INTRODUCTION TO NTM ( BME755A )

Module 1
All Answer are from the prescribed VTU textbook for the above course

1 What is non-traditional machining and what are the need for non-traditional machining.

A machining process is called non-traditional if its material removal mechanism is basically different than
those in the traditional processes, i.e. a different form of energy is applied to remove the excess material
from the work surface, or to separate the workpiece into smaller parts.

Need for Non-Traditional Machining (NTM) Processes

1. Machining of hard and advanced materials:
Modern industries widely use HSTR alloys, titanium alloys, nimonics, ceramics, carbides, and
composites, which are difficult or impossible to machine economically using conventional machining
processes.
2. Increased material strength due to R&D:
Continuous research has increased the strength of steel alloys nearly five times and ultimate tensile
strength up to 20 times, making conventional cutting methods ineffective.
3. Requirement of high strength-to-weight ratio:
Aerospace and nuclear industries demand materials with high strength at elevated temperatures
and low weight, necessitating the use of NTM processes.
4. Machining of complex and intricate shapes:
Components with complicated profiles, blind cavities, and internal features cannot be produced
easily by conventional machining but are efficiently manufactured using NTM.
5. High dimensional accuracy and surface finish:
Modern product designs require close tolerances and superior surface finish, which are difficult to
achieve economically with conventional methods.
6. Low or no cutting forces:
Most NTM processes involve no direct contact between tool and workpiece, resulting in negligible
mechanical stresses, suitable for thin and fragile parts.
7. Machining of deep and micro-size holes:
NTM processes can machine small-diameter deep holes (high L/D ratio) which are difficult using
conventional drilling methods.
8. Special application requirements:
NTM is preferred for low-stress grinding, machining of composites, and high-precision aerospace
and electronic components, where conventional machining fails.
2 Differences between Conventional and Non-conventional machining processes.

Sl.
Conventional Machining Process Non-Conventional Machining (NTM) Process
No.
No physical contact between tool and workpiece in
Cutting tool and workpiece are always in physical
1 most NTM processes; tool wear is very less or
contact, causing friction and tool wear.
absent.
Can machine hard and difficult-to-cut materials
Material removal rate is limited by mechanical
2 like titanium, ceramics, nimonics, stainless steel,
properties of the work material.
composites, and semiconductors.
Relative motion is mainly rotary or
Capable of producing complex 3D shapes, profiles,
3 reciprocating, limiting shapes to circular or flat
and cavities easily.
surfaces; complex 3D shapes are difficult.
Machining small cavities, slits, blind holes, and Machining of small cavities, slits, non-circular,
4
micro holes is difficult. micro-sized and high aspect ratio holes is easy.
Uses simple and inexpensive machines with Requires expensive equipment, tools, and skilled
5
readily available cutting tools. operators, increasing production cost.
6 Capital and maintenance cost are low. Capital and maintenance cost are high.
Processes are well established and the physics of Material removal mechanism of some NTM
7
material removal is well understood. processes is still under research.
Uses non-mechanical energy such as laser,
8 Uses mechanical energy for material removal.
electrical, chemical, or electron beam energy.
Surface finish and tolerances are limited by tool High surface finish (up to 0.1 μm) and close
9
wear and machine inaccuracies. tolerances (up to 25 μm) can be achieved.
10 High material removal rate (MRR). Low material removal rate (MRR).
 3 What are the limitations, advantages and Applications of NTM.

Advantages of NTM
1. Capable of producing any geometric shape with the desired finish, accuracy, and precision on almost
any material.
2. No direct contact between tool and workpiece; hence no cutting forces act on the workpiece.
3. The workpiece is free from changes in microstructure and physical properties caused by tool–work
interaction as in conventional machining.
4. No distortion, burrs, or residual stresses are produced; the process is quiet in operation.
5. Machining is characterized by microscopic chip formation, so chip handling and storage are not
major problems.
6. Complex and intricate shapes can be produced easily.
7. NTM processes can be easily automated, making them suitable for precision manufacturing.

