Non-Traditional Machining 1

NON - TRADITIONAL MACHINING

(BME405A)

MODULE- 1

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MODULE- 1

INTRODUCTION

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.

DEFINITION

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.

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Manufacturing processes can be broadly divided into two groups and

they are
1. Primary manufacturing processes
2. Secondary manufacturing processes.

The primary manufacturing processes provide basic shape and size

to the material as per designer’s requirement. Casting, forming, powder
metallurgy are such processes to name a few. Secondary manufacturing
processes provide the final shape and size with tighter control on
dimension, surface characteristics etc. Material removal processes are
mainly the secondary manufacturing processes.

Material removal processes once again can be divided into mainly

two groups and they are

1. “Conventional Machining Processes”: Examples of conventional

machining processes are turning, boring, milling, shaping, broaching,
slotting, grinding etc.
2. “Non-Traditional Manufacturing Processes”: Similarly, Abrasive Jet
Machining (AJM), Ultrasonic Machining (USM), Water Jet and Abrasive
Water Jet Machining (WJM and AWJM), Electro-discharge Machining
(EDM) are some of the Non-Traditional Machining (NTM) Processes.

NEED FOR NON-TRADITIONAL MACHINING PROCESSES

Shape Metals and

Complexity Non-metals machining

Avoid Surface Damage Precision

Miniaturization Productivity

Figure. 1.1 Need for Non-Traditional Machining Processes

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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, 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.

1. Technologically advanced industries like aerospace, nuclear power,

wafer fabrication, automobiles have ever increasing use of High –strength
temperature resistant (HSTR) alloys (having high strength to weight ratio)
and other difficult to machine materials like titanium, 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

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. 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.

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MECHANISM OF PROCESSES

Mechanism of
Energy type material Energy source Processes
removal

Mechanical
Conventional
motion of tool/
machining
job
Mechanical Plastic shear
Mechanical/
AJM, USM
Fluid motion

Ion
Electrochemical Electric current ECM
displacement

Plastic shear Electric current

Mechanical
and and
and ECG
ion mechanical
Electrochemical
displacement motion

Chemical Corrosive Corrosive agent CHM

reaction

Electric spark EDM

High speed
EBM
Fusion electrons
Thermal and
Powerful
vaporization LBM
radiation

Ionized
IBM, PAM
substance

Table. 1.1 Mechanism of processes

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Comparison between Traditional and Non-Traditional machining

Processes.

Sl. Traditional / Non-Traditional /

No. Conventional Non-Conventional
The cutting tool and work
There is no physical contact
piece are always in physical
between the tool and work piece,
1 contact with relative motion
In some non-Traditional process
with each other, which results
tool wear exists.
in friction and tool wear.
NTM can machine difficult to cut
Material removal rate is
and hard to cut materials like
2 limited by mechanical
titanium, ceramics, composites,
properties of work material.
semiconducting materials
Relative motion between the
tool and work is typically
rotary or reciprocating. Thus,
Many NTM are capable of
the shape of work is limited to
3 producing complex 3D shapes
circular or flat shapes. In
and cavities
spite of CNC systems,
production of 3D surfaces is
still a difficult task.
Machining of small cavities, slits
Machining of small cavities, and Production of non-circular,
4 slits, blind holes or through micro sized, large aspect ratio,
holes are difficult shall entry angle holes be easy
using NTM
Non-traditional processes require
Use relatively simple and expensive tools and equipment
5 inexpensive machinery and as well as skilled labour, which
readily available cutting tools increase the production cost
significantly
Capital cost and maintenance Capital cost and maintenance
6
cost is low cost is high

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Traditional processes are well Mechanics of Material removal of

7 established and physics of Some of NTM process are still
process is well understood under research
Most NTM uses energy in direct
Conventional process mostly form for example: laser, Electron
8
uses mechanical energy beam in its direct forms are used
in LBM and EBM respectively
Surface finish and tolerances High surface finish (up to 0.1
9 are limited by machining micron) and tolerances (25
inaccuracies Microns) can be achieved

10 High metal removal rate. Low material removal rate.

Table 1.2 Comparison of Traditional & Non-Traditional machining

Processes.

