Characteristics of Advanced Machining Processes:

 
Process

S.N Proce Characteris paramet

ers and
o MRR or
ss tics cutting
speed

Shallow removal on large flat

Chemical or curved surfaces; blanking 0.0025-
1 machining of thin sheets; low tooling and 0.1
(CM) equipment cost; suitable for mm/min.
low-production runs.

V: 5-25
Complex shapes with deep DC; A:
cavities; highest rate of 1.5-8
material removal among other A/mm2;
Electrochemic
nontraditional processes; 2.5-12
2 al machining
expensive tooling and mm/min,
(ECM)
equipment; high power dependin
consumption; medium-to-high g on
production quantity. current
density.

Cutting off and sharpening A: 1-3

hard materials, such as A/mm2;
Electrochemic
tungsten-carbide tools; also typically
3 al grinding
used as honing process; 25 mm3/s
(ECG)
higher removal rate than per
grinding. 1000A.

Shaping and cutting complex

V: 50-
parts made of hard materials;
Electrical- 380; A:
some surface damage may
discharge 0.1-500;
4 result; also used as a grinding
machining typically
and cutting process;
(EDM) 300
expensive tooling and
mm3/min.
equipment.

5 Wire electric Contour cutting of flat or Varies

discharge curved surfaces; expensive with
machining equipment. material
 and
thickness.

Cutting and hole making on

Laser-beam thin materials; very small
0.50-7.5
6 machining holes and slots; heat-affected
mm/min.
(LBM) zone; requires a vacuum;
expensive equipment.

Cutting and hole making on

Electro-beam thin materials; very small
1-2
7 machining holes and slots; heat-affected
mm3/min.
(EBM) zone; requires a vacuum;
expensive equipment.

Cutting all types of

Varies
Water-jet nonmetallic materials;
considera
8 machining(WJ suitable for contour cutting of
bly with
M) flexible materials; no thermal
material.
damage; noisy.

Abrasive
Single-layer or multi-layer
water-jet Up to 7.5
9 cutting of metallic and
machining m/min.
nonmetallic materials.
(AWJM)

Cutting, slotting, deburring,

etching and cleaning of Varies
Abrasive-jet
metallic and nonmetallic considera
10 machining
materials; tends to round off bly with
(AJM)
sharp edges; can be material
hazardous.