02 - Non Traditional Machining Processes

Non Traditional Machining
(NTM) Processes
1
Comparison of Conventional and
Non- Conventional Machining Processes
CONVENTIONAL NON-CONVENTIONAL
Generally macroscopic chip formation chips are of generally microscopic

by shear deformation size
There may be a physical tool present There may not be a physical tool
present
Energy domain can be classified as Most NTM processes do not use

mechanical mechanical energy to provide
material removal
Conventional machining involves the Non-conventional machining does not

direct contact of tool and workpiece require the direct contact of tool and
workpiece
2
Comparison of Conventional and
Non- Conventional Machining Processes
CONVENTIONAL NON-CONVENTIONAL
Lower accuracy and surface finish Higher accuracy and surface finish
Suitable for every type of material Not Suitable for every type of material
economically economically
Higher waste of material due to high Lower waste of material due to low or
wear no wear.
Noisy operation mostly cause sound Quieter operation mostly no

pollutions sound pollutions are produced
Lower capital cost Higher capital cost
Skilled or un-skilled operator may Skilled operator required

required 3
Non Traditional Machining (NTM) Processes
The NTM processes have been developed largely in response to the
new and unusual machining requirements that could not be satisfied
by conventional methods.
These requirements include:
 The need to machine newly developed materials (metals, non
metals, composites etc.). These new materials often have
special properties (e.g., high strength, high hardness, high
toughness) that make them difficult or impossible to machine by
conventional methods.
 The need for unusual or complex part geometries that cannot
be easily accomplished and in some cases are impossible to
achieve by conventional machining.
 The need to avoid surface damage that often accompanies the
stresses created by conventional machining.
4
Non Traditional Machining (NTM)
Processes
The term non traditional machining refers to the group of
processes, that remove excess material by various
techniques involving;
 Mechanical energy
 Thermal energy
 Electrical energy
 Chemical energy
5
Types of NTM Processes
The NTM processes are often classified according to principal
form of energy used to effect material removal. By this
classification, there are four types:
1. Mechanical Erosion of the work material by a high velocity

stream of abrasives or fluid is the typical form of mechanical
action in these processes.
2. Electrical These non traditional processes use

electrochemical energy to remove material.
6
Types of NTM Processes
3. Thermal These processes use thermal energy to cut or

shape the work part. The thermal energy is generally applied
to a very small portion of the work surface, causing that
portion to be removed by fusion and/or vaporization of the
material.
4. Chemical Most materials (metals) are susceptible to

chemical attack by certain acids or other corrosive
chemicals. In chemical machining, chemicals selectively
remove material from portions of the workpart, while other
portions of the surface are protected by a mask.
7
Mechanical Energy Processes
Some of the NTM processes that utilizes mechanical

energy for material processing are:
(1) Ultrasonic Processes

(2) Water jet cutting
8
Ultrasonic Processes
Ultrasonic processing of solids utilizes the effect of the high
frequency mechanical vibration producing friction and abrasion
actions.
Common ultrasonic processes are:
 Ultrasonic machining
 Ultrasonic welding
 Ultrasonic cleaning
 Ultrasonic homogenizing
 Ultrasonic degassing 9
Ultrasonic Machining (USM)
 Ultrasonic machining (USM) is a non traditional machining

process in which abrasives contained in a slurry are driven
at high velocity against the work by a tool vibrating at low
amplitude (around 0.075mm) and high frequency
(ultrasonic) approximately 20 kHz.
 The tool oscillates in a direction perpendicular to the work
surface, and is fed slowly into the work, so that shape of
the tool is formed in the part.
 It is the action of the abrasive, impinging against the work
surface, that performs the cutting.
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 Common tool materials used in USM include soft steel and stainless
steel.
 Abrasive materials in USM include boron nitride, boron carbide,
aluminum oxide, silicon carbide and diamond.
 Grit sizes ranges between 100 and 2000 microns
 The vibration amplitude should be set approximately equal to grit
size, and the gap size should be maintained at about two times grit
size. To a significant degree grit size determines the surface finish on
the new work surface.
 The slurry in USM consists of a mixture of water and abrasive
particles. Concentration of abrasives in water ranges from 20% to
60%.
 The cutting action in USM operates on the tool as well as the work.
As the abrasive particles erode the work surface, they also erode the
tool, thus effecting its shape. 12
Applications:
 Tight-tolerance round thru-holes
for semiconductor processing
equipment components
 Micro-machined and micro-
structured glass wafers for
micro-electromechanical
systems (MEMS) applications
Ultrasonic machining can be used to

