MICRO PROJECT ON

STUDY OF NON- CONVENTIONAL PROCESSES.

By:-
➢ SACHIN JHA (3556)

Guide:-
➢ Mr. D.V. MOGEHKAR

SUBJECT:- ADVANCE MANUFACTURING PROCESS

DYP
Department of Mechanical Engineering
Y.B. Patil Polytechnic,
Akurdi , Pune
(2020-21)
 DYP
CERTIFICATE
This is certify that I have successfully completed microproject report entitled “Study of non-
conventional machining process” under my supervision, in the partial fulfillment of Diploma in
Mechanical Engineering (Advance manufacturing processes) of MSBTE.

Date:-
Place:-Akurdi.

Guide
Mr. D.V. Mogehkar
 DECELERATION
We hereby declare that the project report entitled “Study of non-conventional processes” was
carried out and written by us under the guidance of Mr. N.M. Gaikwad, the lecturer department
of mechanical engineering. This work has not been previously formed the basis of the award of
degree or Diploma or certified nor has been submitted elsewhere for the award of any Degree or
Diploma.

Place:-Akurdi
Date:-

(Sachin jha-3556)

Sig of sub teacher:-

 INDEX

Title Page no

Acknowledgment

Abstract

Types & working of non-

conventional machining
Advantages & disadvantage
of non-conventional machining
 ACKNOWLEDGEMENT
Primary i would like to thanks my self for being able to complete this project with success. Then
i would like to thanks Mr. D.V. Mogehkar sir whose valuable guidance has seen success his
suggestion & his instructions has served as the major contribution towards the completion of the
project.
Then i would like to thanks my parents & friends who have helped me with main valuable
suggestions & guidance has been helped me with main valuable suggestions & guidance has
helped me in various phase of completion of the project.

Sachin jha.
 ABSTRACT
Need For Unconventional Machining Processes
Extremely hard and brittle materials or Difficult to machine material are difficult to machine
by traditional machining processes, When the workpiece is too flexible or slender to support the
cutting or grinding forces. This process gives high accuracy which cannot be achieved by
conventional machining.

➢ Short importance
This machining process are developed due to the disadvantages of conventional machining
process such as less surface finish, more tool wear & machining limitations. In-House machining
of complex and less machinable jobs.
Economical and Faster than purchasing readymade job. Processes are computer-controlled, so
negligible human Intervention during machining.
Examples of Non traditional machining :- Drilling micro size holes with Water jet machining.

➢ Conclusion
Non Conventional machining processes are used when Required attributes are impossible to
achieve with Traditional machining processes.
 Types & there application of non-conventional machining

➢ Mechanical processes
1.ABRASIVE JET MECHINING
In Abrasive Jet Machining (AJM), abrasive particles are made to impinge on the work material
at a high velocity. The jet of abrasive particles carried by campier gas or air. The high velocity
stream of abrasive is generated by converting the pressure energy of the carrier gas or AR to its
kinetic energy and hence high velocity jet. The nozzle directs the abrasive jet in a controlled
manner onto the work material, so that the distance between the nozzle and the Workpiece and
the impingement angle can be set desirably. The high velocity abrasive particles remove the
material by micro-cutting action as well as brittle fracture of the work material.
In AJM, generally, the abrasive particles of around 50 um grit sieve would impinge on the work
material at velocity of 200 m/s from a nozzle of I.D. of 0.5 mm with a standoff distance of
around 2 mm. The kinetic energy of the abrasive particles would be sufficient to provide material
removal due to brittle fracture of the work piece or even micro cutting by the abrasives .

Working
In AJM, air is compressed in an air compressor and compressed air at a pressure of around 5bar
is used as the carrier gas as shown in Fig. 1.2. Fig. 1.2 Also shows the other major parts of the
AJM system Gases like CO2, N2 can Akko be used as campier gas which may directly be issued
from a gas cylinder. Generally oxygen is not used as a carrier gas.
The carrier gas is first passed through a pressure regulator to obtain the desired working
Pressure. The gas is then passed through an air dryer to remove any residual water vapor. To
remove any oil vapor or particulate contaminant the same is passed through a series of
filters.Then the carrier gas enters a closed chamber known as the mixing chamber. The abrasive
particles enter the chamber from a hopper through a metallic sieve. The sieve is constantly
vibrated by an electromagnetic shaker. The mass flow rate of abrasive (15 gm/min) entering the
chamber depends on the amplitude of vibration of the sieve and its frequency. The abrasive
particles are then carried by the carrier gas to the machining chamber via an electro- magnetic
on-off valve. The machining enclosure is essential to contain the abrasive and machined particles
in a safe and eco-friendly manner. The machining is carried out as high velocity (200ms)
abrasive particles are issued from the nozzle onto a work piece traversing under the jet.
Process Parameters and Machining Characteristics.

