Removal of material which does not involve

the chip shaving process can be called as

non-conventional or non-traditional
machining processes
Non-conventional machining processes
include the following
Electro-discharge machining. (EDM)
Wire-cut EDM
Electrochemical machining (ECM)
Electrochemical grinding (ELG)
Ultrasonic machining etc
Any electrically conductive material can be machined
regardless of its hardness.
Machining can be done in the hardened state itself.
Any complicated shape can be given in the work
piece
The work piece will not be subjected to distortion or
stress, since the tool (electrode) never comes in
contact with the work piece
Machining can be done on thin and fragile work pieces
also.
These processes are burr-free.
Secondary finishing operations are generally eliminated.
Broken taps and drills can be removed easily without
damaging expensive work pieces.
Electrochemical machining (ECM) is essentially a reverse
metal plating process.
Removing metal by a chemical process is not new. For
many years it has been used by photo engravers to prepare
plates for printing and engraving
The process of ECM takes place in a conducting fluid or
electrolyte that is pumped under pressure between the
electrode and the work piece. As the work piece material is
depleted, it is washed away by the flow of the electrolyte. The
work piece material is removed from the electrolyte by a
filtration system
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 weight of the material, which is deposited.
ECM is just the reverse of electroplating (which also
uses the principle of electrolysis). In electroplating,
two dissimilar metals are in contact with electrolyte
(an electrically conductive fluid) and anode loses
metal to the cathode. In ECM, work is made the anode
and the tool is the cathode. Therefore, work loses
metal but before it can be plated on to the tool the
dissolved metal is carried away in the flowing
electrolyte
ECM is simple, fast and versatile method.

Like EDM, the ECM method has also been developed for
machining new hard, and tough materials (for rocket and
aircraft industry) and also hard refractory materials. ECM has the
following outstanding advantages.

ECM is simple, fast and versatile method.

The metal removal is entirely by metallic ion exchange and so
there are no cutting forces and the workpiece is left in an
undisturbed, stress free state. It is never subjected to high
temperatures or stresses. Also, due to the absence of cutting
forces, very thin sections can be machined. Again, there will be
no residual stresses in the workpiece as a result of the operation
If proper electrolytes are used, there is no tool wear at all
The process character does not depend at all upon the physical
properties of the metal (hardness, toughness, etc.)

Surface finish can be extremely good

 The electrolyte in ECM method serves two purposes.
It is essential for electrolytic process to work, and
It cools the cutting zone, which becomes hot due to
the flow of high current. The electrolytes vary from
strong salt to strong acid
solution, depending on the work material. Neutral
salts are used as electrolytes in preference to highly
corrosive acids and alkalis. The sodium and
potassium salts are probably the most common. A
20% common salt (NaCI) solution is appropriate for
many materials. Some electrolytes are naturally
corrosive and so ECM equipment is made of stainless
steel and plastics.
 The electrolyte solution is pumped
between the tool/workpiece gap at
about 2.5 N/mm2 and 30 m/s. The
electrolyte should never be allowed to
boil. For this, the temperature of the
electrolyte in the tank is thermostatically
controlled (35 deg.to 65 deg. C) by
electric heaters together with a heat
exchanger or evaporative condenser.
Unlike EDM, it is not necessary for the
work to be submerged in liquid solution.
 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
 Four basic groups of material removal using NTM processes
Chemical:
Chemical reaction between a liquid reagent and
workpiece results in etching
Electrochemical
An electrolytic reaction at workpiece surface for
removal of material
Thermal
High temperature in very localized regions evaporate
materials, for example, EDM
Mechanical
High-velocity abrasives or liquids remove materials
 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
 Typical machining parameters
Feed rate (5 200 in./min.)
Surface finish (60 150 min) AA Arithmetic
Average
Dimensional accuracy (0.001 0.002 in.)
Workpiece/feature size (25 x 24 in.); 1 in. deep
NTM processes typically have lower feed
rates and require more power consumption
The feed rate in NTM is independent of the
material being processed
 Electrochemical
machining (ECM)
removes material
by anodic
dissolution with a
rapidly flowing
electrolyte
The tool is the
cathode and the
workpiece is the
electrolyte