form intricate, finely detailed graphite
electrodes
13
Applications:
Ultrasonic machining centers can

perform both conventional and
ultrasonic machining operations.
By combining these technologies in

one machine, the user has the
capability to machine across the
entire material spectrum with
precision and accuracy.
Ultrasonic machining of a carbide die for

the aerospace industry. 14
Ultrasonic Welding (USW)
15
Sonotrode: A tool that creates ultrasonic vibrations and applies this
vibrational energy to a gas, liquid, solid or tissue. A sonotrode usually
consists of a stack of piezoelectric transducers attached to a tapering
metal rod.
Piezoelectric transducer is a device that

transforms one type of energy to another by
taking advantage of the piezoelectric
properties of certain crystals or other
materials. When a piezoelectric material is
subjected to stress or force, it generates an
electrical potential or voltage proportional to
the magnitude of the force. This makes this
type of transducer ideal as a converter of
mechanical energy or force into electric
potential which is used to produce amplitude
and frequency.
16
Advantages:
Welding occurs at low temperatures relative to other methods

The process occurs in fractions of a second to seconds.
It's a safer process as it does not require flammable fuels and open
flames.
Ultrasonic welds are as strong and durable as conventional welds of
the same materials
Disadvantages:
Workers' hearing may be damaged by exposure to high-frequency

sound
The depths of the welds are less than a millimeter
Ultrasonically welding dissimilar materials requires an additional
material 17
Applications:
An ultrasonic welder compressing onto the contact.
The materials in the upper portion of

this athletic shoe were assembled by
ultrasonic welding rather than
traditional sewing.
Two materials are welded together 18
Water Jet Cutting (WJC)
 WJC uses a fine, high pressure, high-velocity stream of
water directed at the work surface to cause cutting of the
work. (also called hydrodynamic machining)
 To obtain the fine stream of water a small nozzle opening of

diameter 0.1 to 0.4 mm is used.
 To provide the stream with sufficient energy for cutting,

pressures up to 400 MPa are used and the jet reaches a
velocity up to 900 m/s. The fluid is pressurized to the desired
level by a hydraulic pump.
19
 Important process parameters includes
1. standoff distance
2. nozzle opening diameter
3. water pressure
4. cutting feed rate
 The standoff distance is the separation between the nozzle

opening and the work surface. It is generally desirable for
this distance to be small to minimize dispersion of the fluid
stream before it strikes the surface.
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21
22
(m3/s)
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 Size of the nozzle orifice affects the precision of the cut;

