NON-TRADITIONAL MACHINING (18ME641)

1. INTRODUCTION
In the early stage of mankind, tools were made of stone for the item being made. When iron
tools were invented, desirable metals and more sophisticated articles could be produced. In
twentieth century products were made from the most durable and consequently, the most un-
machinable materials. In an effort to meet the manufacturing challenges created by these
materials, tools have now evolved to include materials such as alloy steel, carbide, diamond and
ceramics. The conventional manufacturing processing use today for material
removal primarily rely on electric motors and hard tool materials to perform tasks such as
sawing, drilling and broaching.

Manufacturing processes can be broadly divided into two groups:

a) primary manufacturing processes : Provide basic shape and size
b) secondary manufacturing processes : Provide final shape and size with tighter control on
dimension, surface characteristics

Material removal processes once again can be divided into two groups
1. Conventional Machining Processes
2. Non-Traditional Manufacturing Processes or non-conventional Manufacturing processes

Conventional Machining Processes mostly remove material in the form of chips by applying
forces on the work material with a wedge shaped cutting tool that is harder than the work
material under machining condition.

The major characteristics of conventional machining are:

• Generally macroscopic chip formation by shear deformation
• Material removal takes place due to application of cutting forces – energy domain can be
classified as mechanical
• Cutting tool is harder than work piece at room temperature as well as under machining
conditions

Conventional forming operations are performed with the energy from electric
motors, hydraulics and gravity. Likewise, material joining is conventionally accomplished with
thermal energy sources such as burning gases and electric arcs. In contrast, non-traditional
manufacturing processes harness energy sources considered unconventional by yesterday’s
standards. Material removal can now accomplished with electrochemical reaction, high
temperature plasmas and high-velocity jets of liquids and abrasives. Materials that in the past
have been extremely difficult to form, are now formed with magnetic fields, explosives and the
shock waves from powerful electric sparks. Material joining capabilities have been expanded
with the use of high frequency sound waves and beams of electrons and coherent light.

With the development of technology, more and more challenging problems are faced by the
scientists and technologists in the field of manufacturing. The difficulty in adapting the
traditional manufacturing processes can be attributed mainly to the following basic sources:

MODULE – 1 INTRODUCTION TO NTM 1

 NON-TRADITIONAL MACHINING (18ME641)

(i) New materials with low machinability.

(ii) Dimensional and accuracy requirements
(iii) A higher production rate and economy.

The many new materials and alloys that have been developed for specific uses possess a very
low machinability. Producing complicated geometries in such materials becomes extremely
difficult with the usual methods. Also, sometimes the combination of the material properties and
the job dimensions is such that the use of the traditional processes becomes impossible.

Examples of these types of jobs are machining a complicated turbine blade made of super
alloys, and producing holes and slots (both through and blind) in materials such as glass and
semiconductors. At times, the job becomes difficult because of the dimensional complications.
So, drilling a noncircular hole or a micro hole becomes problematic (and sometimes
impossible) if the traditional processes are used. Apart from the situations cited, higher
production rate and economic requirements may demand the use of non-traditional (or
unconventional) machining processes.

To tackle such difficult jobs, two approaches are possible, viz

(i) A modification of the traditional processes (eg: hot machining) and
(ii) The development of new processes.

1.1 DEFINITION FOR NON TRADITIONAL MACHINING

(i) 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 in to smaller parts.

(ii) 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. Nontraditional 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

MODULE – 1 INTRODUCTION TO NTM 2

 NON-TRADITIONAL MACHINING (18ME641)

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.

1.2 NEED FOR NON TRADITIONAL MACHINING PROCESS

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.

1. 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, tungsten, molybdenum, columbium, 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 un economical 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 mm x 15 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, 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

♦ NTM process is useful in machining of composite material.

1.3 NON TRADITIONAL MACHINING (NTM) PROCESSES CHARACTERISTICS

Non Traditional Machining (NTM) Processes are characterized as follows:

MODULE – 1 INTRODUCTION TO NTM 3

 NON-TRADITIONAL MACHINING (18ME641)

1. 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.

2. 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.

3. 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.

4. 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.

1.4 COMPARISON/DIFFERENCES BETWEEN CONVENTIONAL AND NON

CONVENTIONAL MACHINING PROCESSES

Sl. No. Conventional Process Non Conventional Process

1. The cutting tool and work piece are There is no physical contact between the
always in physical contact with relative tool and work piece, In some non-
motion with each other, which results in traditional process tool wear exists
friction and tool wear

2. Material removal rate is limited by NTM can machine difficult to cut and hard
mechanical properties of work material. to cut materials like titanium, ceramics,
nimonics, SST, composites,
semiconducting materials.
3. Relative motion between the tool and Many NTM are capable of producing
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
3Dsurfaces is still a difficult task
4. Machining of small cavities , slits, blind Machining of small cavities, slits and
holes or through holes are difficult Production of non-circular, micro sized,
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 cutting expensive tools and equipment as well as
tools skilled labour, which increase the
production cost significantly
6. Capital cost and maintenance cost is Capital cost and maintenance cost is high
low

MODULE – 1 INTRODUCTION TO NTM 4

 NON-TRADITIONAL MACHINING (18ME641)

7. Traditional processes are well Mechanics of Material removal of Some of

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

1.5 CLASSIFICATION OF NTM PROCESSES

Classification along with the principle of working (type of energy used for material
removal) is described below.