CLASSIFICATION OF NON-TRADITIONAL MACHINING

Figure. 1.2 Classification of NTM processes.

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• Mechanical Processes

a) Abrasive Jet Machining (AJM)

b) Ultrasonic Machining (USM)
c) Water Jet Machining (WJM)

• Electrochemical Processes

a) Electrochemical Machining (ECM)

b) Electro Chemical Grinding (ECG)
c) Electro Jet Drilling (EJD)

• Electro-Thermal Processes

a) Electro-discharge machining (EDM)

b) Laser Jet Machining (LJM)
c) Electron Beam Machining (EBM)

• Chemical Processes

a) Chemical Milling (CHM)

b) Photochemical Milling (PCM)

Figure. 1.3 Schematic representation of various metal cutting

operations

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SELECTION OF NON-TRADITIONAL MACHINING PROCESS:

The correct selection of the NTM must be based on the following

aspects.

1. Physical parameters of the process

2. Shape to be machined
3. Process capability
4. Economics of the processes

1. Physical parameter of the process

The physical parameters of the different NTM are given in the Table
1.3 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.

Non-Traditional Processes
Parameters
USM AJM CHM ECM EDM EBM LBM PAM

Potential 100- 4.5

220 220 - 10-0 150KV 100
(Volts) 300 KV

Current
12 1 - 10000 50 0.001 2 500
(Amps)

Power (KW) 24 0.22 - 100 2.70 0.15 - 50

Gap(mm) 0.25 0.75 - 0.20 0.025 100 150 7.5

Abrasive Abrasive Liquid Dielectric Argon

Medium in water in gas chemical
Electrolyte
oil
Vacuum Air
H2/O2

Table 1.3 Physical Parameters of NTM Process

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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. Shapes cutting Capabilities shown in Table 1.4
and the materials applications is shown in Table 1.5.

Through Through
Efficiency Surfacing
Cavity Cutting

Surfaces of revolution
Precision Small Holes

Double Contouring
Precision
Processes Standard
Small Holes
Standard

Shallow

Deep
<0.025 mm

>0.025 mm

< 20 Dia

> 20 Dia
Length

Length
Dia

Dia

USM - - A C A A C - C -

AJM - - B C C B - - A -

ECM - - A A B A A B A A

CHM B B - - C B - - A -

EDM - - A B A A B - C -

LBM A A B C C C - - A B

PAM - - B - C C - C A A

Note: A-Good B-Fair C-Poor

Table 1.4 Shapes Cutting Capability

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Materials Applications with different processes

Material

Super Alloys

Refectories
Aluminium

Ceramics
Titanium

Plastics
Processes

Glass
USM C Steel
B C B C B A A

AJM B B A B A B A A

ECM B A A B B D D D

CHM A A B B C C C B

EDM B A A A A D D D

EBM B B B B A B A B

LBM B B B B C B A B

PAM A A A B C C D D

D-Not
Note: A-Good B-Fair C-Poor
Applicable

Table 1.5 Materials Applications

3. Process capability

The process capabilities are shown in Table 1.6 whereas process

parameters of NTM are given in Table 1.3 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.

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Metal Surface Surface

Corner
Removal Tolerance Finish damage
Processes radii
Rate µ µ depth
mm
mm3/min µ
USM 300 7.5 0.25-0.5 25 0.025
AJM 0.8 50 0.5-1.2 2.5 0.100
ECM 1500 50 0.1-2.5 5.0 0.025
CHM 15 50 0.4-2.5 50 0.125
EDM 800 15 0.2-12.5 125 0.025
EBM 1.6 25 0.4-2.5 250 2.50
LBM 0.1 25 0.4-1.25 125 2.50
PAM 75000 125 Rough 500 -
Conventional
50000 50 0.4-5.0 25 0.050
Milling of Steel