smaller opening is used for finer cuts on thinner materials.
 The cutting feed rate refers to the velocity at which WJC
nozzle is traversed along the cutting path.
 The WJC process is usually automated using computer
numerical control or industrial robots to manipulate the
nozzle unit along the desired trajectory.
 Water jet cutting can be used effectively to cut narrow slits in
flat stock such as plastic, textiles, composites, floor tile,
carpet, leather and cardboard.
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25
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27
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The WaterJet Orifice (Jewel Orifice)
 The waterjet orifice is the single
most overlooked component in a
waterjet cutting machine; without it
the entire system would fail to
function.
 Waterjet orifice design utilizes
materials like diamond, corundum,
ruby, and sapphire mainly due to
their high hardness property.
29
Orifice Failure Modes
1. FAILURE DUE TO IMPACTS
 Debris and Garnet particles pulled back through the jewel’s orifice via the
vacuum created when the stream is cycled off.
 Metal or plastic particles hit the orifice due to high pressure.
 Other line born contaminants.
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2. FAILURE DUE TO OVAL SHAPED THROUGH HOLES
Faulty manufacturing of orifices may lead to oval shaped or out-of round through
holes within the orifice if proper quality control processes are not followed.
If this type of failure mode has occurred, typically you will see a fluctuating jet
stream and may also hear spitting and sputtering sounds while this occurs.
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3. FAILURE TO SEAL
When a manufacturer machines an orifice mount, it is very important that it is
machined in a way that leaves concentric machine lines. If inconcentric machine
lines result, the jewel is unable to seat properly in the mount and therefore will
not seal.
If unable to seal, water as well as foreign debris is able to pass around the jewel
and cause immediate orifice failure.
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4. ORIFICE RETAINER FAILURE
The key objective of the orifice retainer is to hold the jewel in place without
affecting the coherency of the jet stream.
If the optimal retaining method and materials are not used for each varying
application, this can cause improper jewel retention leading to blown out orifices,
angled jet streams and fractured jewels.
33
The Effects of Cutting with a
Defective Orifice
 Damaged work piece material
 Premature failure of mixing tube
 Slower cut speeds
 Poor edge cut quality
 Decreased pressures
 Over stroking
 Increased flow rate
 Inefficiently focused garnet
34
Abrasive Water Jet Cutting (AWJC)
 When WJC is used on metallic parts, abrasive particles must
usually be added to the jet stream to facilitate cutting. This
process is called abrasive water jet cutting (AWJC).
 Introduction of abrasive particles into the stream increases
the number of parameters that must be controlled. Additional
parameters (other than previously seen) are abrasive type,
grit size, and abrasive flow rate.
 Aluminum Oxide, silicon dioxide and garnet (a silicate
material) are typical abrasive materials used, grit sizes
ranging between 60 and 120 microns.
 One possible configuration is when abrasive particles are
added to the water stream after it has exited the WJC
nozzle.
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Abrasive Water Jet Cutting (AWJC)
36
Difference b/w WJC and AWJC
Abrasive waterjet cutting differs from pure waterjet cutting:
 In pure waterjet cutting, the supersonic stream erodes

the material. In the abrasive waterjet, the waterjet
stream accelerates abrasive particles and those
particles, not the water, erode the material.
 The abrasive waterjet is much more powerful than a

pure waterjet and is capable of cutting hard materials
such as metals, glass, stone, and composites.
37
Abrasive Waterjet Attributes
 No heat affected zones (HAZ)
 No mechanical stresses
 Easy to program
 10 inch thick cutting
 Stack cutting
 Little material loss due to cutting
 Simple to fixture
 Low cutting forces
 One jet setup for nearly all abrasive jet jobs
 Quickly switch from pure waterjet to abrasive waterjet
 Reduced secondary operations
 Little or no burr
38
Fish Metal
Metal Composites 39
Abrasive Air Jet Machining (AJM)
 Abrasive jet machining (AJM) is a material removal

process that results from the action of a high velocity
stream of gas containing small abrasive particles.
 The gas is dry and pressure of 0.2-1.4 MPa is used to
propel the gas through the nozzle orifices.
 Gases include dry air, nitrogen, carbon dioxide and
helium.
 The process is usually performed by directing the
nozzle at the work. The work station must be arranged
to provide proper ventilation for the operator.
40
Abrasive Jet Machining (AJM)
 AJM is normally used as a finishing operation rather
than a production cutting process. Applications include
deburring, trimming and deflashing.
 Cutting is accomplished successfully on hard, brittle
materials (glass, ceramics) that are in the form of thin
flat stock.
41
Abrasive Jet Machining (AJM)
42
Electrochemical Machining Processes
An important group of nontraditional processes use

