Non-traditional machining (NTM) processes have made it

possible to fabricate components that were either

difficult or impossible to produce by conventional
material removal processes.
Refer to a wide range variety of mechanical, electrical,
thermal, and chemical energy based material removal
processes
used to machine super alloys and ceramics, wood, plastics
and textiles

Need to machine newly developed metals and

non-metals with special properties that make them
difficult or impossible to machine by conventional
methods
Need for unusual and/or complex part geometries that
cannot readily be accomplished by conventional
machining
Need to avoid surface damage that often accompanies
conventional machining

2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e

Traditional machines

NTM machines

Cutting tool and workpiece are There is no physical contact between

always in physical contact, with a
the tool and workpiece
relative motion against each other,
which results in friction and a
significant tool wear
Material removal rate is limited by Easily deal with such difficult-to-cut
the mechanical properties of the
materials like ceramics and ceramic
work material
based tool materials, fiber reinforced
materials, carbides, titanium-based
alloys;

Traditional machines

NTM machines

The relative motion between the Most non-traditional processes

tool and workpiece is typically
were develop just to solve this
rotary or reciprocating. Thus, the
problem
shape of the work surfaces is limited
to circular or flat shapes.
Machining of small cavities, slits, It is a simple work for some nonblind or through holes is difficult
traditional processes

Well established, use relatively Require expensive equipment and

simple and inexpensive machinery
tooling as well as skilled labor,
and readily available cutting tools.
which increases significantly the
production cost

Principle energy
form

Description

Examples

1. Mechanical

mechanical erosion of
work material by a high
velocity stream of
abrasives or fluid (or
both)

Ultrasonic machining
Water jet cutting
Abrasive water jet cutting
Abrasive jet machining
Abrasive flow machining

2. Electrical

Based on
Electrochemical machining
electrochemical energy Electrochemical deburring
to remove material
and grinding
(reverse of
electroplating)

3. Thermal

thermal energy applied

to small portion of
work surface, causing
that portion to be
fused and/or vaporized

Electric discharge
processes
Electron beam machining
Laser beam machining
Plasma arc cutting

Principle energy form

4. Chemical

Description
chemical etchants selectively remove material from
portions of workpart, while other portions are
protected by a mask

 A non-traditional process, in which abrasives contained in a slurry are driven

against the work by a tool oscillating at low amplitude (25-100 m) and high
frequency (15-30 KHz)
The basic process is that a ductile and tough tool is pushed against the work
with a constant force
A constant stream of abrasive slurry passes between the tool and the work
(gap is 25-40 m) to provide abrasives and carry away chips.
Can be used to cut through and blind holes of round or irregular crosssections. The process is best suited to poorly conducting, hard and brittle
materials like glass, ceramics, carbides, and semiconductors.

There is a little production of heat and stress in the process, but work may
chip at exit side of the hole.

 Critical parameters to control the process are the tool frequency, amplitude
and material, abrasive grit size and material, feed force, slurry concentration
and viscosity.
Limitations include very low material removal rate, extensive tool wear,
small depth of holes and cavities.

Abrasive slurry consists of a mixture of liquid (water is the most common but
oils or glycerol are also used). The common types of abrasive materials are
boron carbide, silicon carbide, diamond, and corundum (Al2O3).

 In jet machining, high-velocity stream of water (Water Jet Cutting) or water

mixed with abrasive materials (Abrasive Water Jet Cutting) is directed to the
workpiece to cut the material.
uses a fine, high-pressure, high velocity (faster than speed of sound) stream of
water directed at the work surface to cause slotting of the material
Water is the most common fluid used, but additives such as alcohols, oil
products and glycerol are added when they can be dissolved in water to
improve the fluid characteristics.
The fluid is pressurized at 150-1000 MPa to produce jet velocities of 5401400 m/s. The fluid flow rate is typically from 0.5 to 2.5 l/min. The jet have a
well behaved central region surrounded by a fine mist.
Typical work materials involve soft metals, paper, cloth, wood, leather, rubber,
plastics, and frozen food.

 In electric discharge processes, the work material is removed by a series of

sparks that cause localized melting and evaporation of the material on the
work surface
These processes can be used only on electrically conducting work materials

1. A formed electrode tool produces the shape of the finished work

surface.
2. The sparks occur across a small gap between tool and work surface.

3. The EDM process must take place in the presence of a dielectric fluid,
which creates a path for each discharge as the fluid becomes ionized
in the gap.
4. The fluid, quite often kerosene-based oil is also used to carry away
debris.

5. The discharges are generated by a pulsating direct-current power

supply connected to the work and the tool.

6. Typical electrode materials include copper, tungsten, and graphite.

7. The process is based on melting temperature, not hardness, so some
very hard materials can be machined this way.

Tooling for many mechanical processes: molds for

plastic injection molding, extrusion dies, wire drawing
dies, forging and heading dies, and sheetmetal stamping
dies

Production parts: delicate parts not rigid enough to

withstand conventional cutting forces, hole drilling
where hole axis is at an acute angle to surface, and
machining of hard and exotic metals

A special form of EDM that uses a small diameter wire as the

electrode to cut a narrow kerfs in the work.

