Heaven’s Light is Our Guide

Rajshahi University of Engineering & Technology

Welcome to the Lecture

on
Unconventional Machining Processes

Presented by-
Monjur Mourshed
Assistant Professor
Department of Mechanical Engineering
Rajshahi University of Engineering & Technology (RUET)
Rajshahi, Bangladesh
 Conventional and Unconventional Machining
Conventional and Unconventional Machining
The term machinability refers to the easeiness with which a metal can
be machined to an acceptable surface finish. Further the machining
operations can be divided into conventional machining and non-
conventional machining.

Chip
Tool

Work piece

The major characteristics of conventional machining are---

• Cutting tool is harder than work piece at room temperature as well as under
machining conditions
• Material removal takes place due to application of cutting forces
•Generally macroscopic chip formation by shear deformation
Department of Mechanical Engineering, RUET
Conventional
Conventionaland
andUnconventional
UnconventionalMachining…
Machining…
An unconventional machining process (or non-traditional machining process) is a
special type of machining process in which there is no direct contact between the tool
and the work piece.
The requirements that lead to the development of nontraditional machining---

Very high hardness and strength of the material

The work piece: too flexible or slender to support the cutting or grinding forces
The shape of the part is complex, such as internal and external profiles, or small
diameter holes
Surface finish or tolerance better than those obtainable by conventional process
Temperature rise or residual stress in the work piece are undesirable
The machining characteristics of different non-conventional processes can be analyzed
with respect to---

 Metal removal rate

 Tolerance maintained
 Surface finish obtained
 Depth of surface damage
 Power required for machining
Department of Mechanical Engineering, RUET
Conventional
Conventionaland
andUnconventional
UnconventionalMachining…
Machining…
During conventional machining operation of hard and brittle materials like tungsten
carbide, high speed steels, stainless steels, ceramics etc. in several industrial purposes,
either the tool undergoes extreme wear or the work piece material is damaged.
Because-

In conventional machining, there is a direct contact between the tool and the work
piece
Large cutting forces are involved and material is removed in the form of chips
 Huge amounts of heat is produced in the work piece
 This induces residual stresses, which degrades the life and quality of the work piece
material. Hence, produces poor quality work piece with poor surface finish

On the contrary the non conventional machining process offers---

High accuracy and surface finish

Less/no wear 
Tool life is more 
Quieter operation
High cost 
Complex set-up
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Skilled operator required
 Unconventional
Unconventional Machining
Machining Processes
Processes
Non-traditional machining process is defined as a group of processes that
remove excess material by various techniques involving mechanical, electrical,
chemical and thermal energy used in non-traditional machining process.

Unconventional or Untraditional
Machining Processes

Mechanical Electrochemical Electro-Thermal Chemical

Processes Processes Processes Processes
- Abrasive Jet - Electrochemical -Electro-discharge -Chemical
Machining (AJM) Machining (ECM) machining (EDM) Milling (CHM)
- Ultrasonic - Electro Chemical - Laser Beam - Photo-
Machining (USM) Grinding (ECG) Machining (LBM) Chemical
- Abrasive Water Jet - Electro Jet Drilling -Electron Beam Milling (PCM)
Machining (AWJM) (EJD) Machining (EBM)

Department of Mechanical Engineering, RUET

 Abrasive
AbrasiveJet
JetMachining
Machining(AJM)
(AJM)
It is the material removal process where the material is removed or
machined by the impact erosion of the high velocity stream of air or gas
(nitrogen, CO2 or inert gases) and abrasive mixture, which is focused on
to the work piece.

 The fundamental principle of abrasive jet machining involves the use

of a high-speed stream of abrasive particles carried by a high pressure
(25 to 130 psig or170–900 kPag) gas on the work surface through a
nozzle
 The abrasive powders are mixed with air or water and is forced at a
high velocity (300 m/s) on the work piece
 Material removal takes place (usually about 0.001 inch in diameter)
due to the erosion of the work piece at the point of impingement.
 Aluminum Oxide and Silicon Carbide are commonly used abrasives
 Abrasive jet cutting with water as a medium is known as water jet
cutting
Department of Mechanical Engineering, RUET
 Working of Abrasive Jet Machining (AJM)
Working of Abrasive Jet Machining (AJM)
 The nozzle is made of a hard material like Tungsten Carbide here fine
grained abrasive particles are fed from the Hooper into the mixing
chamber.
 High pressure air is forced in to the mixing chamber.
 The stream of abrasive particles bombards the work piece at a very
high speed and removes the work material due to erosion.
 The abrasive particle feed rate is controlled by the amplitude of
vibration of the mixing chamber.