electrical energy to remove material. This group is
identified by the term Electrochemical processes,
because electrical energy is used in combination with
chemical reactions to accomplish material removal.
43
Electrochemical Machining
 Electrochemical machining (ECM) removes metal from
an electrically conductive workpiece by anodic
dissolution (the process of dissolving a solid substance
into a solvent to make a solution)
 The shape of the workpiece is obtained by a formed
electrode tool in close proximity but separated from the
workpiece by a rapidly flowing electrolyte.
 ECM is basically a deplating operation (reverse of
electroplating)
 The workpiece is the anode (+) and the tool is the
cathode (-).
44
 The workpiece material is deplated from the anode
and deposited onto the cathode in the presence of an
electrolyte bath.
 The electrolyte bath flows rapidly between the two
poles to carry off the deplated material, so that it does
not become plated on the tool.
 The electrode tool, usually made of copper, brass or
stainless steel is designed to possess approximately
the inverse of the desired shape of the part.
 An allowance in the tool size must be provided for the
gap that exists between the tool and the work.
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46
 In addition to carrying off the material that has been
removed from the workpiece, the flowing electrolyte
also serves the function of removing heat and
hydrogen bubbles created in the chemical reaction.
 Electrochemical machining is generally used in
applications where the work metal is very hard or
difficult to machine, or where the workpart geometry is
difficult to accomplish by conventional methods.
47
 During ECM, chemical reactions occurs at the electrodes
i.e. at the anode (workpiece) and at the cathode (tool)
along with 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 (NaCl) undergoes ionic dissociation as
potential difference is applied
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 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 electrons from the
cathode (tool) and form hydrogen gas as:
 Similarly, the iron atoms will come out of the anode

(work piece) as:
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 Within the electrolyte, sodium ions would combine with hydroxyl
ions to form sodium hydroxide and similarly iron ions would
combine with chloride ions to form iron chloride
 In this manner, the work piece gets gradually machined and gets
precipitated as the sludge
 As the material removal takes place due to atomic level

dissociation(separation), the machined surface is of excellent
surface finish and stress free.
50
Process Parameters
(Output)
(Output)
51
Advantages: (1) Little surface damage to the workpart

(2) No burrs (3) low tool wear (4) Relatively high metal
removal rates for hard materials
Disadvantages: (1) significant cost of electrical power

(2) problems of disposing of the electrolyte sludge.
Applications: (1) Machining of irregular shapes and

contours into forging dies, plastic molds and other
shaping tools (2) Multiple hole drilling, especially holes
that are not round (3) Deburring
52
Applications:
53
54
Thermal Energy Processes
Material removal processes based on thermal energy are
characterized by very high local temperatures; hot enough to
remove material by fusion or vaporization.
Because of the high temperatures, these processes cause
physical and metallurgical damage to the new work surface.
Processes of commercial importance are:
(1) Electrical discharge machining (EDM)

(2) Electron beam machining
(3) Laser beam machining
55
Electric Discharge Machining (EDM)
 EDM is one of the most widely used non-traditional
processes.
 The shape of the finished work surface is produced by a
formed electrode tool.
 The sparks occur across a small gap between tool and work
surface.
 The EDM process must take place in the presence of a
dielectric fluid, which creates a path for each discharge as
the fluid becomes ionized in the gap.
 The discharges are generated by a pulsating direct current
power supply connected to the work and the tool.
56
Ram EDMs have four sub-systems:

• a DC power supply to provide the
electrical discharges, with controls for
voltage, current, duration, duty cycle,
frequency, and polarity
• a dielectric system to introduce fluid
into the voltage area/discharge zone and
flush away work and electrode debris,
this fluid is usually a hydrocarbon or
silicone based oil
• a consumable electrode, usually of
copper or graphite
• a servo system to control feed of the
electrode and provide gap maintenance
57
 Once the power supply is turned on, thousands of direct
current, or DC, impulses per second cross the gap,
beginning the erosion process.
 The spark temperatures generated can range from 7760° to
11,649° Celsius so that small portion of the workpiece is
suddenly melted and removed. The flowing dielectric flushes
away the small particle.
 Two important process parameters in EDM are discharge
current and frequency of discharges. As either of these
parameters is increased, metal removal rate increases.
 Surface roughness is also affected by current and
frequency. The best surface finish is obtained in EDM at
high frequencies and low discharge currents.
58
 Electrodes are made of graphite, copper, brass, copper
tungsten, silver tungsten and other materials.
 The selection of the electrodes depends on the type of
power supply circuit available, the type of work material, and
whether roughing or finishing is to be done.
 Graphite is generally preferred for many applications
because of its melting characteristics. In fact it does not melt
and vaporizes at very high temperatures.
 Dielectric fluids used in EDM include hydrocarbon oils,
kerosene and distilled water. The dielectric serves as an
insulator in the gap except when ionization occurs in the
presence of a spark. Its other functions are to flush debris
out of the gap and to remove heat from tool and workpart.
59
Advantages:
 EDM is a non-contact process that generates no cutting forces,
permitting the production of small and fragile pieces
 Burr-free edges are produced
 Intricate details and superior finishes are possible
Disadvantages:
 Low metal removal rates compared to chip machining
 Lead time is needed to produce specific consumable electrode
shapes
 The high spark temperatures that melt the work also erodes/melts
the tool
 Chance of flash fire in the dielectric fluid if the level falls too low 60
 Applications of electric discharge machining include

