Nontraditional Machining

• Nontraditional machining refers to a group a

processes which removes excess material by
various techniques involving mechanical,
thermal, electrical or chemical energy

• These processes do not use a sharp cutting

tool in the conventional sense
• Nontraditional processes have been
developed in response to new and unusual
machining requirements, including
– The need to machine newly developed
materials with special properties (high
strength, high hardness, high toughness)
– The need for unusual and/or complex
geometries
– The need to avoid surface damage
• Classification of nontraditional
manufacturing processes by principle form
of energy
– Mechanical - mechanical energy in some form
different from the action of a conventional
cutting tool; erosion of the workpiece
material is typical
– Electrical - electrochemical energy to remove
material
– Thermal - thermal energy generally applied to
a small portion of the work surface, causing
removal by fusion and/or vaporization;
thermal energy is generated by conversion of
electrical energy
– Chemical - most materials are susceptible to
chemical attack by certain acids or other
etchants; chemicals selectively remove
material from portions of the workpiece,
while other portions of the surface are
protected
Non-Traditional Manufacturing Processes

Chemical Machining (CM)

Electrochemical Machining (ECM)
Electro-Discharge Machining (EDM)
Laser cutting
Ultrasonic Machining (USM)
Water-Jet and Abrasive Water-Jet Machining
 ELECTROCHEMICAL MACHINING
• Elecrochemical machining (ECM) is a non-
conventional machining process that is used
for machining complicated shapes and high
strength, high temperature resistant
materials.
• This process works on the principle of
electrolysis.
 ECM reaction

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Electrochemical Machining (ECM)

Schematic diagram of Controlled anodic

Electrochemical dissolution of work piece in
Machining ECM
 Schematic representation of electro-chemical
machining
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 Reactions at Anode Reactions at
cathode

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 The most common electrolytes used are
sodium chloride (NaCl), sodium nitrate
(NaNO3), and sodium hydroxide.

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PARAMETERS IN ECM

Input parameters:
Electrolyte concentration
Voltage
Feed rate
Inter electrode gap

Out put parameters:

Material removal rate
Radial over cut
Surface roughness
Cylindricity error
 Tool Feed Control
Mechanism Panel

Machining
Chamber

Pump Electrolyte
Circulation

Electrochemical Machining setup

Tool without Tool with
insulation insulation
 Electrochemical hole drilling.
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Advantages:
•No mechanical stress impact into the processed work piece.
•No thermal impact on the work piece.
•The removal rate is not determined by the hardness or toughness of
the material.
•No process related tool wear.
•Great versatility for machining of geometrical complex shapes.
•No burr formation.

Disadvantages:
•High specific energy consumption.
•Not suited for non-conducting pieces.
•High initial and working cost.
Various machining operations based on electrochemical
dissolution of anode:

• Electrochemical Boaring
• Electrochemical Broaching
• Electrochemial Drilling
• Electrochemical Honing
• Electrochemial Turning
• Electrochemial Micromachining