Unit-1 ‘ a Non TRADITIONAL MACHINING ii INTRODUCTION Machining is a process of removing excess material from the workpiece material to obtain the desired shape and size. The process is classified into two types: a) Conventional or Traditional machining, and b) Non-conventional or Non-traditional machining* (NTM) Conventional or Traditional machining makes use of a hard, and a sharp cutting tool to remove the excess material from the workpiece. There are different types of machines designed to hold the cutting tool and perform the machining operation. Few of them include: Lathes, Drilling machines, Grinding machines, ete. However, the demand from aerospace, automotive, nuclear, mining, and other sectors for products with superior properties like high-strength-to-weight ratio, hardness, corrosion and heat resistance, led to the research and developments in more precise machines, superior cutting tool materials, and faster methods of production. Although the conventional machines are capable of producing the desired shape and size along with a good surface finish, there are certain instances where they fail to produce the desired results. A few of these instances are listed below: * Machining of hard workpiece materials like nimonics, carbides, stainless steels, heat resisting steels, and similar such materials. Tool wear and failure becomes a serious problem in machining such materials. Further, the high cost of tools and the damage generated during machining made it practically or economically impossible to machine such materials using conventional machining process. * Machining of very small diameter holes, deep cavities, and complex geometrical shapes. * Workpiece is too flexible or slender (thin) to withstand the high cutting forces during machining. * A very high surface finish with close dimensional accuracy of the product is required. The above mentioned instances led to the development of new machining methods, and are referred as non-conventional or non-traditional machining processes. There are a variety of non-traditional processes based on scientific and technical achievements of new findings for * Also known as Modern machining, Advanced machining, or Un-conventional machining.2 ~ Non Traditional Machining using laws of nature relating to light (lasers), seund (ultrasoftic process), magnetism, atomic physics (plasma); electrical sparks, chemical dissolution process, and other theories. In simple words, non-traditional processes make use of lasers, ultras@nic vibrations ¢lectron beam, chemical erosion technique, clectrachemical energy ete., instead of the raditional cutting tool to obtain the desired shape and size; hence the name noa-fraditional or non-conventional process. 1.2 CLASSIFICATION OF NIM PROCESSES Non-traditional machining processes are typically classified based on the aattre of energy employed in machining. These include: a) Mechanical energy ‘The excess material is removed by the mechanical erosion of the workpiece material. The various machining processes that utilize mechanical energy include: + Ultrasonic Machining (USM) + Water Jet Machining (WJM) + Abrasive Jet Machining (AIM) b) Chemical or Electrochemical energy Material is removed from the worksurface by the mechanism of ion displacement, or by chemical dissolution using chemical reagents or etchants like acids and alkaline solutions, Machining processes that utilize chemical energy inelude + Electrochemical Machining (ECM) + Electrochemical Grinding (ECG) + Electrochemical Honing (ECH) + Electrochemical deburring (ECD) + Chemical Machining (CM) ©) Thermal or Electrothermal energy Thermal energy is employed to melt and vaporize tiny bits of the workpiece material by concentrating the heat energy on a small arca of the workpiece. Machining processes that utilize thermal energy include: + Laser Beam Machining (LBM) + Plasma Arc Machining (PAM) + Electrical Discharge Machining (EDM) + Electron Beam Machining (EBM) +» lon Beam Machining (IBM)on Non Traditional Machining - Introduction 13 CONVENTIONAL v/s NON-CONVENTIONAL MACHINING Table 1.1 gives a brief comparison between conventional and ngn-conventional machining. Sl. Non-conventional or No. Traditional machining Non-Traditional machining. 1. | The cutting tool must be harder than | Cutting tool need not be harder than the the workpiece material workpiece material. In some processes like Laser beam machining, physically there is no cutting tool, instead, the laser beam acts asa cutting tool. 2. | Conventional machining involves | There is no physical contact between the direct contact between the tool and | cutting tool and workpiece. the workpiece, 3. _ | Tool life is less due to wear of the tool | Tool life is comparatively more. resulting from its direct contact with the workpiece metal. 4, | Conventional processes use | NIM processes utilize different energy mechanical energy (application of | sources like mechanical, electrical, cutting forces) for metal removal, chemical, and thermal sources. 5. | Machining is characterized by | Machining is mostly characterized by macroscopic chip formation by shear | microscopic chip formation. In some deformation, processes like electrochemical machining, there is no chip formation, instead material removal occurs due to electrochemical dissolution at atomic level. %, | Difficult to obtain high accuracy and | NIM processes result in high accuracy and surface finish. surface finish. 7. | Metal removal rate is limited by the | ‘No such limitations. NTM process can mechanical properties of the | remove material with much ease even with workpiece material. difficult-to-cut materials, 8. | Conventional processes may requite | Requires skilled operator, skilled or unskilled operator. 9, | Low capital cost Comparatively higher. 10. | Easy set-up of equipment ‘Comparatively comple: ‘Table 1.1 Conventional v/s Non-conventional Machining, 1.4 NTM PROCESS SELECTION Non-traditional machining although advantageous in many aspects, however cannot completely replace the conventional machining process, A particular NTM process suitable fora givenmaterial= - 4 Non Traditional Machining under the given conditions may not be equally efficient uMder other conditions. Hence, a careful selection of a NTM process for a given machining condition becomes essential. The various aspects need to be considered before selecting a NTM process are discussed briefly below. a) Properties of the work material and shape to be machined Workpiece materials possess different properties. They may be hard or sofi, conducting or non-conducting, ductile or brittle, etc. USM process is good for machining ceramics and glasses, while ECM and EDM process are not, because ceramics and glasses are non-conductive. ‘On the other hand, ECM and EDM are good for machining steel and super alloys, but not with USM, Further, with respect to some shapes, say for example, USM and LBM process are not suitable for machining deep holes, but ECM & EDM are comparatively good. Hence, selection of a particular NTM process must be made by due consideration. b) Physical parameters of NTM process Power, voltage potential, current, gap between tool and workpiece material, are a few common. parameters in NTM process. Process like USM and EDM consume approximately the same power for machining a particular material, while ECM and CM consume a comparatively greater amount of power, Further, with respect to the gap between tool and workpiece, a sual gap results in greater metal removal from the workpiece, however some process conditions restrict the gap and hence a proper choice has to be made herein. ¢) Process capabilities Process capabilities of NTM processes include: metal removal rate, surface finish, tolerance, and other related parameters. PAM has a higher metal removal rate compared to USM and EDM process. ECM results in excellent surface finish, however it causes extensive surface damage when compared to AJM or USM process. d) Economic considerations Economical factors include costs related to capital investment, tooling & fixtures, power requirement and other expenses incurred for machining process. AJM, USM and PAM process require very low capital investment, compared to EBM, EDM, ECM, and LBM process. Tooling costs are high for EDM and ECM process. The power consumption is very low for USM and LBM process. Economic consideration is a very important aspect as it determines the final cost for machining a particular component. er