Limitations of NTM
1. Initial cost of tooling and equipment is high.
2. NTM involves many process parameters; failure to control them results in poor and undesired
results.
3. Skilled operators are required to operate and control the machines.
4. Machine setup is very complex.
5. Regular monitoring and maintenance of machine components is essential.
6. Most NTM processes consume more power compared to conventional machining.

Applications of NTM
1. Used for machining hard and difficult-to-cut materials such as superalloys, nimonics, carbides, heat-
resistant steels, ceramics, and composites.
2. Used for machining thin, fragile parts and complex geometrical profiles with high accuracy and
superior surface finish.
3. Widely used in aerospace, automobile, electronics, and medical industries.
4. Suitable for machining shapes that cannot be machined easily by conventional cutting tools.
5. Used for micro-machining, engraving, drilling of very small holes, and precision components.
6. Used in engraving, marking, graphics, logos, symbols, and artistic applications.

4 list and explain the various factors to be considered for the selection of NTM process

Factors to be Considered for Selection of NTM Process

a) Properties of Work Material
Workpiece materials have different properties such as hardness, brittleness, electrical conductivity, and
thermal conductivity.
• Hard and brittle materials like ceramics and glass are suitable for USM.
• Electrically conductive materials are required for EDM and ECM.
Thus, the nature of the work material plays a major role in selecting the appropriate NTM process.
b) Shape to be Machined
The geometry and shape of the component affect process selection.
• USM and LBM are not suitable for machining deep holes.
• EDM and ECM are comparatively better for deep cavities and complex shapes.
Hence, the required shape and complexity must be considered.

c) Physical Parameters of NTM Process

Common physical parameters include power requirement, material removal mechanism, and interaction
between tool and workpiece.
• Processes like USM and EDM consume moderate power.
• ECM and CM consume comparatively higher power.
The gap between tool and workpiece and energy transfer mechanism influence the selection.

d) Process Capabilities
This includes material removal rate (MRR), surface finish, accuracy, and tolerance.
• PAM has a higher MRR but causes surface damage.
• EDM and ECM provide good surface finish and accuracy.
The required output quality determines the choice of process.

e) Economic Considerations
Economic factors include initial investment, tooling cost, operating cost, and power consumption.
• USM and AJM have low power consumption.
• EDM, ECM, and LBM involve high equipment and tooling costs.
The overall cost-effectiveness of machining a component is a crucial factor.

5 Classification of NTM Processes.

Classification of NTM Processes
Non-Traditional Machining processes are classified based on the type of energy used for material removal.

1. Mechanical Energy Based Processes

Material removal takes place due to mechanical erosion or abrasion of the workpiece.
Processes include:
• AJM – Abrasive Jet Machining
• USM – Ultrasonic Machining
• WJM – Water Jet Machining
• AWJM – Abrasive Water Jet Machining
• AFM – Abrasive Flow Machining
• MAF – Magnetic Abrasive Finishing
Features:
• No thermal damage
• Suitable for brittle and hard materials
• Used for cutting, drilling, deburring, and finishing

2. Chemical / Electrochemical Energy Based Processes

Material removal occurs due to chemical dissolution or electrochemical reactions.
a) Chemical Machining (CHM)
• Material is removed by controlled chemical etching using acids or alkaline solutions.
Processes include:
• CHM – Chemical Machining
• PCM – Photochemical Machining

b) Electrochemical Machining (ECM)

• Material removal takes place due to anodic dissolution using electric current and electrolyte.
Processes include:
• ECM – Electrochemical Machining
• ECG – Electrochemical Grinding
• EJD / ECD – Electrochemical Jet / Deburring
Features:
• No tool wear
• High surface finish
• Applicable only for electrically conductive materials

3. Electro-Thermal (Thermal) Energy Based Processes

Material is removed by localized melting and vaporization due to intense thermal energy.
Processes include:
• EDM – Electrical Discharge Machining
• LBM – Laser Beam Machining
• EBM – Electron Beam Machining
• PAM – Plasma Arc Machining
• IBM – Ion Beam Machining
Features:
• Suitable for very hard materials
• High precision possible
• Heat-affected zone may be present