KARNATAK LAW SOCIETY’S

GOGTE INSTITUTE OF TECHNOLOGY

UDYAMBAG, BELAGAVI-590008
(An Autonomous Institution under Visvesvaraya Technological University, Belagavi)
(APPROVED BY AICTE, NEW DELHI)

Course Activity on

NEW TRENDS IN UNCONVENTIONAL

MACHINING
 Submitted in the partial fulfillment for the academic requirement of
4th Semester B.E.
in
Mechanical Engineering

Submitted by
NAME OF THE CANDIDATE USN
Harshit D Kulkarni 2GI18ME050
Megh Shivalkar 2GI18ME066
Omkar Gurav 2GI18ME074
Rohin Lengade 2GI18ME095

GUIDE
Prof. A A Kulkarni
2019-2020
 What are unconventional machining process?

• Special type of machining process in which there is no direct contact between the tool and the work
piece.

• a form of energy is used to remove unwanted material from a given work piece.

Why unconventional machining processes are used?

• In several industries, hard and brittle materials like tungsten carbide, high speed steels, stainless steels,
ceramics etc., find a variety of applications.

• For example, tungsten carbide is used for making cutting tools while high speed steel is used for making
gear cutters, drills, taps, milling cutters etc.
• The most outstanding areas of work in the field of unconventional processes

are the following:

1.Laser micro machining

2.Rotary Ultrasonic Machining

3.Electrochemical machining
1. LASER MACRO MACHING
• Laser micromachining is a laser enabled
process used to make micrometer scale
features in materials.

• A pulsed laser deposits finite amounts of

energy into a material for precise and
reproducible material removal enabling the
laser machining process to cut, scribe, drill, or
ablate a material.
Courtesy:-https://www.newport.com/
Working principle
 • Due to the speed of machining and the degree
of precision achieved. Figure 1 shows some
examples of the capabilities of laser
technology.

• In the aeronautical and automotive field, laser

micro-drilling and texturing technology has
demonstrated its good capabilities in obtaining
Figure 1. functional surfaces and components.
Courtesy:-CMM Magazine
• Figures 2 shows some of the laser drilling and texturing treatments carried out on steels,
metallic glasses and rubbers, revealing the degree of precision achieved by this
technology.

Figure 2:-Micro-drilled in 1 mm stainless steel sheet and 50

µm thick metallic glass sheet (Nickel alloy)
Courtesy:- https://www.interempresas.net
2. Rotary Ultrasonic Machining
• Rotary Ultrasonic Machining (RUM) is part of
unconventional machining processes that allow
the machining of hard and brittle materials in an
efficient way with moderate costs.

• RUM is a process that consists of the removal of

material using a super abrasive tool by
combining three movements: rotation, ultrasonic
axial vibration (frequency 20 kHz and amplitude
Courtesy :- CMM magazine
5-50 microns)
Working principle
• The material removal mechanism in the RUM is the combination of the mechanisms present in
diamond grinding and traditional ultrasound machining (USM)

• the field of application of the RUM is mainly focused on the manufacture of components in
hard and brittle materials such as technical ceramics, glass, hardened metals,etc

Figure 3:- Decorative details in natural stone

(Santiago cross in granite) and synthetic stone
(soap dishes in Siltstone).
Courtesy :- https://www.interempresas.net
3.ELECTROCHEMICAL MACHINING
• The ECM uses chemical action to remove the
material.

• It is normally used for mass production and is

used for working extremely hard materials or
materials that are difficult to machine using
conventional methods.

• Its use is limited to electrically

Courtesy :- CMM magazine conductive materials.

Working principle
 • This new variant of ECM is called Pulsed
Electrochemical Machining or PECM.

• PECM process provide an efficient alternative

for the manufacture of a wide variety of
components such as turbine blades, surgical
implants,etc

Figure 4:- turbine blades

Courtesy:-www.pemtec.de.
• Very accurate (tolerance of +-02mm).
• Tool wear is nearly absent
• Better surface finish (0.2 to 0.8 micron).
• Relatively fast.

Figure 4:- examples of ECM machined parts

Courtesy:- AEG-Elotherm-Germany
REFERENCES

1. https://www.potomac-laser.com/blog/advantages-of-laser-micromachining/

2.https://www.researchgate.net/publication/329118047_Rotary_Ultrasonic_Machining_of_Hard_to_Machine_Mate
rials-A_review

3.https://www.cnccookbook.com/what-is-cryogenic-
machining/#:~:text=Cryogenic%20Machining%20is%20the%20process,perform%20this%20kind%20of%20work

4. http://mechteacher.com/
Thank You