Non-Traditional Machining and

Automation
(MET 255)
B.Tech. (4th Sem) Spring 2021
Department of Mechanical Engineering
NIT Srinagar

Course Incharge
Dr. Noor Zaman Khan
Course Outcomes
At the end of the course, a student should be able to:

• CO1: Analyze and access the importance of automation and industrial automated systems.

• CO2: Identify and Analyze functions and functioning of CNC machines.

• CO3: Recognize the need of non-traditional machining processes and understand the working of high energy
beam machining.

• CO4: Illustrate underlying mechanisms in non-traditional machining processes along with their applications
 Syllabus of Unit 2
• Introduction to machining processes.

• Limitations of traditional machining processes.

• Introduction, need and applications of non- traditional machining processes.

• Classification of non- traditional machining processes.

• Mechanical machining,

• Thermal machining,

• Electrochemical machining.

• Introduction, working and applications of high energy beam machining processes.

• Virtual machining.
Problems with Traditional Machining
• New materials with low machinability
• Dimensional accuracy.
• Higher production rate and economy

Machining a complicated turbine blade made of superalloys

Producing holes and slots in materials such as glass and semiconductors.
 Why Advanced Machining Processes?
• Development of materials having higher strength, hardness, toughness and other diverse
properties.
• In conventional machining processes, an increase in work hardness results in a decrease in
economic cutting speed.

• It is no longer possible to find hard and strong tool to cut (at economic cutting speeds) materials
like nimonics, fiber-reinforced composites, ceramics.

• Production of complex shapes in such materials by traditional methods is still more difficult.

• Requirements are better finish, low values of tolerances, higher production rates, complex
shapes miniaturization etc
• Making of holes (non-circular, micro-sized, large aspect ratio, a large number of small holes in
one workpiece, contoured holes, hole without burrs, etc.) in difficult-to-machine materials
 Advanced Machining Processes
• To meet various challenges, a number of newer material removal processes have now
been developed to the level of commercial utilization.
• These newer methods are also called unconventional in the sense that the
conventional tools are not employed for metal cutting.
• Instead the energy in its direct form is used to remove the materials from the
workpiece.
• Non-traditional machining (NTM) processes can be defined as a group of processes
that remove excess material from workpiece by various techniques constituting
mechanical, thermal, electrical, chemical energies or combinations of these energies
without the involvement of sharp cutting tools which are used for traditional
manufacturing techniques.
 Limitations of traditional machining processes.
• Traditional processes are not satisfactory, economical, or
even possible, for the following reasons
1. The hardness and strength of the material is very high
or the material is too brittle.
2. The work piece is too flexible, slender, or delicate to
withstand the cutting or grinding forces, or the parts
are too difficult to fix.
3. The shape of the part is complex.
4. Surface finish and dimensional tolerance requirements
are more rigorous than those obtained by other
processes.
5. Temperature rise and residual stresses in the work
piece are not desirable or acceptable.
Advanced Machining Processes
• Ultrasonic Machining (USM)
• Abrasive Jet Machining (AJM)
• Water Jet Machining (WJM)
• Abrasive Water Jet machining (AWJM)
• Electric Discharge Machining (EDM)
• Chemical Machining (CM)
• Electrochemical Machining (ECM)
• Plasma Arc machining (PAM)
• High-Energy beam machining
✓ Laser beam machining (LBM)
✓ Electron Beam Machining (EBM)
✓ Ion beam machining (IBM)
Classification of Advanced Machining Process.

Mechanical Thermal Chemical and

Electrochemical

PAM
USM
EBM CM
AJM
LBM ECM
WJM
IBM
AWJM
EDM
 Classification of Advanced Machining Process.

• Mechanical processes: Mechanical abrasion (USM, AJM, WJM, AWJM)

• Thermal Machining: The material removal in this case takes place by

melting or vaporizing the workpiece. (PAM, EDM, EBM, LBM, IBM).

• Chemical and Electrochemical Machining: Chemical machining (CM)

and photochemical machining (PCM): Chemical dissolution action.
Electrochemical machining (ECM): Ion transfer in an electrolytic
solution
Some micro machined parts

•
Thank You