Department of Mechanical Engineering, RUET

Abrasive
Abrasive Water
Water Jet
Jet Machining
Machining (AWJM)
(AWJM)
Narrow jet of water directed at high pressure and velocity against the
surface of work piece. Water jet acts like a saw, erodes the work piece
surface and cuts through a narrow groove on the material.

-The cutter is commonly connected to a high-pressure water pump

- Water is ejected out of the nozzle, cutting through the material by
bombarding it with the stream of high-speed water and the pressure
level is upto 400Mpa
- Additives in the form of suspended grit or other abrasives, such as sand
and silicon carbide, can assist in this process
- Because the nature of the cutting stream can be easily modified, water
jets can be used to cut materials as diverse as fish sticks and titanium.

Department of Mechanical Engineering, RUET

 Abrasive
AbrasiveJet
JetMachining
Machining(AJM)
(AJM)
Advantages
- There is no heating of work piece
- Cut can be started anywhere without the need for predrilled holes
- Burr produced is minimum
-Environmentally safe and friendly manufacturing
-It can cut non conducting material
-The investment cost is low
-There is no contact between the tool and work piece
Disadvantages
- Material removing rate is low
- Taper occur due to flaring of the jet
Applications
- For drilling holes of intricate shapes in hard and brittle material
- Micro-machining of brittle material
- AJM is used for drilling, cutting, deburring, cleaning
Department of Mechanical Engineering, RUET
 Ultrasonic
UltrasonicMachining
Machining(USM)
(USM)
USM is a mechanical material removal process where piezoelectric transducer
vibrates a cone shaped tool at ultrasonic frequency in a direction normal to the
surface being machined and material is removed from work piece by of
abrasive slurry. The tool vibrates with a high frequency but low amplitude.

Transducer- the transducer used in USM is used to convert the electrical

energy to vibratory motion utilizing either the piezoelectric or magnetostrictive
principles. Piezoelectric material such as quartz or lead zirconate, titanate
increase in size when current is applied and comes into normal size when
current is removed. It can be used upto a power of 900W. Magnetostrictive
material are constructed from nickel or permalloy and changes their length in
strong magnetic field. It can be used at high power upto 2400W.

Tool cone- it amplifies the mechanical energy produced by the transducer. It

amplifies the vibratory energy to give the required force- amplitude ratio.

Abrasive slurry- the most common abrasive slurry used for USM are
aluminum oxide, silicon carbide, boron carbide.
Department of Mechanical Engineering, RUET
Working
Workingof
ofUltrasonic
UltrasonicMachining
Machining(USM)
(USM)
 The tool vibrate with longitudinally at 20 to 30 kHz with amplitude between 0.01 to
0.06 mm is pressed on to the work surface with light force.
 The electronic oscillator and amplifier is also known as generator. It converts the
electrical energy of low frequency to high frequency.
 At the time high frequency current is passed through the coil therefore change in
electromagnetic field which produces longitudinal strain. The tool holder transmits
these strains to the tool so tool oscillates linearly over the work piece.
 As the tool vibrate with specific frequency the abrasive slurry mix with water and
grain of definite proportion is made to flow under pressure through the tool work piece
interface and remove the work material by abrasion.

Department of Mechanical Engineering, RUET

 Ultrasonic
UltrasonicMachining
Machining(USM)
(USM)
Advantages
 Any materials can be machined regardless of their electrical
conductivity
 Especially suitable for machining of brittle materials
 Machined parts by USM possess better surface finish and higher
structural integrity
 USM does not produce thermal, electrical and chemical abnormal
surface
Disadvantages
 Tool wears fast in USM
 Machining area and depth is restraint in USM
 High cost of tooling
 MRR is low
Applications
USM is best suitable for hard, brittle material, such as ceramics,
carbides, glass, precious stone etc.
Department of Mechanical Engineering, RUET
 Electro
Electro Chemical
Chemical Machining
Machining (ECM)
(ECM)
ECM is opposite to the electroplating is the controlled removal of metals by the anodic
dissolution in an electrolytic medium, where the work piece (anode) and the tool
(cathode) are connected to the electrolytic circuit, which is kept, immersed in the
electrolytic medium. In contrast to electroplating a high current density is used in
ECM.
This machining process is based on Faraday’s law of electrolysis. It states that, the
weight of substance produced during electrolysis is directly proportional to the current
which passes, the length of time of the electrolysis process and the equivalent of the
material which is deposited.

