NON-TRADITIONAL MACHINING

Sub Code:BME755A

Module -1

Introduction to Non-Traditional
Machining
 NON TRADITIONAL MACHINING SYLLABUS
Module-1
Introduction to Non-traditional machining 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.
Module-2
Ultrasonic Machining (USM): Introduction, Equipment and material process, Effect
of process parameters: Effect of amplitude and frequency, Effect of abrasive grain
diameter, effect of slurry, tool & work material. Process characteristics: Material
removal rate, tool wear, accuracy, surface finish, applications, advantages & limitations
of USM.
Abrasive Jet Machining (AJM): Introduction, Equipment and process of material
removal, process variables: carrier gas, type of abrasive, work material, stand-off
distance (SOD). Process characteristics-Material removal rate, Nozzle wear, accuracy
& surface finish. Applications, advantages & limitations of AJM.
Module-3
Electrochemical machining (ECM): Introduction, Principle of electro chemical
machining, ECM equipment, elements of ECM operation, Chemistry of ECM.
ECM Process characteristics: Material removal rate, accuracy, surface finish.
Process parameters: Current density, Tool feed rate, Gap between tool & work
piece, velocity of electrolyte flow, type of electrolyte, its concentration
temperature, and choice of electrolytes. ECM Tooling: ECM tooling technique &
example, Tool & insulation materials. Applications ECM: Electrochemical
grinding and electrochemical honing process. Advantages, disadvantages and
application of ECG, ECH.
Chemical Machining (CHM): Elements of the process, Resists (maskants),
Etchants. Types of chemical machining process-chemical 2 2 blanking process,
chemical milling process. Process characteristics of CHM: material removal rate,
accuracy, surface finish, advantages, limitations and applications of chemical
machining process.
Module-4
Electrical Discharge Machining (EDM): Introduction, mechanism of metal
removal, EDM equipment: spark erosion generator (relaxation type), dielectric
medium-its functions & desirable properties, electrode feed control system.
Flushing types; pressure flushing, suction flushing, side flushing, pulsed
flushing. EDM process parameters: Spark frequency, current & spark gap,
surface finish, Heat Affected Zone. Advantages, limitations & applications of
EDM, Electrical discharge grinding, Traveling wire EDM. Plasma
Arc Machining (PAM): Introduction, non-thermal generation of plasma,
equipment mechanism of metal removal, Plasma torch, process parameters,
process characteristics. Safety precautions. Safety precautions, applications,
advantages and limitations
Module-5
Laser Beam Machining (LBM): Introduction, generation of LASER, Equipment and
mechanism of metal removal, LBM parameters and characteristics, Applications,
Advantages & limitations.
Electron Beam Machining (EBM): Introduction, Principle, equipment and
mechanism of metal removal, applications, advantages and limitations
 Course Outcomes (CO):
 CO1: Describe non-traditional machining process and compare with
Traditional machining process. Recognize the need for Non-traditional
machining process.
 CO2: Describe the constructional features, performance parameters,
process characteristics , applications, advantages, and limitations of
USM, AJM and WJM
 CO3: Characterize the need of Chemical and electro-chemical
machining process along with the constructional features, process
parameters, process characteristics, applications, advantages, and
limitations
 CO4: Illustrate the constructional feature of the equipment, process
parameters, process characteristics, applications, advantages and
limitations EDM & PAM
 CO5: Illustrate the constructional feature of the equipment, process
parameters, process characteristics, applications, advantages and
limitations LBM & EBM
 LESSON STRUCTURE:

 Introduction to NTM
 Definition
 Need for Non-traditional machining process
 Comparison between traditional and non-traditional
machining
 General classification of Non-traditional machining processes
 Selection of non-traditional machining processes
 Advantages, Limitations and Applications of NTM processes
 INTRODUCTION to NTM

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.
Although the traditional machines are capable of producing the desired
shape and size along with a good surface finish, there are certain instances
where they fail to produce the desired results.
 Machining of hard work piece materials like nimonics, carbides,
stainless steel, heat resisting steels . Tool wear and failure becomes a
serious problem in machining such materials.
 Machining of small diameter holes, deep cavities and complex
geometrical shapes.
 When the work piece is too flexible or slender(thin) to withstand the
high cutting force during machining
 A very high surface finish with close dimensional accuracy of the
product is required.
Definition of NTM:
 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
work piece into smaller parts.
 Conventional Machining or Traditional Machining
 Non-Conventional Machining or Non-Traditional Machining
 Need for 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.
 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.

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

1) Mechanical Energy:
The various machining processes that utilize mechanical energy include:
 Abrasive Jet Machining (AJM)
 Ultrasonic Machining (USM)
 Water Jet Machining (WJM)
2) Chemical or Electrochemical Energy:
The various machining processes that utilize chemical energy include:
 Electrochemical Machining (ECM)
 Electro Chemical Grinding (ECG)
 Electro Jet Drilling (EJD)
 Electro Chemical Honing (ECH)
 Electro Chemical deburring (ECD)
 Chemical Milling (CHM)
3) Electro-Thermal Processes:
The various machining processes that utilize chemical energy include:
Electro-Discharge Machining (EDM)
Laser Jet Machining (LJM)
Electron Beam Machining (EBM)
Plasma Arc machining(PAM)
Ion Beam Machining(IBM)
4) Hybrid:
Electro Chemical Discharge Machining(ECDM)
Abrasive Water Jet Machining(AWJM)
Electro Chemical Grinding(ECG)
 Selection of non-traditional machining processes

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
i) Physical parameter of the process
Power, voltage potential, current, gap between tool and work piece are
few common parameters in NTM process. Process like USM and EDM
consume approximately the same power for machining a particular
material, while ECM and CM consume a comparatively greater amount of
power. EBM and LBM require high voltages and require careful handling
of equipment. EBM can be used in vacuum and PAM uses oxygen and
hydrogen gas.
ii) Shape to be machined
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.

iii) Process capability

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.
iv) Economics considerations

Economic factors include costs related to capital investments, tooling and

fixtures, power requirement and other expenses incurred for machining
process. AJM, USM and PAM process require very low capital investment
compared to EBM, ECM, EDM and LBM process. Tooling cost are high
for EDM and ECM [Link] considerations is very important
aspects as it determines the final cost for machining a particular
component.
 Advantages, Limitations and Applications of NTM
processes
Advantages of NTM
Suitable for hard and brittle materials.
Precise machining of intricate shapes.
Minimal heat-affected zones.
Works with materials of varying hardness.
Minimal tool wear and longer tool life.
Capable of micro-machining and small-hole drilling.
No burrs or mechanical stresses on workpieces.
Minimal environmental impact with reduced waste.
Versatility across diverse materials and
applications.
Limitations of NTM
This process can only be employed in electrically
conductive materials.
Material removal rate is low and the process
overall is slow compared to conventional
machining processes.
Unwanted erosion and over cutting of material can
occur.
Machining hard materials like die steel, tool
steel, and tungsten requires tools at least 30 to
50% harder than the work piece.
Rough surface finish when at high rates of
material removal
Certain non traditional machining process may
be more complex to set up and operate.
Applications of NTM
Aerospace: Used for intricate parts and exotic materials.
Medical: Precision machining of medical devices.
Electronics: Micro-machining for circuit boards.
Automotive: For complex engine components.
Tool and Die: Making intricate molds and dies.
Energy: Cutting turbine components.