Applications
For drilling holes of intricate shapes in hard and brittle material’s. For machining fragile,
brittle and heat sensitive materials AJM can be used for drilling, cutting,deburring. Cleaning and
etching .Micro-machining of brittle materials.
Limitations
MRR is rather low (around ~ 15 mm3/min for machining glass)Abrasive particles tend to get
embedded particularly if the work material is ductile Tapering occurs due to firing of the jet
Environmental load is rather high.
 2.ABRASIVE WATER-JET MACHINING (AWJM)
Abrasive water jet cutting is an extended version of water jet cutting, n which the water jet
Contains abrasive particles such as silicon carbide or aluminum oxide in order to increase the
Material removal rate above that of water jet machining. Almost any type of material ranging
From hard brittle materials such as ceramics, metals and glass to extremely soft materials such
As foam and rubbers can be cut by abrasive water jet cutting. The narrow cutting stream and
Computer controlled movement enables this process to produce parts accurately and efficiently.
This machining process is especially ideal for cutting materials that cannot be cut by laser or mal
cut. Metallic, non-metallic and advanced composite materials of various thicknesses Can be cut
by this process. This process is particularly suitable for heat sensitive materials hat Cannot be
achieved by processes that produce heat while machining The schematic of abrasive water jet
cutting is shown in Figure 15 which is similar to water jet Cutting apart from some more features
underneath the jewel namely abrasive, guard and Mixing tube. In this process, high velocity
water exiting the jewel creates a vacuum which Sucks abrasive from the abrasive line, which
mixes with the water in the mixing tube to from a High velocity beam of abrasives.

Application
Abrasive water jet Cutting is highly used in aerospace, automotive and electronic industries In
aerospace industries, parts such as Titanium bodies for military aircrafts, engine Components
(aluminium,Titanium,Heat Resistant alloys), aluminum body parts and Interior cabin parts are
made using abrasive Water jet cutting In automotive industries, parts like interior Trim (head
liners, trunk liners, door panels)And fiber gas’s body components and Bumpers are made by this
process. Similarly, IN electronics industries, circuit boards and Cable stripping are made by
abrasive water Jet cutting.
Limitations of abrasive water jet cutting
Cannot drill fat bottom Cannot cut materials that degrades quickly with moisture Surface finish
degrades at higher cut speeds which are frequently used for rough cut.The major disadvantages
of abrasive water jet cutting are high capital cost and high noise level During operation.
 3.Ultrasonic Machining (USM)
USM is mechanical material removal process or an abrasive process used to erode holes or
Cavities on hard or brittle work piece by using shaped tools, high frequency mechanical motion
And an abrasive scurry. USM offers a solution to the expanding need for machining brittle
Materials such as single crystals, glasses and polycrystalline in ceramics, and increasing complex
Operations to provide intricate shapes and workpiece profiles. It is therefore used extensively In
machining hard and brittle materials that are difficult to machine by traditional Manufacturing
processes. The hard particles in slurry are accelerated toward the surface of the Workpiece by a
tool oscillating at a frequency up to 100 KHz – through repeated abrasions, the Tool machines a
cavity of a cross section identical to its own. A schematic representation of

Usm is shown n Figure.

In ultrasonic machining, a tool of desired shape vibrates at an ultrasonic frequency (19 – 25
kHz) with an amplitude of around 15-50 um over the workpiece. Generally the tool is pressed
downward with a feed force, F. Between the tool and workpiece, the machining zone is flooded
with hard abrasive particles generally in the form of a water based slurry. As the tool vibrates
over the workpiece, the abrasive particles act as the indenters and indent both the work material
and the tool. The abrasive particles, as they indent, the work material, would remove the same,
particularly if the work material is brittle, due to crack initiation, propagation and brittle fracture
of the material. Hence, USM is mainly used for machining brittle materials {which are poor
conductors of electricity and thus cannot be processed by Electrochemical and Electro-discharge
machining (ECM and ED)}.
USM is primarily targeted for the machining of hard and brittle materials (dielectric or
Conductive) such as boron carbide, ceramics, titanium carbides, rubies, quartz etc. USM is a
Versatile machining process as far as properties of materials are concerned. This process is able
To effectively machine all materials whether they are electrically conductive or insulator.

