MT Unit- 5

Q1. What is the need for unconventional machining processes?

Ans: Unconventional machining processes are used when traditional machining methods, such as
turning or milling, are not suitable for a particular workpiece or application. These processes are often
used to produce parts with complex shapes or intricate features that cannot be produced using
conventional methods. Additionally, unconventional machining processes can also be used to produce
parts with high precision, high surface finish, and high material removal rates. Overall, the need for
unconventional machining processes arises when traditional methods are not able to produce the
desired results efficiently or cost-effectively.
Q2. What are the characteristics of UCM processes?
Ans: Unconventional machining processes (UCM) have several characteristics that distinguish them
from traditional machining methods. Some of these characteristics include:
1. Non-traditional energy sources: Many UCM processes use non-traditional energy sources,
such as electricity, chemical reactions, or pressure, to remove material from the workpiece.
2. No direct contact between tool and workpiece: Some UCM processes do not involve direct
contact between the tool and the workpiece. Instead, they use a non-contact method, such as a
beam of energy, to remove material.
3. Complex process control: UCM processes often require complex process control systems to
ensure accurate and consistent results.
4. High precision and surface finish: UCM processes can produce parts with high precision and
high surface finish due to their non-traditional energy sources and non-contact methods.
5. High material removal rate: UCM processes can have high material removal rates, which can
be useful for mass production or rapid prototyping.
6. Variety of materials can be processed: UCM processes can be used to process a wide range of
materials, including hard and brittle materials that are difficult to machine using conventional
methods.
7. Specialized equipment and tooling: Many UCM processes require specialized equipment and
tooling, which can be expensive and may require specialized training to operate.

Q3. What is meant by conventional machining processes?

Ans: Conventional machining processes refer to a group of manufacturing methods that use a cutting
tool to remove material from a workpiece in order to shape or form it into a desired final product. The
cutting tool is typically a single-point cutting tool, such as a lathe tool or a milling cutter, which is
moved relative to the workpiece to remove material. Common examples of conventional machining
processes include:
1. Turning: The cutting tool is moved along the axis of the workpiece, which is typically rotated
about its axis.
2. Milling: The cutting tool is moved in a linear or rotary motion to remove material from the
surface of the workpiece.
3. Drilling: The cutting tool is rotated and moved along the axis of the workpiece in order to
make a hole.
4. Boring: The cutting tool is rotated and moved along the axis of a hole that has already been
drilled in the workpiece in order to enlarge or finish the hole.
5. Grinding: The cutting tool is a abrasive wheel that is moved along the surface of the
workpiece to remove material and create a smooth finish.
Q4. What is meant by Unconventional machining processes?
Ans: Unconventional machining processes (UCM) refer to a group of manufacturing methods that use
non-traditional methods to remove material from a workpiece. These methods differ from
conventional machining processes, which typically use a cutting tool that removes material by cutting
or abrasion.
Some examples of unconventional machining processes include:
1. Electrical Discharge Machining (EDM): EDM uses electrical discharges to remove material
from the workpiece.
2. Electrochemical Machining (ECM): ECM uses a chemical reaction to remove material from
the workpiece.
3. Laser Beam Machining (LBM): LBM uses a beam of intense light to remove material from
the workpiece.
4. Water Jet Machining (WJM): WJM uses a high-pressure jet of water to remove material from
the workpiece.
5. Ultrasonic Machining (USM): USM uses high frequency vibration to remove material from
the workpiece.

Q5. Differentiate the conventional and unconventional machining processes in terms of principles.
(or) Distinguish between traditional and non-traditional machining processes?
Ans: Conventional machining processes and unconventional machining processes differ in terms of
their principles of material removal.

 Conventional machining processes rely on the use of a cutting tool that removes material by
cutting or abrasion. The cutting tool is typically made of a hard and durable material, such as
steel or carbide, and is moved in a specific pattern over the workpiece to remove material.
Examples of conventional machining processes include turning, milling, drilling, and
grinding.
 Unconventional machining processes, on the other hand, use non-traditional methods to
remove material from the workpiece. These methods do not rely on a cutting tool and instead
use a variety of energy sources to remove material. Some examples of unconventional
machining processes include electrical discharge machining (EDM), laser beam machining
(LBM), and electrochemical machining (ECM).