Table 1.6 Process capability

4. Economics of the processes

The economics of the various processes are analysed on the basis of

following factors and the process economy is shown in Table 1.7

Tooling
Capital Power Tool
Processes investment
&
requirements
Efficiency
consumptions
fixtures
USM B B B D C
AJM A B B D B
ECM E C C B A
CHM C B D C A
EDM C D B D D
EBM D B B E A
LBM C B A E A
PAM A B A A A
Conventional
B B B A B
Machining
A-Very
Note: B-Low C-Medium D-High E-Very High
Low Cost

Table 1.7 Economics of Processes

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Advantages and Disadvantages of Non-Traditional Machining

Processes

ADVANTAGES:
1. It provides high accuracy and surface finish.
2. No physical tool is used hence, no tool wear occurs.
3. They do not generate chips or generate microscopic chips.
4. These are quieter in operation.
5. It can be easily automated.
6. It can machine any complex shape.

DISADVANTAGES:
1. High initial or setup cost.
2. High skilled labour is required.
3. Lower metal removal rate.
4. More power required for machining.
5. It is not economical for bulk production.

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Important Questions:

1. What is non-traditional machining or unconventional machining or

modern machining technique? How are they classified?
2. Differentiate between conventional (traditional) and unconventional
(non-traditional) or modern machining processes. (5 to 6 Marks)
(VTU June/July 2016) (VTU June/July 2014) (VTU June/July 2013)
(VTU Dec 2011)
3. What are the applications of non-traditional machining methods?
4. What are the advantages and disadvantages of non-traditional
machining?
5. Classify non-traditional machining processes based on nature of
energy employed in machining.
6. Write a note on the source of energy harnessed and mechanism of
material removal in non-traditional machining. (6 Marks) (VTU
June/July 2011)
7. Explain the need for development of non-traditional machining. (4
Marks) (VTU June/July 2011)
8. Classify the modern machining processes. (7 Marks) (VTU Dec 2011)
9. Explain the principle of modern machining process. What are the
factors to be considered while selecting a process? (7 Marks) (VTU
Dec 2011)
10. Explain the need to develop modern machining processes. (4 Marks)
(VTU Dec 2012)
11. Explain parameter to select to employ the new machining methods.
(6 Marks) (VTU Dec 2012)
12. Give the broad classification of non-traditional machining processes.
(6 Marks) (VTU Dec 2012)
13. Justify the need of unconventional manufacturing process in today’s
industries. (6 Marks) (VTU June/July 2013)
14. What are the basic factors upon which the unconventional
manufacturing processes are classified? Explain. (10 Marks) (VTU
June/July 2013)

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15. Explain how the non-traditional machining processes are classified.

(6 Marks) (VTU June/July 2014)
16. List the unconventional machining processes under mechanical
energy thermal and chemical energy category. (6 Marks) (VTU Dec
2014/Jan 2015)
17. Differentiate between conventional (traditional) and non-traditional
machining processes with examples. (6 Marks) (VTU Dec 2014/Jan
2015)
18. Make a comparison between traditional and non-traditional
machining process in terms of cost, application, scope, machine
time and limitations. (8 Marks) (VTU Dec 2014/Jan 2015)
19. List and explain the various factors to be considered for selection of
machining processes. (7 Marks) (VTU June/July 2015)
20. Classify various non-traditional machining processes based on
energy source used with giving suitable examples. (6 Marks) (VTU
June/July 2015)
21. Based on the various parameters of machining, compare the
conventional and non-conventional machining processes. (7 Marks)
(VTU June/July 2015)
22. How modern machining processes are classified? (6 Marks) (VTU
June/July 2016)
23. What are the essential physical process parameters for an efficient
use of modern machining processes? (5 Marks) (VTU June/July
2016)
24. Why Non-traditional machining (NTM) processes are selected for
manufacturing? (4 Marks) (VTU June/July 2016)

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