both tool fabrication and parts production.
 Most of the tooling equipments are made by EDM,
including molds for plastic injection molding,
extrusion dies, wire drawing dies, forging dies and
sheet metal dies.
 EDM is also used for certain parts production.
Examples include delicate parts that are not rigid to
withstand conventional cutting forces, hole drilling
where the axis of the hole is at an angle to the surface
and production machining of hard metals.
61
Comparison between EDM and ECM
 The tool and workpiece are separated by a very small gap,

i.e. no contact in between them is made.
 The tool and material must both be conductors of electricity.
 Needs high capital investment.
 Systems consume lots of power.
 A fluid is used as a medium between the tool and the work
piece (conductive for ECM and dielectric for EDM).
 The tool is fed continuously towards the workpiece to
maintain a constant gap between them.
 High metal removal rates are possible with ECM, with no
thermal or mechanical stresses being transferred to the part,
and mirror surface finishes can be achieved.
62
63
Electric Discharge Wire Cutting (EDWC)
or Wire EDM
 Electric discharge wire cutting commonly called wire EDM is
a special form of electric discharge machining that uses small
diameter wire as the electrode to cut a narrow kerf in the
work.
 The cutting action in wire EDM is achieved by thermal energy
from electric discharges between the electrode wire and the
workpiece.
 The workpiece is fed continuously and slowly past the wire in
order to achieve the desired cutting path. NC is used to
control the workpart motion during cutting.
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or Wire EDM
 As it cuts, the wire is continuously advanced between a
supply pool and a take up pool to present a fresh electrode of
constant diameter to the work.
 As in EDM, wire EDM must also be carried out in the
presence of dielectric.
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or Wire EDM
The four basic wire EDM subsystems include:
• the DC power supply

• the dielectric system
• the wire feeding system
• the work positioning system
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or Wire EDM
 Since the wire electrode is very thin, power used is limited
and removal rates are slow.
 A two-axis wire EDM can only make cuts at right-angles to

the work table.
 Independent four-axis machines can cut tapered angles and

make cuts that result in different top and bottom profiles. This
capability is needed in making extrusion dies and flow valves.
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or Wire EDM
68
Electron Beam Machining (EBM)
 Electron beam machining (EBM) is one of several industrial
processes that use electron beams.
 Electron beam machining uses a high velocity stream of
electrons focused on the workpiece surface to remove material
by melting and vaporization.
 An electron beam gun generates a continuous stream of
electrons that is accelerated to approximately 75% of the
speed of light and focused through an electromagnetic lens on
the work surface.
 The lens is capable of reducing the area of the beam to a
diameter as small as 0.025mm.
 On impinging the surface, the kinetic energy of the electrons is
converted into thermal energy of extremely high density that
melts or vaporizes the material in a very localized area.
69
Electron Beam Machining
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 The EBM beam is operated in pulse mode.

 Beam current is directly related to the number of
electrons emitted by the cathode.
 Increasing the beam current or pulse duration directly
increases the energy per pulse.
 High-energy pulses (in excess of 100 J/pulse) can
machine larger holes on thicker plates.
 The energy density (J/mm2) and power density (W/mm2)
is governed by energy per pulse duration and spot size.
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 Electron beam machining is used for a variety of high

precision cutting applications on any known material.
 EBM must be carried out in a vacuum chamber to
eliminate collision of electrons with gas molecules and to
avoid oxidizing of tungsten filament.
72
Advantages:
 There is no mechanical contact between tool and work

