Fabrication of large

size domes

Fabrication of
Micro-lens

An overview
of
Non Traditional Manufacturing

Conventional Machining Processes (Material Removal):

Primarily rely on electrical motors and hard tool materials to
perform tasks e.g. Turning, Drilling, Boring, Milling,
Shaping, Sawing, Slotting, & Grinding etc.
60 m square hole Curved slot in SS
in Si

Micro-lenses Main Characteristics of Conventional Machining:

* Material removal by chip formation
* Material removal by mechanical force
* Cutting tool harder than work piece under machining condition
* Direct mechanical contact - residual mechanical & thermal stress.
 Need of Modern Manufacturing Processes !
Other requirements of the New Manufacturing Process
Challenges & Competition in manufacturing industries:
New Products - Better Performance, More Features, More Durable, Less Production Low machining cost
Time, Energy Efficient, Low cost, * Automated processing, Fast production
Demand for Products with
Rapid change of Product design
New exotic work materials: Improved mechanical, thermal, & chemical * Elimination of Traditional tooling to reduce time & cost
properties
Super alloys, ceramics and composites Less Temperature rise or residual stresses
* Too hard / brittle to machine with traditional process
* Materials too flexible / slender to cut or clamp
Ex: Machining Polycrystalline diamond
- fast wear of grinding wheel; Quartz
Silicon wafer, Ceramic Damage during machining
Innovative designs, complex shapes, high precision & high surface quality
* Stringent design requirements * Micro- Nano Sizes

Micro-lenses
Photochemical Machining Electro-Discharge Machining

60 m square hole in Si Curved slot in SS

Basic NTM Process Groups:

Modern / Nontraditional Manufacturing processes employing
New tools and
* Thermal NTM Processes
New forms of energy
- Laser Beam Machining (LBM)
Developed as
- Electron Beam Machining (EBM)
Efficient and economic alternatives to conventional ones - Plasma Arc Machining (PAC)
- Electrical Discharge Machining (EDM)
Often the first choice for certain technical requirements.
* Mechanical NTM Processes( Plastic deformation / Abrasive Erosion)
- Abrasive Jet Machining (AJM)
Modern / Nontraditional Manufacturing Processes differ to Traditional Mfg. - Ultrasonic Machining (USM)
Processes in following aspects - Water Jet Machining (WJM)
- Abrasive Water Jet Machining (AWJM)
Unconventional Energy Sources : Thermal, Chemical, Kinetic Energy ---- * Electrochemical NTM Processes
- Electrochemical Machining (ECM)
Processing usually not by direct MECHANICAL contact: Nontraditional
- Electrochemical Grinding (ECG)
mechanism of interaction between the tool and the work piece: Evaporation,
Ablation, Melt Ejection, Dissolution, Erosion---- * Chemical NTM Processes
- Chemical Machining (CHM)
Nontraditional media to transfer energy from the tool to the work piece : - Thermo chemical Machining (TCM)
Photons, E-beam, Dielectric media, Electrolytic media, Water, Abrasive slurry.
* Kinetic Energy ( Atom by atom knocking)
- Ion beam
 Characteristics of Modern / Non Traditional Machining (NTM) Processes:
Examples where NTM processes is the first choice
Mostly NTM processes do not use mechanical energy for material removal.
Intricate shaped blind holes- e.g. square holes of say 10x10mm with a depth of They use different forms of energy for machining.
20mm EDM / ECM Example, USM, AJM, WJM - Mechanical energy
ECM- Electrochemical dissolution
Machining hard materials- e.g. Diamond, Inconel, Ti-Alloys, Composites, Laser, EDM, EB - Thermal
Ceramics or Carbides EDM, ECM, LBM
Material removal with chip formation or even without chip formation
Small diameter holes with large aspect ratio (0.5mm , 10mm l) Example: AJM - Microscopic size chips
ECM - Electrochemical dissolution at atomic level
LBM, EBM, EDM
Flexible , Brittle materials WJ, AWJ, EDM, PCM, LBM, EBM In NTM, Physical tool may or may not be present.
Example: Laser beam machining- No tool,
Electrochemical Machining- Physical tool needed

In NTM, Tool need not be harder than the work piece material.
Example, EDM, copper tool to machine hardened steels.
Abrasive Machining
Nontraditional media for energy transfer:
EDM: Dielectric fluid,
Laser Cutting Laser: Coherent photon beam

Modern Manufacturing Processes Course Outline by Topical Areas:

1. Laser Beam Machining ((Processing) (LBM) AJM
2. Electron Beam Machining (EBM)
3. Plasma Arc Machining (PAC) WJM & AWJM
4. Ion Beam Machining (IBM)
5. Physical Vapour Deposition (PVD)
USM
6. Chemical Vapour Deposition (CVD) PAM
7. Abrasive Jet Machining (AJM)
8. Water Jet Machining (WJM) CHM
9. Abrasive Water Jet Machining (AWJM)
ECM
10. Ultrasonic Machining (USM)
11. Electro- Discharge Machining (EDM) EBM
12. Electrochemical Machining (ECM)
13. Chemical Machining (CHM) EDM
14. Hybrid & Other Advanced Manufacturing Processes W-EDM