NON TRADITIONAL

MACHINING PROCESSES
Chapter1
Basics of Non Traditional Machining Processes
Material removal processes are divided into mainly two
groups.
1. Conventional Machining Processes
These processes mostly remove material in the form of chips
by applying forces on the work material with a wedge shaped
cutting tool that is harder than the work material
Eg. turning, boring, milling, shaping, broaching, slotting,
grinding etc.
2. Non-Traditional Manufacturing Processes
It is defined as a group of processes that remove excess
material by various techniques involving mechanical, thermal,
electrical or chemical energy or combinations of these
energies but do not use a sharp cutting tools as it needs to be
used for traditional manufacturing processes.
Eg. AJM, EDM,ECM, LBM, EBM etc.
PROCESS SELECTION

1.Physical Parameters
2.Shapes to be machined
3.Process Capability or Machining Parameters
4.Economic Consideration
Material applications of various machining methods
Material applications of various machining
methods
3. Machining characteristics/Process Capabilities

The machining characteristics and process

various
capabilities are governing Non-Traditional
that
Manufacturing Techniques are
(i)Metal removal rate
(ii) Tolerance maintained
(iii) Surface finish obtained
(iv) Depth of surface damage
(v) Power required for
machining
Comparison of process capabilities of different
Non-Traditional Machining
 4.Economic
Consideration
The economics of the various processes are analysed on the basis of
following factors
(i) Capital cost (ii) Tooling cost
(iii) Consumed power (iv) Metal removal rate
cost efficiency
(v) Tool wear.
Effect of Metal Removal Rate on Power
Consumption
 COMPARISION OF TRADITIONAL
AND NON-TRADITIONAL
S.No TRADITIONAL MACHINING
1. Macroscopic size chip
formation There may be a physical
tool2present e.g.. cutting tool
2. Cutting tool is harder than work
piece at room temperature and
machining condition
3. Material removal takes place due to
cutting action. It falls in mechanical
4. energy domain.
5. Direct contact of tool and work
6. Lower accuracy and surface finish
7. Tool life is less due to high surface
8. contact and wear
9. Higher waste of material due to high
wear
10. Lower capital cost
11. Easy set up of equipment
NON TRADITIONAL MACHINING
Microscopic size chip formation
There may not be a physical
tool present except in ECM
There may not be a physical
tool present except in ECM
They fall in different energy domain.
Mechanical, thermal and chemical
No direct contact of tool and work
Higher accuracy and surface fininsh
Tool life is more.
Lower waste of material due to low
wear
Higher capital cost
Complex set up of equipment
Advantages

1.Increases Productivity

2.Reduces number of rejected components

3.Close tolerance is possible

4.Tool material need not be harder than work piece.

5.Machined surface do not have residual stresses.

6.Hard materials can be machined easily
Limitations
1.More Expensive
2.MRR is slow
3.AJM, PAM and EBM are not commercially economical process