The workpiece is fed continuously and slowly past the wire in order
to achieve the desired cutting path.

Numerical control is used to control the work-part motions during

cutting.

As it cuts, the wire is continuously advanced between a supply spool

and a take-up spool to present a fresh electrode of constant
diameter to the work. This helps to maintain a constant kerfs width
during cutting.

As in EDM, wire EDM must be carried out in the presence of a

dielectric. This is applied by nozzles directed at the tool-work
interface is submerged in a dielectric bath.

Wire diameters range from 0.08 to 0.30 mm, depending on

required kerf width.

Materials used for the wire include brass, copper, tungsten, and
molybdenum.

Dielectric fluids include deionized water or oil. As in EDM, an

overcut in the range from 0.02 to 0.05 mm exists in wire EDM that
makes the kerf larger than the wire diameter.

Wire EDM

Definition of kerf and overcut in electric discharge wire cutting

2013 John Wiley & Sons, Inc.

M P Groover, Principles of
Modern Manufacturing 5/e

Ideal for stamping die components

Since kerf is so narrow, it is often
possible to fabricate punch and
die in a single cut

Other tools and parts with

intricate outline shapes, such as
lathe form tools, extrusion dies, and
flat templates

Irregular outline cut

from a solid slab by wire
EDM (photo courtesy of
Makino).

 LBM uses the light energy from a laser to remove material by

vaporization.
The types of lasers used in LBM are basically the carbon dioxide
(CO2) gas lasers.

Lasers produce collimated monochromatic light with constant

wavelength.
In the laser beam, all of the light rays are parallel, which allows the
light not to diffuse quickly like normal light.
The light produced by the laser has significantly less power than a
normal white light, but it can be highly focused, thus delivering a
significantly higher light intensity and respectively temperature in a
very localized area.

Laser beam cutting

operation performed on
sheet metal (photo
courtesy of PRC Corp.)

Industrial applications, including heat treatment, welding, and

measurement, as well as a number of cutting operations such as
drilling, slitting, slotting, and marking operations.

Drilling small-diameter holes is possible, down to 0.025 mm. For

larger holes, the laser beam is controlled to cut the outline of the
hole.

Work materials is virtually unlimited including metals with high

hardness and strength, soft metals, ceramics, glass, plastics, rubber,
cloth, and wood.

Parts produced by
LBM. The model
bicycles are about
20 mm (0.8 in)
long (Courtesy of
George E. Kane
Manufacturing
Technology
Laboratory, Lehigh
University)
2013 John Wiley & Sons, Inc.
M P Groover, Principles of
Modern Manufacturing 5/e

Uses high velocity stream of electrons focused on

workpiece surface to remove material by melting and
vaporization
EB gun accelerates a continuous stream of electrons to
about 75% of light speed
Beam is focused through electromagnetic lens, reducing
diameter to as small as 0.025 mm (0.001 in)
On impinging work surface, kinetic energy of electrons
is converted to thermal energy of extremely high
density which melts or vaporizes material in a very
localized area

Works on any material

Ideal for micromachining
Drilling small diameter
holes - down to 0.05 mm
(0.002 in)
Cutting slots only about 0.025
mm (0.001 in.) wide
Drilling holes with very high
depth-to-diameter ratios
Ratios greater than 100:1

A group of processes in which electrical energy is used in

combination with chemical reactions to remove material
Reverse of electroplating
Work material must be a conductor
Material removal by anodic dissolution, using electrode
(the tool) in close proximity to work but separated by a
rapidly flowing electrolyte
Processes:
Electrochemical machining (ECM)
Electrochemical deburring (ECD)
Electrochemical grinding (ECG)

Material is deplated from anode

workpiece (positive pole) and
transported to a cathode tool
(negative pole) in an electrolyte
bath
Electrolyte flows rapidly
between two poles to carry off
deplated material, so it does
not plate onto tool
Electrode materials: Cu, brass,
or stainless steel
Tool has inverse shape of part
Tool size and shape must
allow for the gap

Die sinking - irregular shapes and contours for forging

dies, plastic molds, and other tools
Multiple hole drilling - many holes can be drilled
simultaneously with ECM
Holes that are not round
Rotating drill is not used in ECM
Deburring

Design Considerations for EBM

Guidelines for EBM:
1. Individual parts or batches should closely match
the size of the vacuum chamber for a high
production rate per cycle
2. Manufacture in small batches
Design Considerations for LBM
General design guidelines:
1. Sharp corners should be avoided
2. Deep cuts will produce tapered walls
3. Reflectivity of the workpiece surface
4. Adverse effects on the properties of
the machined materials

Design Considerations for EDM

General design guidelines:
1. Parts should be designed so that the required electrodes
can be shaped properly and economically
2. Deep slots and narrow openings should be avoided
3. The surface finish specified should not be too fine.
4. Bulk of material removal should be done by conventional
processes

Source:
Prof. Madya Mohd Yusuff Mohd,
Manufacturing Processes Course Manual 1A, 2009