machining process,

Comparison between traditional and non-traditional machining, general classification, Non-
traditional machining processes, classification based on nature of energy employed in
machining, selection of non-traditional machining processes, Specific advantages, limitations
and applications of non- traditional machining processes.

1.1. Introduction to Non-traditional machining

Non-traditional manufacturing processes is defined as a group of processes that remove
excess material by various techniques involving mechanical, thermal, electrical or chemical
energy or combinations of these energies but do not use a sharp cutting tool as it needs to be
used for traditional manufacturing processes.

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.

 Very hard fragile materials difficult to clamp for traditional machining

 When the work piece is too flexible or slender
 When the shape of the part is too complex.

Several types of non-traditional machining processes have been developed to meet extra
required machining conditions. When these processes are employed properly, they offer
many advantages over non-traditional machining processes. The common non-traditional
machining processes are described in this section.

Definition: A machining process is called Non-traditional machining if its material removal

mechanism is basically different than those in the traditional processes, i.e. a different form
of energy (other than the excessive forces exercised by a tool, which is in physical contact
with the work piece) is applied to remove the excess material from the work surface, or to
separate the workpiece into smaller parts.

1.2. Need for development of Non-Conventional Processes

The strength of steel alloys has increased five folds due to continuous R&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 (Nickel based) alloys, 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.

 Technologically advanced industries like aerospace, nuclear power, wafer fabrication,

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.
 Production and processing parts of complicated shapes (in HSTR and other hard to
machine alloys) is difficult, time consuming an uneconomical by conventional methods
of machining.
 Innovative geometric design of products and components made of new exotic materials
with desired tolerance, surface finish cannot be produced economically by conventional
machining.
 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 mmx15 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
• Machining of composites.

Non-Traditional Machining (NTM) Processes are characterized as follows:

 Material removal may occur with chip formation or even no chip formation may take
place. For example in AJM, chips are of microscopic size and in case of Electrochemical
machining material 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. However in Electrochemical Machining there is
a physical tool that is very much required for machining
 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.
 Mostly NTM processes do not necessarily use mechanical energy to provide material
removal. They use different energy domains to provide machining. For example, in
USM, AJM, WJM mechanical energy is used to machine material.

1.3. Differences between Conventional and Non-Conventional

machining processes
Sl
Conventional Process Non-Conventional Process
No.
The cutting tool and work piece are always
There is no physical contact between the
in physical contact with relative motion
1. tool and work piece, In some non-
with each other, which results in friction
traditional process tool wear exists
and tool wear
NTM can machine difficult to cut and hard
Material removal rate is limited by to cut materials like titanium, ceramics,
2.
mechanical properties of work material nimonics, SST, composites,
semiconducting materials
Relative motion between the tool and
work is typically rotary or reciprocating.
Thus the shape of work is limited to Many NTM are capable of producing
3.
circular or flat shapes. In spite of CNC complex 3D shapes and cavities
systems, production of 3D surfaces is still
a difficult task
Machining of small cavities, slits and
Machining of small cavities, slits, blind Production of non-circular, micro sized,
4.
holes or through holes are difficult large aspect ratio, shall entry angle holes
are easy using NTM
Non-traditional processes requires
Use relative simple and inexpensive
expensive tools and equipment as well as
5. machinery and readily available cutting
skilled labour, which increase the
tools
production cost significantly
6. Capital cost and maintenance cost is low Capital cost and maintenance cost is high
Traditional processes are well established Mechanics of Material removal of some of
7.
and physics of process is well understood NTM process are still under research
Most NTM uses energy in direct form. For
Conventional process mostly uses example: laser, Electron beam in its direct
8.
mechanical energy forms are used in LBM and EBM
respectively
Surface finish and tolerances are limited High surface finish (up to 0.1 µm) and
9.
by machining inaccuracies tolerances (25 µm) can be achieved
10. High metal removal rate Low material removal rate

1.4. Classification of NTM process

 Mechanical Processes - Erosion of work material by a high velocity stream of abrasives
or fluid (or both) is the typical form of mechanical action. It is characterized by the fact
that the material removal is due to the application of mechanical energy in the form of
 high frequency vibrations or kinetic energy of an abrasive jet.
• Abrasive Jet Machining (AJM)
• Ultrasonic Machining (USM)
• Water Jet Machining (WJM)
 Electrochemical Processes – Electro chemical energy to remove material (reverse of
electroplating). Electrical energy used in combination with chemical reactions to remove
material.
• Electro Chemical Machining (ECM)
• Electro Chemical Grinding (ECG)
• Electro Jet Drilling (EJD)
• Electro-Thermal Processes - Thermal energy usually applied to small
portion of work surface, causing that portion to be removed by
fusion and/or vaporization
• Electro-discharge machining (EDM)
• Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)
 Chemical Processes - Chemical etchants selectively remove material from portions of
work part, while other portions are protected by a mask.
• Chemical Milling (CHM)
• Photochemical Milling (PCM)