(i) Use of Mechanical Energy

Mechanical energy is used for removing material from work piece. In this process,
cutting tool with sharp edge is not used but material is removed by the abrasive action of high
velocity of stream of hard, tiny abrasive particles. The particles are kept vibrating with very high
velocity and ultra high frequency to remove the material.

(ii) Electrical Energy

In this category of non-traditional machining electrical energy is used in the form of
electrochemical energy or electro-heat energy to erode the material or to melt and vaporized it
respectively. Electrochemical machining, electroplating or electro discharge machining are the
examples work on this principle.

(iii) Use of Thermal Energy

According to this principle heat is generated by electrical energy. The generated thermal
energy is focused to a very small portion of work piece. This heat is utilized in melting and
evaporating of metal. The example based o this principle is electric discharge machining.

(iv) Use of Chemical Energy

According to this principle of working chemicals are used to erode material from the
work piece. Selection of a chemical depends upon the work piece material. Example of this type
of machining is electrochemical machining. The dame principle can also be applied in reversed
way in the process of electrochemical plating.

There can be one more way of classification of the non-conventional machining

processes which is mechanisms of metal removal.

(i) Abrasion and Shear

MODULE – 1 INTRODUCTION TO NTM 5

 NON-TRADITIONAL MACHINING (18ME641)

When small and hard metallic particles are made vibrating against the work piece to be
machined, the material is removed by shear action and abrasion. This phenomenon generally
takes place in case of ultrasonic machining.

(ii) Chemical Ablation and Ionic Dissolution

This is the dissolution of work piece material into electrolyte solution (chemical) which
takes place atom by atom. This happens in case electrochemical machining.

(iii) Vaporization by Spark Erosion

Concentrated heat is focused at a point of the work piece by electric spark which melts
and evaporates the work piece material like electric discharge machining and LBM.

NTM processes can be divided into four groups based upon the material removal mechanism:

1. Chemical-Chemical reaction between a liquid reagent and the work piece results in etching.

2. Electrochemical- An electrolytic reaction at the work piece surface is responsible material

removal.

3. Mechanical- High velocity abrasives or liquids remove material.

4. Thermal- High temperatures in localized regions evaporate materials.

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

used for material removal. The broad classification is given as follows:

•Mechanical Processes

Abrasive Jet Machining (AJM)

Ultrasonic Machining (USM)
Water Jet Machining (WJM)

•Electrochemical Processes

Electrochemical Machining (ECM)

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

•Electro-Thermal Processes

Electro-discharge machining (EDM)

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

MODULE – 1 INTRODUCTION TO NTM 6

 NON-TRADITIONAL MACHINING (18ME641)

•Chemical Processes

Chemical Milling (CHM)

Photochemical Milling (PCM)

Fig. 1 Schematic representation of various metal cutting operations

Table-1 Classification of unconventional machining processes

Thus, these non-conventional processes can be classified into various groups according to the
basic requirements which are as follows:

MODULE – 1 INTRODUCTION TO NTM 7

 NON-TRADITIONAL MACHINING (18ME641)

(i) Type of energy required, namely, mechanical, electrical, chemical etc.

(ii) Basic mechanism involved in the processes, like erosion, ionic dissolution,
vaporization etc.
(iii) Source of immediate energy required for material removal, namely, hydrostatic
pressure, high current density, high voltage, ionised material, etc.
(iv) Medium for transfer of those energies, like high velocity particles, electrolyte,
electron, hot gases, etc.

1.6 SELECTION OF NTM 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:

The physical parameters of the different NTM are given in the Table 1.2 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. And also comparative study of the

MODULE – 1 INTRODUCTION TO NTM 8

 NON-TRADITIONAL MACHINING (18ME641)

effect of metal removal rate on the power consumed by various non-conventional machining
processes shown in fig. 1.2. It is found that some of the processes (e.g. EBM, ECM) above the
mean power consumption line consume a greater amount of power than the processes (e.g. EDM,
PAM, ECG) below the mean power consumption line. Thus, the capital cost involved in the
processes (EBM, ECM etc.) lying above the mean line is high whereas for the processes below
that line (e.g., EDM, PAM, MCG) is comparatively low.

