Non-Traditional Machining

NON-TRADITIONAL MACHINING
UNIT -1

INTRODUCTION
LESSON STRUCTURE:
1.1 Definition

1.2 Non traditional machining (ntm) processes characteristics

1.3 Need for development of non-conventional processes

1.4 Differences between conventional and non conventional machining processes

1.5 Selection of process

1.6 Physical parameter of the process

OBJECTIVES
 ii. Identify the characteristics of non traditional machining
 iii. Differentiate between conventional and non traditional machining
 iv. Classify different non traditional machining processes
 v. Identify the need for non traditional machining processes
 Non-Traditional Machining

NON-TRADITIONAL MACHINING

INTRODUCTION

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 tools 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 workpiece 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.

1.1 Definition:
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 (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.
Non-Traditional Machining

1.2 Non Traditional Machining (NTM) Processes are characterised 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 Need for development of Non-Conventional 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, 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.
[Link] 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.
2. 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
Non-Traditional Machining

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.
4. 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

1.4 Differences between Conventional and Non-conventional machining

Processes.

Sl Conventional Process Non-Conventional Process

No.
1. The cutting tool and work piece are There is no physical contact between
always in physical contact with the tool and work piece, In some non
relative motion with each other, traditional process tool wear exists.
which results in friction and tool
wear.
2. Material removal rate is limited by NTM can machine difficult to cut and
mechanical properties of work hard to cut materials like
material. titanium,ceramics,nimonics,
SST,composites,semiconducting
materials
Non-Traditional Machining

3. Relative motion between the tool Many NTM are capable of producing
and work is typically rotary or complex 3D shapes and cavities
reciprocating. Thus the shape of
work is limited to circular or flat
shapes. In spite of CNC systems,
production of 3D surfaces is still a
difficult task.
4. Machining of small cavities , slits , Machining of small cavities, slits and
blind holes or through holes are Production of non-circular, micro sized,
difficult large aspect ratio, shall entry angle
holes are easy using NTM
5. Use relative simple and inexpensive Non-traditional processes requires
machinery and readily available expensive tools and equipment as well
cutting tools as skilled labour, which increase the
production cost significantly
6. Capital cost and maintenance cost is Capital cost and maintenance cost is
low high
7. Traditional processes are well Mechanics of Material removal of Some
established and physics of process of NTM process are still under research
is well understood
8. Conventional process mostly uses Most NTM uses energy in direct form
mechanical energy For example : laser, Electron beam in
its direct forms are used in LBM and
EBM respectively
9. Surface finish and tolerances are High surface finish(up to 0.1 micron)
limited by machining inaccuracies and tolerances (25 Microns)can be
achieved
10. High metal removal rate. Low material removal rate.
Non-Traditional Machining

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

Physical parameter of the process:

The physical parameters of the different NTM are given in the Table 1.0 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.

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

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 are used non metal 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.
Non-Traditional Machining

1.6 PHYSICAL PARAMETER OF THE PROCESS:

Classification of NTM processes is carried out depending on the nature of energy

used for material removal. The broad classification is given as follows:
1) Mechanical Processes

Abrasive Jet Machining (AJM)

Ultrasonic Machining (USM)
Water Jet Machining (WJM)
2) Electrochemical Processes
Electrochemical Machining (ECM)
Electro Chemical Grinding (ECG)
Electro Jet Drilling (EJD)
3) Electro-Thermal Processes
Electro-discharge machining (EDM)
Laser Jet Machining (LJM)
Electron Beam Machining (EBM)
4) Chemical Processes
Chemical Milling (CHM)
Photochemical Milling (PCM)
Non-Traditional Machining

FURTHER READING:
1. Modern machining process, Pandey and Shah, Tata McGraw Hill 2000
2. New Technology, Bhattacharya 2000
3. Production Technology, HMT Tata McGraw Hill. 2001

Self-Assessment Questions
1. What is necessity for unconventional machining processes?
2. How non-traditional machining processes are classified?
3. Enlist the requirement that demands the use of advanced machining process.
4. Why unconventional mechanical machining process is not so effective on soft metals
like aluminium?
Scanned with CamScanner