Q6. What are the various types of energy sources used in non-traditional machining techniques? Give
examples for each. (or) How non – traditional machining processes are classified?
Ans: Unconventional machining processes (UCM) use non-traditional energy sources to remove
material from the workpiece. These energy sources are used to generate heat, pressure, or a chemical
reaction that removes material from the workpiece.
UCM processes can be classified based on the energy source used, some of the common energy
sources used in non-traditional machining processes are:
1. Thermal energy: Thermal energy is generated by heating the workpiece or the cutting tool.
Examples of thermal energy sources include electric arc, laser, and electron beams.
2. Mechanical energy: Mechanical energy is generated by applying a force to the workpiece.
Examples of mechanical energy sources include ultrasonic, abrasive jet, and water jet
machining.
 3. Chemical energy: Chemical energy is generated by a chemical reaction between the
workpiece and the cutting tool. Examples of chemical energy sources include electrochemical
and electro-discharge machining.
4. Electrical energy: Electrical energy is generated by applying an electric current to the
workpiece. Examples of electrical energy sources include electrical discharge machining
(EDM) and electrochemical machining (ECM).
5. Magnetic energy: Magnetic energy is generated by applying a magnetic field to the
workpiece. Examples of magnetic energy sources include Magnetic Abrasive Finishing
(MAF)
6. Hydro-energy: Hydro-energy is generated by applying a pressurized water jet to the
workpiece. Examples of Hydro-energy sources include water jet machining (WJM)
7. Photonic energy: Photonic energy is generated by applying a beam of intense light to the
workpiece. Examples of Photonic energy sources include Laser Beam Machining (LBM)
8. Kinetic energy: Kinetic energy is generated by the motion of the tool. Examples of kinetic
energy sources include Ultrasonic Machining (USM)

Q7. Identify the mechanism of material removal, transfer media and energy source for EDM.
Ans: Electrical Discharge Machining (EDM) is a non-traditional machining process that uses
electrical discharges to remove material from a workpiece.
1. Mechanism of Material Removal: In EDM, electrical discharges are generated between an
electrode and the workpiece, which vaporize or erode small amounts of material from the
workpiece surface. The electrode is typically a small, thin wire made of a conductive material,
such as copper or tungsten. The workpiece is typically made of a conductive material, such as
metal or graphite.
2. Transfer Media: The transfer media used in EDM is typically a dielectric fluid, such as
deionized water or oil, which is used to insulate the electrode from the workpiece and to cool
the system during machining. The dielectric fluid also helps to flush away the molten or
vaporized material from the cutting area.
3. Energy Source: The energy source used in EDM is electrical energy, which is used to
generate the electrical discharges between the electrode and the workpiece. The electrical
energy is supplied through a power supply unit, which controls the voltage and current to the
electrode. The energy source is in the form of electrical pulses that are applied to the
electrode, and cause sparks to occur between the electrode and the workpiece, as a result
material is removed by the process called electro-discharge erosion.

Q8. Identify the mechanism of material removal, transfer media and energy source for ECM & ECG.
Ans: Electrochemical Machining (ECM) and Electrochemical Grinding (ECG) are non-traditional
machining processes that use a chemical reaction to remove material from a workpiece.
1. Mechanism of Material Removal: In ECM, a chemical reaction is used to dissolve or erode
material from the workpiece surface. The workpiece is typically made of a conductive
material, such as metal, and an electrolyte solution is used to facilitate the chemical reaction.
The electrolyte solution contains an ion that can react with the workpiece material to form a
compound that is dissolved or eroded away. The electrode is typically made of a material that
does not react with the electrolyte solution and does not participate in the chemical reaction.
2. Transfer Media: The transfer media used in ECM is typically an electrolyte solution, which is
used to conduct the electrical current and to facilitate the chemical reaction. The electrolyte
 solution can be made of various materials, such as water or oil, and is typically combined
with a chemical compound that can react with the workpiece material.
3. Energy Source: The energy source used in ECM is electrical energy, which is used to
generate the electrical current between the electrode and the workpiece. The electrical energy
is supplied through a power supply unit, which controls the voltage and current to the
electrode. The electrical current causes the chemical reaction to occur between the workpiece
and the electrolyte solution, which results in the removal of material.

