UNCONVENTIONAL

MACHINING PROCESSES

UNIT-I

Varun Chebrolu, MVGRCE

 INTRODUCTION
Manufacturing processes can be broadly divided into two groups

primary manufacturing processes

Need or Purpose: To impart basic shape and size to the material as per
designers requirement.
1. Liquid stage forming processes: Casting
2. Solid stage forming processes: All metal working processes-Forging,
Rolling, Extrusion , Drawing etc..
3. Powder stage forming processes: Powder metallurgy- Cutting tool inserts
( Diamond tip), Tungsten filament, Lubricating bearings etc..

secondary manufacturing processes.

Need or Purpose: To impart final shape and size with tight control on
dimensions and shape.
-Mostly material removal processes

Partially manufacturing processes: Coatings , rapid proto typing

Varun Chebrolu, MVGRCE
 Classification of secondary manufacturing processes
Conventional Machining Processes
Examples of conventional machining processes: Turning, Boring, Milling, Shaping,
Broaching, Slotting, Grinding etc.

Non-Traditional Manufacturing Processes.

Unconventional 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.

Abrasive Jet Machining (AJM),

Ultrasonic Machining (USM),
Water Jet and Abrasive Water Jet Machining (WJM and AWJM),
Electro-discharge Machining (EDM)
Electro chemical machining (ECM)
Laser beam machining (LBM)
Electron beam machining (EBM)
Plasma machining (PAM)
Ion beam machining
Varun Chebrolu, (IBM)
MVGRCE
Characteristics of conventional machining process

Material removed due to the application of cutting forces

Energy domain Mechanical
Macroscopic chip formed
Chip formed due to the shear deformation
Cutting tool is harder than work piece at room temperature as
well as under machining conditions

Varun Chebrolu, MVGRCE

Characteristics of Unconventional machining process
Material removal- Chip formation or Even no chip formation
AJM- Microscopic size
ECM- Electro chemical dissolution at atomic level ( No chip formed)
Physical tool : May be absent
LBM: Machining is carried out by laser beam
WJM: Machining is carried out by high pressure of water
EDM: Physical tool very much required
ECM: Similarly required a tool
Tool need not be harder than work piece: In EDM copper or graphite is used
as the tool material to machine hardened steels, titanium, Inconel etc...
Energy Domain:
Different energy domains for machining
- USM, AJM, WJM, AWJM mechanical energy
- ECM Electro chemical dissolution
- EDM Electro thermal energy
Varun Chebrolu, MVGRCE
Non-conventional processes classified into various groups
according to the basic requirements like:

(i) Type of energy required namely mechanical, electrical, chemical etc.

(ii)Basic mechanism involved in the processes, like brittle fracture,

erosion, ionic dissolution, vaporization etc.

(iii) Source of immediate energy required for material removal namely,

hydrostatic pressure, high current density, high voltage, ionized
material, etc.

(iv) Medium for transfer of those energies, like high velocity particles,
electrolyte, electron, hot gases, etc.

On the basis of above requirements, the various processes may

be classified

Varun Chebrolu, MVGRCE

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)

Electro-Thermal Processes
Electro-discharge machining (EDM
Laser Jet Machining (LJM)
Electron Beam Machining (EBM)

Chemical Processes
Chemical etching
Photochemical Milling (PCM) etc

Varun Chebrolu, MVGRCE

Varun Chebrolu, MVGRCE
Varun Chebrolu, MVGRCE
Varun Chebrolu, MVGRCE
Varun Chebrolu, MVGRCE
Varun Chebrolu, MVGRCE
Physical parameters

Varun Chebrolu, MVGRCE

Varun Chebrolu, MVGRCE
Capability to shape
Shape Application of Non-conventional Processes

Varun Chebrolu, MVGRCE

Applicability to materials

Varun Chebrolu, MVGRCE

Machining characteristics
The machining characteristics of different non-conventional
processes can be analyzed with respect to :
(i) Metal removal rate
(ii) Tolerance maintained
(iii) Surface finish obtained
(iv) Depth of surface damage
(v) Power required for machining

Varun Chebrolu, MVGRCE

Varun Chebrolu, MVGRCE
Economics of the processes

The economics of the various processes are analyzed on the

basis of following factors

(i) Capital cost

(ii) Tooling cost

(iii) Consumed power cost

(iv) Metal removal rate efficiency

(v) Tool wear.

Varun Chebrolu, MVGRCE

Varun Chebrolu, MVGRCE
Need for NTM
Exotic materials, innovative design and requirement, tighter tolerance and
micro machining etc..
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 (ECM, EDM).
Low Stress Grinding Electrochemical Grinding is preferred as compared to
conventional grinding
Deep hole with small hole diameter e.g. 1.5 mm hole with l/d = 20
Machining of composites.

Varun Chebrolu, MVGRCE

 Conventional Manufacturing Non-Conventional Manufacturing

Generally macroscopic chip formation by shear Material removal may occur with chip formation or even
deformation. no chip formation may take place

physical tool present physical tool is not necessary

Cutting tool is harder than work piece Cutting tool is softer than work piece
Material removal takes place due to application of Mostly NTM processes do not necessarily use
cutting forces mechanical energy to provide material removal. They use
different energy domains to provide machining

Direct contact of tool and work piece Does not require the direct contact of tool and work
piece.
High tool wear as there is a physical contact between the Tool wear is not the concern.
tool and the work.

Lower accuracy and surface finish. Higher accuracy and surface finish.
Noisy operation mostly cause sound pollutions Quieter operation mostly no sound pollutions are
produced

Lower capital cost Higher capital cost

Easy set-up of equipment. Complex set-up equipment.
Skilled or un-skilled operator may required Skilled operator required
Generally they are manual to operate. Generally they are fully automated process.
They cannot be used to produce prototype parts very Can be used to produce prototype parts very efficiently
Varun
efficiently andChebrolu, MVGRCE
economically. And economically.