NON TRADITIONAL
MACHINING PROCESS
Manufacturing – Classifications
⚫ Primary Manufacturing
⚫ To impart basic shape and size
⚫ Liquid stage forming processes – casting
⚫ Solid stage forming processes
⚫ all metal working processes – forging, rolling, extrusion
etc.
⚫ Powder stage forming processes – powder metallurgy
⚫ Secondary Manufacturing
⚫ To impart final shape and size with tight control on
dimension and shape
⚫ Mostly material removal processes
Secondary Manufacturing – Classifications
⚫ Conventional Manufacturing / Machining Processes
⚫ Turning, Milling, Drilling, Shaping
⚫ Broaching, Gear Cutting, Grinding
⚫ Non-Traditional (Conventional) Machining Processes
⚫ Abrasive Jet Machining (AJM)
⚫ Ultrasonic Machining (USM)
⚫ Water Jet and Abrasive Water Jet Machining (WJM &
AWJM)
⚫ Electrochemical Machining (ECM)
⚫ Electro-discharge Machining (EDM)
⚫ Laser Beam Machining (LBM)
Conventional Machining Processes
⚫ Material removal due to
application of cutting forces
⚫ Energy domain – mechanical
⚫ Macroscopic chip
⚫ Chip formation due to
shear deformation
⚫ Cutting tool is harder
Limitations of Conventional Machining
Processes
⚫ Machining processes that involve chip formation have
a number of limitations
⚫ Large amounts of energy
⚫ Unwanted distortion
⚫ Residual stresses
⚫ Burrs
⚫ Delicate or complex geometries may be difficult or
impossible
Non-traditional Machining Processes
⚫ Material removal – chip formation or even no chip
formation –
⚫ AJM – microscopic size
⚫ ECM – electrochemical dissolution at atomic level
⚫ Physical tool – may be absent
⚫ LBM, machining is carried out by laser beam
⚫ WJM, machining is done by a high pressure water
jet
⚫ EDM, a physical tool is very much required
⚫ ECM, similarly requires a tool
Non-traditional Machining Processes
⚫ Tool need not be harder than the work piece
⚫ EDM, copper is used as the tool material to
machine hardened steels
⚫ Energy domain – not necessarily mechanical
⚫ Different energy domains for machining.
⚫ USM, AJM, WJM mechanical energy
⚫ ECM electrochemical dissolution
⚫ EDM, electro-thermal energy
Classification of NTM Processes
⚫ Mechanical Processes
⚫ Abrasive Jet Machining (AJM)
⚫ Ultrasonic Machining (USM)
⚫ Water Jet Machining (WJM)
⚫ Abrasive Water Jet Machining (AWJM)
⚫ Electrochemical Processes
⚫ Electrochemical Machining (ECM)
⚫ Electro Chemical Grinding (ECG)
⚫ Electro Jet Drilling (EJD)
Classification of NTM Processes
⚫ Electro-Thermal Processes
⚫ Electro-discharge machining (EDM)
⚫ Electron Beam Machining (EBM)
⚫ Laser Jet Machining (LJM) {Electro-Optical-Thermal
Process}
⚫ Chemical Processes
⚫ Chemical Milling (CHM)
⚫ Photochemical Milling (PCM) etc
Ultrasonic Machining (USM)
Electro Discharge Machining (EDM)
Abrasive Jet Machining(AJM)
Need for NTM Processes
⚫ Exotic materials, innovative design & requirement,
tighter tolerances & micro-machining, economy
⚫ Intricate shaped blind hole – e.g. square hole of 15
mmx15 mm with a depth of 30 mm
⚫ Difficult to machine material – e.g. same example as
above in Inconel, Ti-alloys or carbides.
⚫ Low Stress Grinding – Electrochemical Grinding is
preferred as compared to conventional grinding
⚫ Deep hole with small hole diameter – e.g. φ 1.5 mm
hole with l/d = 20
⚫ Machining of composites.
Non-traditional machining (NTM) processes have
several advantages
Complex geometries are possible
Extreme surface finish
Tight tolerances
Delicate components
Little or no burring or residual stresses
Brittle materials with high hardness can be machined
Microelectronic or integrated circuits (IC) are possible to mass
produce
Process Selection
⚫ Study
Physical parameters
Properties of work material & the shape
Process capability
Economic considerations
⚫ Performance of Nontraditional Processes