Q15. Identify the energy source applied in the following processes: i) IBM ii) CHM iii) ECG iv) ECM
v) EDM vi) EBM vii) AJM viii) LBM.
Ans
1. IBM (Ion Beam Machining) - The energy source applied in IBM is a beam of high-energy
ions, typically generated by an ion source.
2. CHM (Chemical Beam Machining) - The energy source applied in CHM is chemical energy,
typically generated by a chemical reaction between a reactant gas and the workpiece.
3. ECG (Electrochemical Grinding) - The energy source applied in ECG is electrical energy,
used to generate the electrical current between the electrode and the workpiece.
4. ECM (Electrochemical Machining) - The energy source applied in ECM is electrical energy,
used to generate the electrical current between the electrode and the workpiece.
5. EDM (Electrical Discharge Machining) - The energy source applied in EDM is electrical
energy, used to generate the electrical discharges between the electrode and the workpiece.
6. EBM (Electron Beam Machining) - The energy source applied in EBM is electrical energy,
used to generate the beam of high-energy electrons.
7. AJM (Abrasive Jet Machining) - The energy source applied in AJM is mechanical energy,
typically generated by the high-pressure of abrasive particles mixed with a gas.
8. LBM (Laser Beam Machining) - The energy source applied in LBM is thermal energy,
generated by a beam of intense light.

Q16. What is the necessity for unconventional machining processes? What are the importance of
unconventional machining? Enlist the requirement that demands the use of advanced machining
process.
Ans: i> The necessity for unconventional machining processes arises from the need to machine
certain types of materials or produce certain types of parts that cannot be effectively produced using
conventional machining methods.
ii> Unconventional machining processes offer several important advantages over conventional
methods, some of the key benefits include:
1. High-speed machining: Unconventional machining processes such as electrochemical
machining or ultrasonic machining can be used to achieve high-speed material removal rates.
2. Surface finish: Unconventional machining processes can produce high-quality surface
finishes that are difficult or impossible to achieve with conventional machining methods.
3. Minimal or no contact between tool and workpiece: Some unconventional machining
processes do not require direct contact between the tool and the workpiece, which eliminates
the possibility of tool wear and prolongs tool life.
4. Cost-effective: Unconventional machining processes can be cost-effective in certain
applications, especially when conventional methods are not suitable.
iii> The use of advanced machining processes, also known as unconventional or non-traditional
machining processes, may be required in certain situations, such as:
1. Manufacturing of complex geometries and shapes: When parts require complex geometries
and shapes that cannot be produced with conventional methods, advanced machining
processes such as wire EDM or LBM may be used.
2. High precision and tolerance requirements: When parts require high precision and tight
tolerances, advanced methods such as ultrasonic machining or electron beam machining may
be used.
3. Production of large volume of parts: Advanced methods such as abrasive water jet machining
or electrochemical grinding can be used to produce large volumes of parts with high material
removal rate.
4. Surface finishing: Some advanced methods such as chemical beam machining or
electrochemical polishing can produce high-quality surface finishes that are difficult or
impossible to achieve with conventional methods.

Q17. Explain the classification of Unconventional machining according to major energy source
employed.
Ans: Unconventional machining processes can be classified according to the major energy source
employed in the machining process. The main types of energy sources used in unconventional
machining are:
1. Thermal energy: Unconventional machining processes that use thermal energy as the major
energy source include laser beam machining (LBM), electron beam machining (EBM), and
plasma arc machining (PAM). These methods use intense heat to vaporize or melt the
material, which is then removed by the cutting tool or a gas stream.
2. Chemical energy: Unconventional machining processes that use chemical energy as the major
energy source include electrochemical machining (ECM) and chemical beam machining
(CHM). These methods use a chemical reaction to dissolve or erode the material, which is
then removed by the cutting tool or a gas stream.
3. Mechanical energy: Unconventional machining processes that use mechanical energy as the
major energy source include abrasive jet machining (AJM), abrasive water jet machining
(AWJM), and ultrasonic machining (USM). These methods use high-speed particles or
vibration to remove the material.
4. Electrical energy: Unconventional machining processes that use electrical energy as the major
energy source include electrical discharge machining (EDM) and electrochemical grinding
(ECG). These methods use electrical discharges or electrical current to remove the material.
5. Ion energy: Unconventional machining processes that use ion energy as the major energy
source include ion beam machining (IBM). These methods use a beam of high-energy ions to
remove the material.