Department of Mechanical Engineering, RUET

 Electro
ElectroChemical
ChemicalMachining
Machining(ECM)
(ECM)
- In the ECM process, current passes through an electrolyte in the gap
between the work piece (anode) and the tool (cathode) and tool is advanced
into work piece
- The pressurized electrolyte is injected at a set temperature to the area
being cut
- The metal removal rate depends on the current density which is a function
of conductance of the electrolyte and voltage applied as well as the shape
and the gap (80-800 micrometers ) between the electrodes
-As electrons cross the gap, material from the work piece is dissolved, as the
tool (made of bronze, copper, brass or stainless steel) forms the desired
shape in the work piece
- The chemical reaction that occurs in ECM is the conversion of metal into
its hydroxide
- The metal hydroxide is dissolved in the electrolyte and is washed away by
the circulating electrolyte

Department of Mechanical Engineering, RUET

 Electrolyte
Electrolytefor
forElectro
ElectroChemical
ChemicalMachining
Machining(ECM)
(ECM)
An electrolyte is any substance containing free ions that make the
substance electrically conductive. The most typical electrolyte is an ionic
solution, but molten electrolytes and solid electrolytes are also possible.

Functions of electrolyte-
 Carrying current between tool and work piece
 Remove products of machining and other insoluble products from
cutting region
 Dissipate heat produced in the operation

Characteristics of electrolyte-
 Good electrical conductivity
 Non toxicity and chemical stability
 Non corrosive property
 Low viscosity and high specific heat
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 Electro
ElectroChemical
ChemicalMachining
Machining(ECM)
(ECM)
Advantages
 Process leaves a burr free highly finished surface
 Does not cause any thermal damage to the parts
 Lack of tool force prevents distortion of parts especially thin parts
 Capable of machining complex parts and hard materials
Disadvantages
- Non conducting material cannot be machined
-The specific power consumption is more

Applications
- Cutting slots in a valve plates.
- Machining of turbine blades.
- For cutting cavities in forging dies.
Department of Mechanical Engineering, RUET
 Electrolyte
Electrolytefor
forElectro
ElectroChemical
ChemicalMachining
Machining(ECM)
(ECM)
The material removal rate is given by- Where,
AI A= atomic weight of the work material
MRR  Kg/s I= Current in Amp.
ZF Z= Valency of the work material
F= Faraday’s Constant (96500
The volumetric material removal rate is given by - Coulombs)
AI Ƿa= density of work material
MRR  m3/s
 s ZF

The gap resistance R is given by-

Where,
h Ƿ = Specific resistance of the electrolyte
R h = Equilibrium gap
AGAP AGAP = Cross sectional area of the gap

Department of Mechanical Engineering, RUET

 Electrolyte
Electrolytefor
forElectro
ElectroChemical
ChemicalMachining
Machining(ECM)
(ECM)
Calculate the material removal rate and electrode feed rate in the electrochemical machining of
an iron surface that is 25mm×25mm in cross section using NaCl in water as electrolyte. The gap
between the tool and workpiece is 0.25 mm. the supply voltage is 12 V DC. The specific
resistance of the electrolyte is 3Ω cm.

Given, AGAP = 25mm×25mm = 625 mm2 For Iron, Z=2,

Atomic weight= 55.85
h= 0.25 mm, V= 12V, Ƿ = 3Ω cm
Ƿa= 7860 kg/m3

R = (30×0.25) ÷ 625 = 0.012 Ω

I = (12÷ 0.012) = 1000A

MRR at 100% current efficiency,

MRR = (55.85×1000) ÷ (2×96540) = 289.3×10-6 kg/s = 0.03677× 10-6 m3/s

Feed rate = MRR/Surface area = (0.03677× 10-6 m3/s) / (625× 10-9 m3/s) = 3.53 mm/min

Department of Mechanical Engineering, RUET

 Electrical
ElectricalDischarge
DischargeMachining
Machining(EDM)
(EDM)
EDM is the controlled erosion of electrically conductive materials by the
initiation of rapid and repetitive spark discharge between the electrode tool
(cathode) and work (anode), separated by a small gap kept in the bath of
dielectric medium. This process is also called spark erosion.

 A dielectric fluid is an electrical insulator that can be ionized by an

applied electric field. The electrode and the work piece are separated by a
dielectric medium. The role of the dielectric fluid-
1. acts as a insulator until the potential is sufficiently high
2. acts as a flushing medium and carries away the debris
3. also acts as a cooling medium
Dielectric fluid – mineral oils, kerosene, distilled and deionized water etc.