piece, hence no tool wear.
 Very small holes can be machined in every type of

material with high accuracy
 Drilling of extremely small diameter holes down to 0.002

in (0.05 mm).
 Drilling holes with high depth/diameter ratios, greater

than 100:1.
73
Disadvantages:
 Cost of equipment is high.
 Rate of material removal is low.
 It can used for small cuts only.
 Vacuum requirements limits the size of work piece.
 The interaction of the electron beam with the work piece

can produce hazardous x-rays, and only highly trained
personnel should use EBM equipment.
74
Applications:
 Drilling of holes in pressure differential devices used in

nuclear reactors, air craft engine
 Machining of wire drawing dies having small cross

sectional area.
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Comparative advantages and disadvantages of the EBW and LBW processes
76
Laser Beam Machining (LBM)
Separate module …
77
Chemical Machining
 Chemical machining (CHM) is a nontraditional process in
which material removal occurs through contact with a
strong chemical etchant (acid).
 The use of chemicals to remove unwanted material from a
workpart can be applied in several ways, and several
different terms have been developed to distinguish the
applications.
 Material is removed by microscopic electrochemical cell
action, as occurs in chemical dissolution of a metal.
 This controlled chemical dissolution will simultaneously
etch all exposed surfaces even though the penetration
rates of the material removal may be only 0.0025–
0.1 mm/min 78
Chemical Machining
The chemical machining process consists of several steps.
Differences in applications and the ways in which the steps are
implemented account for different forms of CHM.
The Steps are:
(1) Cleaning: The first step is a cleaning operation to ensure
that material will be removed uniformly from the surfaces to be
etched (engraved or cut).
(2) Masking: A protective coating called a maskant is applied to
certain portion of the part surface. This maskant is made of a
material that is chemically resistant to the etchant. It is therefore
applied to those portions of the work surface that are not to be
etched.
79
Chemical Machining
(3) Etching: This is the material removal step. The part is

immersed in an etchant(chemical/acid) that attacks those
portions of the part surface that are not masked.
The usual method of attack is to convert the work material into
a salt that dissolves in the etchant and is thereby removed
from the surface.
When the desired amount of material has been removed, the
part is withdrawn from the etchant and washed to stop the
process.
(4) Demasking: The maskant is removed from the part.
80
Chemical Machining
Maskant materials include neoprene, polyvinylchloride,
polyethylene and other chemicals.
Masking can be accomplished by different methods, two major

processes are:
(1) cut and peel

(2) photographic resist
81
Chemical Machining
Cut and peel method:
The cut and peel method involves application of the maskant

over the entire part by dipping, painting or spraying.
After the maskant has hardened, it is cut using a scribing knife
and peeled away in the areas of the work surface that are to be
etched.
The maskant cutting operation is performed by hand, usually
guiding the knife with a template. The cut and peel method is
generally used for large workparts, low production quantities and
where accuracy is not a critical factor.
82
Chemical Machining
Photographic resist method (photoresist method):
It uses photographic techniques to perform the masking step.

The masking material contain photosensitive chemicals.
The mask (photoresist) is applied to the entire work surface and
exposed to light through a negative image of the desired areas
to be etched.
The mask removes from the areas where UV light is exposed.
The naked areas can then be removed using etchant spray.
This procedure leaves the desired surfaces of the part protected
by the maskant and the remaining areas unprotected, exposed
to chemical etching.
83
Chemical Machining
 Selection of the etchant(chemical/acid) depends on work

material to be etched, desired depth, rate of material removal
and surface finish requirements.
 The etchant must also be matched with the type of maskant

that is used to ensure that the maskant material is not
chemically attacked by the etchant.
84
Chemical Machining
Common work materials and etchants in CHM, with typical

penetration rates and etch factors.
85
Chemical Machining
Penetration rate:
Material removal rates in CHM are generally indicated as
penetration rates, mm/min (in/min), because rate of chemical attack
of the work material by the etchant is directed into the surface.
Undercut:
Along with the penetration into the work, etching also occurs
sideways under the maskant, this effect is referred to as the
undercut. It must be accounted for in the design of the mask for the
resulting cut to have the specified dimensions.
The undercut is directly related to the depth of cut.
86
Chemical Machining
The constant of proportionality for the material is called the etch factor,
defined as
where Fe = etch factor; d = depth of cut(mm); and u = undercut(mm)
The etch factor can be used to determine the dimensions of the cutaway(inner)
areas in the maskant, so that the specified dimensions of the etched areas on
the part can be achieved.
87
Chemical Machining Processes
Principle chemical machining processes are;
(1) chemical milling