Q18. Name the important factors that should be considered during the selection of an unconventional
machining process for a given job.
Ans: When selecting an unconventional machining process for a given job, several important factors
should be considered:
 1. Material properties: The material properties of the workpiece, such as hardness, brittleness,
electrical conductivity, and chemical reactivity, will affect the suitability of different
unconventional machining processes. For example, electrochemical machining (ECM) is
well-suited for machining conductive materials, while laser beam machining (LBM) is well-
suited for machining non-conductive materials.
2. Geometry and size of the workpiece: The geometry and size of the workpiece will also affect
the suitability of different unconventional machining processes. For example, abrasive jet
machining (AJM) and water jet machining (WJM) are well-suited for machining large,
complex parts, while electrical discharge machining (EDM) and laser beam machining
(LBM) are well-suited for machining small, intricate parts.
3. Surface finish and tolerance requirements: The surface finish and tolerance requirements of
the workpiece will also affect the suitability of different unconventional machining processes.
For example, electrochemical machining (ECM) and ultrasonic machining (USM) are well-
suited for producing high-quality surface finishes, while abrasive jet machining (AJM) and
water jet machining (WJM) are well-suited for producing parts with lower surface finish
requirements.
4. Production volume and lead time: The production volume and lead time of the job will also
affect the suitability of different unconventional machining processes. For example,
electrochemical machining (ECM) and abrasive jet machining (AJM) are well-suited for high-
volume production, while laser beam machining (LBM) and electrical discharge machining
(EDM) are well-suited for low-volume production or prototyping.
5. Cost and environmental impact: The cost and environmental impact of the job should also be
considered when selecting an unconventional machining process. Some methods such as
electrochemical deburring or electro-discharge texturing may be more environmentally
friendly, while others may be more cost-effective for large volume production.

Q20. Is unconventional machining process an alternate or complement to conventional machining

process? Justify.
Ans: Unconventional machining processes can be both an alternate and a complement to conventional
machining processes.

 As an alternate: Unconventional machining processes can be used as an alternative to

conventional machining processes in certain situations. For example, when machining hard or
brittle materials, or producing parts with high precision and complex geometries,
unconventional methods such as electrochemical machining (ECM) or laser beam machining
(LBM) may be used instead of conventional methods such as turning or milling.
 As a complement: Unconventional machining processes can also be used in conjunction with
conventional machining processes to enhance their capabilities. For example, electrochemical
grinding (ECG) can be used to improve the surface finish of a part that has been machined
using conventional methods such as turning or milling. Similarly, abrasive jet machining
(AJM) can be used to remove burrs or other surface imperfections that cannot be removed by
conventional methods such as grinding.

Q21. Explain the process parameter which controls the AJM machining quality. With a neat sketch
explain the process of AJM? Explain the process control measures to be taken to control quality and
MRR.
Ans: i> Abrasive Jet Machining (AJM) is a process that uses a high-pressure jet of abrasive particles
to remove material from a workpiece.
ii> The process of AJM involves the following steps:

1. Abrasive particles are fed into a high-pressure air or gas stream through a nozzle.
2. The abrasive jet is directed towards the workpiece and begins to remove material as it comes
into contact with the surface.
3. The workpiece is moved relative to the abrasive jet, allowing the jet to remove material from
the entire surface.
4. The removed material, along with the abrasive particles, is collected and removed from the
machining area.

iii> To control the quality and MRR of AJM, the following process control measures can be taken:
1. Proper selection of abrasive particles: The size and shape of the abrasive particles should be
carefully selected to achieve the desired surface finish and MRR.
2. Proper nozzle design: The nozzle design should be optimized to achieve the desired jet shape
and size, which in turn will affect the MRR and the surface finish.
3. Proper jet pressure: The pressure of the abrasive jet should be carefully controlled to achieve
the desired MRR and surface finish.
4. Proper distance between nozzle and workpiece: The distance between the nozzle and the
workpiece should be carefully controlled to achieve the desired MRR and surface finish.
5. Proper machining strategy: The machining strategy, including the cutting speed and the feed
rate, should be carefully selected to achieve the desired MRR and surface finish.