 Electrodes are made from graphite, copper or copper-tungsten alloy. The

material of the tool is usually a material which conduct electricity and which
can be easily shaped.
Department of Mechanical Engineering, RUET
Electrical
Electrical Discharge
Discharge Machining
Machining (EDM)…
(EDM)…
 When the distance between the two electrodes is reduced, the intensity of the electric
field in the volume between the electrodes becomes greater than the strength of the
dielectric
 Dielectric fluid ionized and allowing current to flow between the two electrodes
 As a result, a transient spark discharges through the fluid, the metal at the sparking
zone melts instantaneously and removing a small amount of metal from the work piece
surface
 Once the current flow stops new liquid dielectric is usually conveyed into the inter
electrode volume referred as flushing, enabling the solid particles (debris)
to be carried away and the insulating proprieties of the dielectric to be restored

Department of Mechanical Engineering, RUET

 Wire
Wire EDM
EDM
 This process is similar to contour cutting with a band saw.
 A slow moving wire travels along a prescribed path, cutting the work piece
with discharge sparks.
 Wire should have sufficient tensile strength and fracture toughness.
 Wire is made of brass, copper or tungsten. (about 0.25mm in diameter).

Department of Mechanical Engineering, RUET

 Electrical
ElectricalDischarge
DischargeMachining
Machining(EDM)
(EDM)
Advantages
-Smaller holes can be easy machined
-No contact between tool and work piece then tool life is increase
-Any complex shape can be machined

Disadvantages

-Tool life is not longer

-Power consumption is high
-Cycle time is more.

Department of Mechanical Engineering, RUET

 EDM
EDMvs.
vs.ECM
ECM ECM
EDM
1. Uses dielectric fluid as a conducting 1. Using electrolyte as a conducting
medium between tool and work piece medium between tool and work piece
2. Wear of tool takes place during the 2. No wear of tool during process so tool
process life is high
3. No heat is generated during the process 3. Large heat is generated during the
process
4. Low metal removal rate 4. Metal removal rate is high
5. It works on the principle of spark 5. It works on principle of Faraday’s law of
erosion electrolysis
 

6. Metal is removed by melting and 6. Metal is removed by electrochemical

vaporization reaction
7. Tools used are oversize for machining 7. Tool used are of required size of the
inside surfaces and undersize for work piece
machining outside surfaces

Department of Mechanical Engineering, RUET

 LASER
LASERBeam
BeamMachining
Machining(LBM)
(LBM)
LASER Beam machining (LBM) is an unconventional machining
process in which a beam of highly coherent light called a LASER is
directed towards the work piece for machining.

 The rays of a laser beam are monochromatic and parallel it can be

focused to a very small diameter and can produce energy as high as 100
MW of energy for a square millimeter of area
 A pulsed ruby laser is normally used for developing a high power and
the beam can be focused using optical lenses as their wavelength ranges
from half micron to around 70 microns
 As laser interacts with the material, the energy of the photon is
absorbed by the work material leading to rapid substantial rise in local
temperature
 Successive pulses from laser gun melting and vaporizing tiny bits of
work piece

Department of Mechanical Engineering, RUET

 LASER
LASER Beam
Beam Machining
Machining (LBM)
(LBM)
 The work piece is placed on the aluminum work table which material is hard not cut by laser
beam
 Ruby rod is used into form of cylindrical crystal both ends of ruby rod are finished to optical
tolerance
 The flash lamp wound around the ruby rod and connected to power supply.
 The ruby rod becomes high efficient on low temperature and low efficient on high
temperature. It is thus continuous cooled with water, air or liquid nitrogen.
 When the light beam has been amplified sufficiently and intensity beam of light comes out
form partially reflected end it is focused on the work piece at the focused very high temperature
which vaporized and removes the metal on work piece.

Department of Mechanical Engineering, RUET

 LASER
LASERBeam
BeamMachining
Machining(LBM)
(LBM)
Advantages

-There is no tool wear

-Extremely small and complex holes are drills
-No contact between tool and work piece

Disadvantages

-Investment cost is more

-Skilled operator is required
-Operating cost is more
-Flash lamp life is too short

Applications

-It is used for welding of thin metal sheet

-Leaser can be used for cutting as well as drilling
-Heat treatment
-It is used for cutting complex profile
Department of Mechanical Engineering, RUET