(2) chemical blanking
(3) chemical engraving
(4) photochemical machining
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Chemical milling
89
Photochemical machining
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Advantages:
1. No effect of workpiece materials properties such as hardness

2. Simultaneous material removal operation
3. No burr formation
4. No stress introduction to the workpiece
5. Low capital cost of equipment
6. Easy and quick design changes
7. Requirement of less skilled worker
8. Low tooling costs
9. Low scrap rates (3%).
91
Disadvantages:
1. Most of the chemicals such as cleaning solutions are very

hazardous liquids. Therefore handling and disposal of them
is costly.
2. Industries struggle to select more environmentally accepted

etchants for chemical machining process
92
Applications:
Missile skin-panel section contoured by chemical

milling to improve the stiffness- to- weight ratio of
the part (Kalpakjain & Schmid) 93
Applications:
94

02 - Non Traditional Machining Processes

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02 - Non Traditional Machining Processes

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Non Traditional Machining

Generally macroscopic chip formation chips are of generally microscopic

Energy domain can be classified as Most NTM processes do not use

Conventional machining involves the Non-conventional machining does not

Noisy operation mostly cause sound Quieter operation mostly no

Lower capital cost Higher capital cost

Skilled or un-skilled operator may Skilled operator required

1. Mechanical Erosion of the work material by a high velocity

2. Electrical These non traditional processes use

3. Thermal These processes use thermal energy to cut or

4. Chemical Most materials (metals) are susceptible to

Some of the NTM processes that utilizes mechanical

(1) Ultrasonic Processes

Common ultrasonic processes are:

 Ultrasonic machining (USM) is a non traditional machining

Ultrasonic machining can be used to

Ultrasonic machining centers can

By combining these technologies in

Ultrasonic machining of a carbide die for

Piezoelectric transducer is a device that

Welding occurs at low temperatures relative to other methods

Workers' hearing may be damaged by exposure to high-frequency

An ultrasonic welder compressing onto the contact.

The materials in the upper portion of

 To obtain the fine stream of water a small nozzle opening of

 To provide the stream with sufficient energy for cutting,

 The standoff distance is the separation between the nozzle

 Size of the nozzle orifice affects the precision of the cut;

Abrasive waterjet cutting differs from pure waterjet cutting:

 In pure waterjet cutting, the supersonic stream erodes

 The abrasive waterjet is much more powerful than a

 Abrasive jet machining (AJM) is a material removal

An important group of nontraditional processes use

 Similarly, the iron atoms will come out of the anode

 As the material removal takes place due to atomic level

Advantages: (1) Little surface damage to the workpart

Disadvantages: (1) significant cost of electrical power

Applications: (1) Machining of irregular shapes and

Processes of commercial importance are:

(1) Electrical discharge machining (EDM)

Ram EDMs have four sub-systems:

 Applications of electric discharge machining include

 The tool and workpiece are separated by a very small gap,

The four basic wire EDM subsystems include:

• the DC power supply

 A two-axis wire EDM can only make cuts at right-angles to

 Independent four-axis machines can cut tapered angles and

 The EBM beam is operated in pulse mode.

 Electron beam machining is used for a variety of high

 There is no mechanical contact between tool and work

 Very small holes can be machined in every type of

 Drilling of extremely small diameter holes down to 0.002

 Drilling holes with high depth/diameter ratios, greater

 Cost of equipment is high.

 Rate of material removal is low.

 It can used for small cuts only.

 Vacuum requirements limits the size of work piece.

 The interaction of the electron beam with the work piece

 Drilling of holes in pressure differential devices used in

 Machining of wire drawing dies having small cross

(3) Etching: This is the material removal step. The part is

Masking can be accomplished by different methods, two major

(1) cut and peel