Classification based on energy employed in machining is shown in Fig.1

Fig.1 Classification non-traditional machining processes

1.5. Selection of Process

The correct selection of the non-traditional machining methods must be based on the
following aspects.

i) Physical parameters of the process

ii) Shape to be machined
iii) Process capability
iv) Economics of the processes

1.5.1. Physical parameter of the process

The physical parameters of the different NTM are given in the Table (refer ppt.) which
indicates that 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.

1.5.2. Shapes cutting capability

The different shapes can be machined by NTM. EBM and LBM are used for micro drilling
and cutting. USM and EDM are useful for cavity sinking and standard hole drilling. ECM is
useful for fine-hole drilling and contour machining. PAM can be used for cutting and AJM is
useful for shallow pocketing.

1.5.3. Process capability

The process capability of NTM is given in Table 2.0 EDM which achieves higher accuracy
has the lowest specific power requirement. ECM can machine faster and has a low thermal
surface damage depth. USM and AJM have very material removal rates combined with high
tool wear and is used for nonmetal cutting. LBM and EBM are, due to their high penetration
depth can be used for micro drilling, sheet cutting and welding. CHM is used for manufacture
of PCM and other shallow components.

1.5.4. Economic consideration

1.6. Applications of NTM

 NTM are used to machine hard and difficult-to-cut materials like superalloys, nimonics,
carbides, heat resisting steel, etc, which are widely used in various engineering
applications.
 NTM is used for machining very thin and fragile parts, complex geometrical profiles
with superior finish, accuracy and tolerance, which are mostly preferred in aerospace,
automotive, nuclear, mining and other sectors.
 NTM are used for shaping hard cutting tools having complex geometrical profiles with
much precise accuracy.
 Apart from engineering applications, NTM processes are also used for preparation of
jewels for watch and timer movements; removing glue and paint from leather objects and
paintings; engraving of products with alphanumeric or bar codes, logos, symbols,
graphics and other applications.
 In addition, NTM are also used in machining of cavities in forging dies, drilling deeper
holes and irregular shaped holes which cannot be obtained by conventional machining
methods.

1.7. Advantages
 Difficult to machine materials can be machined with non-conventional process
 Machining materials in the complex shapes is possible with non-conventional process
 Economical for mass production for long duration
 High strength to weight ratio, hardness and heat resisting materials can be machined with
non- conventional process
 High accuracy and surface finish
 Burr-free machining(ECM, EDM, CHM)
 Material removed without mechanical contact with the workpiece (ECM, EDM, LBM,
CHM).
 Material removal rate is independent of workpiece hardnesss (ECM, LBM, EDM)
 Cutting forces are independent of workpiece hardness (ECM, LBM, EDM, CHM)
 Tool material need not be harder than the workpiece material (ECM, LBM, EDM, CHM,
USM)
 Tool wear is not a problem (ECM, LBM, CHM)
 Ability to machine any material.(LBM)
 Stress- free machining (ECM, ECG, CHM)
 Uniform material removal over the entire area simultaneously (ECM, CHM)
 Superior surface integrity possible (ECM, CHM, ECG)
 Intricately shaped, very hard and fragile materials can be machined.(USM)
 Finely focused micro machining
 Micro- hole drilling at shallow entrance angles possible (EDM, ECM, LBM, EBM)
 Easy compatibility with numerical control and mini- computer controls (ECM, EDM,
LBM, EBM)

1.8. Limitations
 Work piece and tool must be electrically conductive (EDM,ECM)
 Depth of cut is limited (LBM)
 Recast or heat affected zones (HAZ) of surfaces produced may be troublesome
(EDM,LBM,EBM)
 For this purpose the compatibility of the process with the metallurgical state of the work
piece materials can be studied before using a particular non-traditional machining
process for production work.
 There may be taper in the sidewalls of holes or cavities (EDM,LBM)
 Most of these limitations can be overcome and controlled, so that the advantages can be
obtained with good product quality assurance.