(ii) Shapes cutting capability

The different shapes can be machined by NTM. The capability of different processes can be
analyzed on the basis of various machining operation point of view such as micro-drilling,
drilling, cavity sinking, pocketing (shallow and deep), contouring a surface, through cutting
(shallow and deep) etc. 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.

MODULE – 1 INTRODUCTION TO NTM 9

 NON-TRADITIONAL MACHINING (18ME641)

(iii) Process capability

The process capability of NTM is given in 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 nonmetal 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.
(a) Applicability to materials
Materials applications of the various machining methods are summarized in the table 1.4
and table 1.5. For the machining of electrically non-conducting materials, both ECM and EDM
are unsuitable, whereas the mechanical methods can achieve the desired results.

USM is suitable for machining of refractory type of material while AJM are for super
alloys and refractory materials.

MODULE – 1 INTRODUCTION TO NTM 10

 NON-TRADITIONAL MACHINING (18ME641)

(b) Machining characteristics

The machining characteristics of different non-conventional processes can be analyzed

with respect to:

(i) Metal removal rate

(ii) Tolerance maintained
(iii) Surface finish obtained
(iv) Depth of surface damage
(v) Power required for machining

The process capabilities of non-conventional manufacturing processes have been

compared in table 1.6. The metal removal rates by ECM and PAM are respectively one-fourth
and 1.25 times that of conventional whereas others are only small fractions of it. Power
requirement of ECM and PAM is also very high when compared with other non-conventional
machining processes.
This involves higher capital cost for those processes. ECM has very low tool wear rate
but it has certain fairly serious problems regarding the contamination of the electrolyte used and
the corrosion of machine parts. The surface finish and tolerance obtained by various processes
except PAM is satisfactory.

MODULE – 1 INTRODUCTION TO NTM 11

 NON-TRADITIONAL MACHINING (18ME641)

(iv) Economics of the processes

The economics of the various processes are analyzed on the basis of following factors and given
in Table 1.7.
(a) Capital cost
(b) Tooling cost
(c) Consumed power cost
(d) Metal removal rate efficiency
(e)Tool wear.

The capital cost of ECM is very high when compared with traditional mechanical contour
grinding and other non-conventional machining processes whereas capital costs for AJM and
PAM are comparatively low. EDM has got higher tooling cost than other machining processes.
Power consumption is very low for PAM and LBM processes whereas it is greater in case of
ECM. The metal removal efficiency is very high for EBM and LBM than for other processes. In
conclusion, the suitability of application of any of the processes is dependent upon various
factors and must be considered all or some of them before applying no conventional processes.

MODULE – 1 INTRODUCTION TO NTM 12

 NON-TRADITIONAL MACHINING (18ME641)

1.7 ADVANTAGES AND DISADVANTAGES:

(i) Advantages:

▪ It provides high accuracy and surface finish.

▪ No physical tool is used hence, no tool wear occur.
▪ They do not generate chips or generate microscopic chips.
▪ These are quieter in operation.
▪ It can be easily automated.
▪ It can machine any complex shape.

(ii) Disadvantages:

▪ High initial or setup cost.

▪ High skilled labor is required.
▪ Lower metal removal rate.
▪ More power required for machining.
▪ It is not economical for bulk production.

1.8 APPLICATIONS OF NTM

1. USM
➢ Hard, brittle work materials such as ceramics, glass, and carbides, precious stones, and
hardened steels.
➢ Also successful on certain metals, such as stainless steel and titanium
➢ Shapes include non-round holes, holes along a curved axis.

2. AJM
➢ Normally used as a finishing process rather than cutting process
➢ Applications: deburring, trimming and cleaning, and polishing
➢ Work materials: thin flat stock of hard, brittle materials (e.g., glass, silicon, mica,
ceramics)

MODULE – 1 INTRODUCTION TO NTM 13

 NON-TRADITIONAL MACHINING (18ME641)

3. WJM
➢ Used in mining, aerospace.
➢ Cutting thin details in stone, glass and metals.
➢ Drilling of titanium materials.

4. ECM
➢ Used in tool & die making industries, automotive, aerospace, power generation, oil &
gas industries.
➢ Facing & turning complex 3D surfaces, deburring, grinding, honing, trepanning,
broaching, multiple hole drilling etc.
5. LBM
➢ LBM is used to perform precision micro-machining on all materials such as steel,
ceramic, glass, diamond, graphite etc.
➢ It is used for cutting, drilling, marking, scribing etc.
6. PAM
➢ Manufacturers of transportation and agricultural equipment, aircraft components etc.
➢ Used in sawing, cutting, drilling, machining, and punching.
➢ Also used in the heating, ventilating, air conditioning industries to cut complex work.

MODULE – 1 INTRODUCTION TO NTM 14