Non-Convectional

Machining
Processes
GROUP ACTIVITY DIV-13
By
Roll No- 113056 TO 113069
 Machining Processes

Manufacturing Processes can be broadly divided into two groups:

a) Primary Manufacturing Processes : Provide basic shape
and size
b) Secondary Manufacturing Processes : Provide final shape and size
with tighter control on dimension, surface characteristics

Material removal processes once again can be divided into two groups
1. Conventional Machining Processes
2. Non-Conventional Manufacturing processes
 Convectional Machining Processes

Conventional Machining 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
under machining condition.

The major characteristics of conventional machining are:

• Generally macroscopic chip formation by shear
deformation
•Material removal takes place due to application of cutting
forces – energy domain can be classified as mechanical
• Cutting tool is harder than work piece at room
temperature as well as under machining conditions
Non-Convectional Machining Processes
Non-conventional manufacturing processes 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.
 Non-Convectional Machining Processes
The major characteristics of Non-conventional machining:

2. In this process, there may not be a physical tool present. For example
in laser jet machining, machining is carried out by laser beam.
However in Electrochemical Machining there is a physical tool that is
very much required for machining
3. In this process, the tool need not be harder than the work piece
material. For example, in EDM, copper is used as the tool material to
machine hardened steels.
4. Mostly this processes do not necessarily use mechanical energy to
provide material removal. They use different energy domains to
provide machining. For example, in non conditional processing
mechanical energy is used to machine material, whereas in ECM
electrochemical dissolution constitutes material removal.
 Classification of NCP processes
CLassification of NCP processes is carried out depending on the
nature of energy used for material removal.
1. Mechanical Processes
• Abrasive Jet Machining (AJM)
• Ultrasonic Machining (USM)
• Water Jet Machining (WJM)
• Abrasive Water Jet Machining (AWJM)
2. Electrochemical Processes
• Electrochemical Machining (ECM)
• Electro Chemical Grinding (ECG)
• Electro Jet Drilling (EJD)
3. Electro-Thermal Processes
• Electro-discharge machining (EDM)
• Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)
4. Chemical Processes
• Chemical Milling (CHM)
• Photochemical Milling (PCM)
 Needs for Non Traditional Machining
•Extremely hard and brittle materials or
Difficult to machine materials are difficult to
machine by traditional machining processes.

•When the workpiece is too flexible or slender

to support the cutting or grinding forces.

•When the shape of the part is too complex.

Mechanical Processes
 Abrasive Jet Machining
Abrasive Jet Machining (AJM), also known as micro-abrasive blasting, is
a mechanical energy based unconventional machining process used to
remove unwanted material from a given workpiece.
The process makes use of an abrasive jet with high velocity, to remove
material
and provide smooth surface finish to hard metallic workpieces
Abrasive Jet Machining

AJM set-up
 Ultrasonic Machining(USM)

•This machining uses ultrasonic waves to produce high

frequency force of low amplitude, which act as driving
force of abrasive.
•Ultrasonic machine generates high frequency vibrating
wave of frequency about 20000 to 30000 Hz. This high
frequency vibration transfer to abrasive particle contains in
abrasive slurry.
•This leads indentation of abrasive particle to brittle work
piece and removes metal from the contact surface.
•USM for machining brittle work material
•Material removal primarily occurs due to the indentation of
the hard abrasive grits on the brittle work material.
Ultrasonic Machining(USM)
Ultrasonic Machining Equipment
 Water Jet Machining
•A water jet cutter, also known as a water
jet or waterjet, is an industrial tool capable of cutting a
wide variety of materials using a very high-pressure jet of
water, or a mixture of water and
an abrasive substance.
•The term abrasive jet refers specifically to the use of a
mixture of water and abrasive to cut hard materials such
as metal or granite, while the terms pure waterjet and
water-only cutting refer to waterjet cutting without the use
of added abrasives, often used for softer materials such as
wood or rubber.
Water Jet Machining(USM)
Water Jet Equipment
 Abrasive Water Jet Machining

The primary difference between pure and

abrasive waterjet cutting is whether additives are
mixed into the pressurized water that streams
from the machine nozzle. In pure waterjets, the
pressure of the water alone, when forced through
a tiny orifice, is used to cut through materials
like foam .
Abrasive Water Jet Machining
Advantages of AWJM

• Extremely fast set-up and programming

• Very little fixturing for most parts
• Machine virtually any 2D shape on any
material
• Very low side forces during the machining
• Almost no heat generated on the part
• Machine thick plates
Electro-Chemical Processe
Electro-Chemical
Machining (ECM)
⚫ The process of
removing a metal
or alloy from a material,
through electrolytic
action.

⚫ Works on the principle

of electrolysis .

⚫ Low DC voltage, very

High current (700A)
 Electrochemical grinding
⚫ Combines electrochemical machining
with conventional grinding
◦ Grinding wheel is the cathode
◦ Metal bonded wheel with diamond or
Al2O3 abrasive
◦ Majority of material removal from
electrolytic action (95%) therefore very
low wheel wear
◦ Much faster than conventional grinding
Electrochemical grinding
 Electro-Jet Drilling
⚫ Itis a process in which a negatively
charged stream of acid electrolyte is
impinged on the workpiece to form a
hole
⚫ Electro jet drilling (EJD) is one such
technique, which is finding ever-
increasing applications in several
industries including aerospace, medical,
automobile and micro fabrication
(electronic and computers).
Electro-Jet Drilling
Electro-Thermal Process
Electrode Discharge Machining (EDM)

⚫ The tool acts as a cathode (typically graphite) is immersed in

a
Dielectric fluid with conductive workpiece

⚫ DC voltage (~300V) is applied.

⚫ As voltage builds up over gap between workpiece and tool,

eventually you get dielectric breakdown (sparking at
around 12,000 deg F)

⚫ The sparking erodes the workpiece in the shape of the tool

⚫ Cycle is repeated at 200,000-500,000 Hz

Electrode Discharge Machining (EDM)
 Laser Beam Machining
⚫ Lasersare high intensity focused light
sources
◦ CO2
🞄 Most widely used
🞄 Generally more powerful that YAG lasers
🞄 Cutting operations commonly
◦ Nd:YAG (Neodymium ions in an Yttrium Aluminum
Garnet)
🞄 Less powerful
🞄 Etching/marking type operations more commonly
⚫ Limited in depth of cut (focus of light)
⚫ Would limit workpiece to less than 1 inch (<
½” typically)
Laser Beam Machining
 Electron Beam Machining
⚫ Electron-beam machining (EBM) is a
process where high-
velocity electrons concentrated into a narrow
beam are directed toward the work piece,
creating heat and vaporizing the material.
EBM can be used for very accurate cutting or
boring of a wide variety of metals.
⚫ The process of heating by electron beam is
used for annealing, welding or metal removal.
Electron Beam Machining
Chemical Processes
 Chemical Milling
⚫ Chemical milling or industrial etching is the
subtractive manufacturing process of using baths
of temperature-regulated etching chemicals
to remove material to create an object with the
desired shape.
⚫ It has applications in the printed circuit board
and semiconductor fabrication industries. It is
also used in the aerospace industry to remove
shallow layers of material from large aircraft
components, missile skin panels, and extruded
parts for airframes
Chemical Milling
 Photo Chemical Milling
⚫ Photochemical machining (PCM), or photo
etching, is a chemical milling process used to
fabricate sheet metal components using
a photo resist and etchants to
corrosively machine away selected areas.
⚫ Industrial applications include fine screens
and meshes, apertures and masks, battery
grids, fuel
cell components, sensors, springs, pressure
membranes, heat sinks, and much more.