WORKING
The basic mechanical structure of an USM is very similar to a drill press. However, it has
Additional features to carry out USM of brittle work material. The workpiece is mounted on a
Vice, which can be located at the desired position under the tool using a 2 axis tube. The table
Can further be lowered or raised to accommodate work of different thickness. The typical
Elements of an USM are,
 1. Surry delivery and return system
2. Feed mechanism to provide a Downward feed force on the tool During machining
3. The transducer, which generates the Ultrasonic vibration
4. The horn or concentrator, which Mechanically amplifies the vibration To the required
amplitude of 15-50 Um and accommodates the tool at its tip.

Advantages of USM
USM process is a non-thermal, non-chemical, creates no changes in the microstructures,
Chemical or physical properties of the workpiece and offers virtually stress free machined
Surfaces.
• Any materials can be machined regardless of the electrical conductivity
• Especially suitable for machining of brittle materials
• Machined parts by USM possess better surface finish and higher structural integrty.
• USM does not produce thermal, electrical and chemical abnormal surface

Some disadvantages of USM

• USM has higher power consumption and lower material-removal rates than tradtional
Fabrication processes.
• Tool wears fast in USM.
• Machining area and depth is restraint in USM.

➢ ELECTRICAL ENERGY BASED PROCESSES

• Electrical discharge machining (EDM)

Electrical discharge machining is one of the most widely used non-traditional machining
processes. The main attraction of EDM over traditional machining processes such as metal
cutting using different tools and grinding is that this technique utilizes thermoelectric process
to erode undesired materials from the workpiece by a series of discrete electrical sparks
between the workpiece and the electrode. A picture of EDM machine in operation.
The traditional machining processes rely on harder tool or abrasive material to remove the
softer material whereas non-traditional machining processes such as EDM uses electrical spark
or thermal energy to erode unwanted material in order to create desired shape. So, the hardness
of the material is no longer a dominating factor for EDM process. A schematic of an EDM1
process is shown in Figure where the tool and the workpiece are immersed in a dielectric
fluid.
EDM removes material by discharging an electrical current, normally stored in a capacitor
bank, across a small gap between the tool (cathode) and the workpiece (anode) typically in
order.

Working principle of EDM

At the beginning of EDM operation, a high voltage is applied across the Narrow gap between the
electrode and the workpiece. This high voltage induces an electric Field in the insula ting
dielectric that is present in narrow gap between electrode and workpiece.
This cause conducting particles suspended in the dielectric to concentrate at the points of
Strongest electrical field. When the potential difference between the electrode and the
Workpiece is sufficiently high, the dielectric breaks down and a transient spark discharges
Through the dielectric fluid, removing small amount of material from the workpiece surface.
The volume of the material removed per spark discharge is typically in the range of 10-6 to 10-
6 mm.
The material removal rate, MRR, in EDM is calculated by the following formula:
MRR = 40 1/ Tm 1.23 (cm’/hmin)
Where, I is the current amp, Tm is the melting temperature of workpiece in °C.

Application of EDM
The EDM process has the ability machine hard, deltaic u h-to-machine materials. Pats with
Complex, precise and irregular shapes for forging. Press tools, extrusion dies, difficult internal
Shapes for aerospace and medical applications can be made by EDM process.

Advantages of EDM
The main advantages of EDM are:
By this process, material s of any hardness can be machined;
No bus are kit in machined surface;One of the main advantages of this process is that thin and
fragilebrittle components can Be machined without distortion;

Limitations of EDM
The main limitations of this process are This process can only be embayed 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,Rough surface finish when at high rates of material removal.

Dielectric fluids
Diclectric fluids used in EDM process are hydrocarbon oils, kerosene and deionized water. The
Functions of the dielectric fluid are to:Act as an insulator between the tool and the workpiece.
Act as coolant. Act as a flushing medium for the removal of the chips.
The encodes for EDM process usually are made of graphite, brass, copper and copper
Tungsten abyss.
Design considerations for EDM process are as follows:
Deep slots and narrow openings should be avoided. The surface smoothness value should not be
specified too fine. Rough cut should be done by other machining process. Only finishing
operation should be Done in this process as MRR for this process is low.