Figure 19-17 Schematic diagram of

electrochemical machining process
(ECM).
 Electrochemical
machining (ECM)
removes material
by anodic
dissolution with a
rapidly flowing
electrolyte
The tool is the
cathode and the
workpiece is the
electrolyte

Figure 19-17 Schematic diagram of

electrochemical machining process
(ECM).
 Pulsed-current ECM (PECM)
Pulsed on and off for durations of
approximately 1ms
Pulsed currents are also used in
electrochemical machining (EMM)
Electrochemical polishing is a
modification of the ECM process
Much slower penetration rate
 Electrochemical hole machining
Used to drill small holes with high aspect ratios
Electrostream drilling
High velocity stream of charged acidic, electrolyte
Shaped-tube elecrolytic machining (STEM)
Capable of drilling small holes in difficult to
machine materials
Electrochemical grinding (ECG)
Low voltage, high-current variant of ECM
Figure 19-19 The shaped-tube electrolytic
machining (STEM) cell process is a specialized
ECM technique for drilling small holes using a
metal tube electrode or metal tube electrode with
dielectric coating.
Figure 19-20 Equipment setup and electrical circuit for electrochemical grinding.
 Electrochemical deburring
Electrolysis is accelerated in areas with small
interelectrode gaps and prevented in areas
with insulation between electrodes
Design factors in electrochemical
machining
Current densities tend to concentrate at sharp
edges or features
Control of electrolyte flow can be difficult
Parts may have lower fatigue resistance
 Advantages Disadvantages
ECM is well suited for the Initial tooling can be
machining of complex timely and costly
two-dimensional shapes Environmentally
Delicate parts may be harmful by-products
made
Difficult-to machine
geometries
Poorly machinable
materials may be
processed
Little or no tool wear
 Electrical discharge machining (EDM)
removes metal by discharging electric
current from a pulsating DC power
supply across a thin interelectrode gap
The gap is filled by a dielectric fluid,
which becomes locally ionized
Two different types of EDM exist based
on the shape of the tool electrode
Ram EDM/ sinker EDM
Wire EDM
Figure 19-21 EDM or spark erosion machining of metal, using high-frequency spark discharges in
a dielectric, between the shaped tool (cathode) and the work (anode). The table can make X-Y
movements.
Figure 19-21 EDM or spark erosion machining of metal, using high-frequency spark discharges in
a dielectric, between the shaped tool (cathode) and the work (anode). The table can make X-Y
movements.
 Slow compared to
conventional
machining
Produce a matte
surface
Complex geometries
are possible
Often used in tool Figure 19-22 Schematic diagram of equipment
for wire EDM using a moving wire electrode.
and die making
 Figure 19-23 (left) Examples of wire EDM
workpieces made on NC machine (Hatachi).

Figure 19-24 (above) SEM micrograph of EDM

surface (right) on top of a ground surface in steel.
The spherical nature of debris on the surface is in
evidence around the craters (300 x).
MRR = (C I)/(Tm1.23),
Where MRR material removal rate in in.3/min.; C constant of
proportionality equal to 5.08 in US customary units; I
discharge current in amps; Tm melting temperature of
workpiece material, 0F.

Example:
A certain alloy whose melting point = 2,000 0F is to be machined
in EDM. If a discharge current = 25A, what is the expected
metal removal rate?

MRR = (C I)/(Tm1.23) = (5.08 x 25)/(2,0001.23)

= 0.011 in.3/min.
From Fig 19 25: we have the conclusions:
Generally higher duty cycles with higher
currents and lower frequencies are used to
maximize MRR.
Higher frequencies and lower discharge
currents are used to improve surface finish
while reducing MRR.
Higher frequencies generally cause increased
tool wear.
 Graphite is the most widely used tool
electrode
The choice of electrode material depends
on its machinability and coast as well as
the desired MRR, surface finish, and tool
wear
The dielectric fluid has four main functions
Electrical insulation
Spark conductor
Flushing medium
Coolant
 Advantages Disadvantages
Applicable to all Produces a hard
materials that are recast surface
fairly good electrical Surface may
conductors contain fine cracks
Hardness, toughness, caused by thermal
or brittleness of the stress
material imposes no Fumes can be toxic
limitations
Fragile and delicate
parts