CHEMICAL AND ELECTRO CHEMICAL BASED PROCESSES

4.Electrochemical machining (Ecm)
Electrochemical machining (ECM) is a metal-removal process based on the
principle of reveres Electroplating. In this process, particles travel from the anodic
material (workpiece) toward the Catholic material (machining too). A current of
ekctrolyte fluid caries away the depleted Material before it has a chance to reach
the machining tool The cavity produced is the female Mating image of the tool
shape.
Similar to EDM, the workpiece hardness is not a factor, making ECM suitable for
machining Difficult-to -machine materials. Difficult shapes can be made by this
process on material ls Regardless of their hardness. The ECM tool is positioned
very close to the workpiece and a low voltage, high amperage DC Current is
passed between the workpiece and electrode. Some of the shapes made by ECM.

PROCESS
During ECM, there will be reactions occurring at the electrodes ie. At the anode or workpiece
And at the cathode or the tool along with within the electrolyte. Let us take an example of
Machining of low carbon steel which is primarily a ferrous alloy mainly containing iron. For
Electrochemical machining of steel generally a neutral salt solution of sodium chloride (NaCl)
Is taken as the electrolyte. The electrolyte and water undergoes ionic dissociate as shown
Below as potential differences applied
NaCl Nat + C
H:0H+ + (OH)
As the potential difference is applied between the work piece (anode) and the tool (cathode),
The positive ions move towards the tool and negative ions move towards the workpiece. Thus
the hydrogen ions will take away electron from the cathode (tool) and from hydrogen gas
as:2H+2e= H2 at cathode.

Similarly, the iron atoms will come out of the anode (work piece) as: Fe = Fe** + 2e

Within the electrolyte iron ions would combine with chloride ions to form iron
chloride and Similarly sodium ions would combine with hydroxyl ions to form
sodium hydroxide
Na*+OH- = NaOH
In practice FeC2 and Fe(OH)2 would foam and get precipitated in the fom of
sludge. In this Manner it can be noted that the work piece gets gradually machined
and gets precipitated as the Smudge. Moreover there s not coating on the tool, only
hydrogen gas evolves at the tool or Cathode. Fig. 2 depicts the elctro-chemical
reactions schematically. As the material removal Takes pace due to atomic level
dissociate ion, the machined surface is of excellent surface finish And stress free.
The voltages required to be applied for the electrochemical reaction to proceed at
a steady State. That voltage or potential difference is around 2 to 30 V. The applied
potential difference, However, also overcomes the following resistances or
potential drops. They are:
• The electrode potential
• Concentration over potential
• The activation over potential
• Osmic resistance of electrolyte
• Ohm potential drop
Equipment
The electrochemical machining system has the following modules:
• Power supply
• Electrolyte filtration and delivery system
• Tool feed system
• Working tank

Advantages of ECM
• The components are not subject to ether thermal or mechanical stress.
• No tool wear during ECM process.
• Fragile parts can be machined easily as there is no stress involved.
• ECM debuting can debar difficult to access areas of parts.
• High surface finish (up to 25 um in) can be achieved by ECM process.
• Complex geometrical shapes in high-strength materials particularly in the aerospace
industry
• For the mass production of turbine blades, jet-engine parts and nozzles can be achened
• Repeatedly and accurately.
• Deep holes can be made by this process.

Limitations of ECM
• ECM is not suitable to produce sharp square comers or fat bottoms because of the
tendency
 • For the electrolyte to erode away sharp profiles.
• ECM can be applied to most metals but, due to the high equipment costs, is usually used
• Primarily for highly specialized applications.
• Material removal rate, MRR, in ECM
• MRR = C . h (cm3/min)
C:specifie (material) removal rate (e.g., 0.2052 cm3/amp-min for nickel);
I: current (amp);
h: current efficiency (90-100%).
The rates at which metal can electrochemically remove are in proportion to the current
passed through the electrolyte and the elapsed time for that operation. Many factors other
than current influence the rate of machining. These involve electrolyte type, rate of
electrolyte flow, and some other process conditions.

Application
Conclusion
In the latest field of technology respect to welding and machining, plasma arc welding and
machining have a huge success, Due to its improved weld quality and increased weld output it
is been used for precision welding of surgical instruments, to automatic repair of jet engine
blades to the manual welding for repair of components in the tool, die and mold industry. But
due to its high equipment expense and high production of ozone, i's been outnumbered by
other advance welding equipment like sheer beam welding and electro beam welding.