The document provides information about the Advanced Manufacturing Processes course taught by Dr. Manoj Kumar Pandey at BITS Pilani K. K. Birla Goa campus. It includes details about the instructor, office number, contact information, reference books, and course materials. The document then defines non-traditional manufacturing processes and provides examples of when these processes would be preferred over conventional machining. It discusses the need for non-traditional processes due to new materials, part geometries, and other factors. Finally, it provides overviews of several specific non-traditional processes including abrasive jet machining.

1. Dr. Manoj Kumar Pandey
Advanced manufacturing processes (ME F315)
Department of Mechanical Engineering
BITS Pilani K. K. Birla Goa campus
Instructor in charge: Dr. Biswajit Das
Office No.- E107
Tel: +91-832-2580381 (O)
BITS Pilani K. K. Birla Goa campus

2. Course Materials : Lecture Notes
Reference Books for NTM processes :
1. Nontraditional Manufacturing Processes
Gary F. Benedict, Marcel Dekker,Inc
2. Modern Machining Processes
P C Pandey & H S Shan, Tata McGraw-Hill
3. Nonconventional Machining
P K Mishra, Narosa Publishing House
4. Manufacturing Science
Amitabha Ghosh & A K Mallik, Affiliated East-West Press
5. www.nptel.iitm.ac.in
National Programme on Technology Enhanced Learning (NPTEL)
Course- IIT Kharagpur- Manufacturing-Module 9 (on NTM)
Lessons 35-40.
6. Laser Material Processing, by W M Steen

3. Different Names

4. Need

5. Definition
• Non-traditional 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.
• The nontraditional processes have been developed since World War
II largely in response to new and unusual machining requirements
 The need to machine newly developed metals and nonmetals. These
new materials often have special properties (e.g., high strength, high
hardness, high toughness) that make them difficult or impossible to
machine by conventional methods.
 The need for unusual and/or complex part geometries that cannot
easily be accomplished and in some cases are impossible to achieve by
conventional machining.
 The need to avoid surface damage that often accompanies the
stresses created by conventional machining.

6. Examples
The following examples are provided where NTM processes are
preferred over the conventional machining process:
 Non circular / Intricate shaped blind hole – e.g. square hole of 15
mmx15 mm with a depth of 30 mm with a tolerance of 100 microns
 3D contour on Die, Inaccessible deburring, curved axis holes, etc.
 Difficult to machine material – e.g. Inconel, Ti-alloys or carbides,
Ceramics, composites , HSTR alloys, satellites etc.,
 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.
 Micro and nano components

7. ECM

8. WJM

9. CHM

10. Fabrication of large size
domes
Fabrication of
Micro-lens

11. Conventional Machining Processes (Material Removal):
Primarily rely on electrical motors and hard tool materials to
perform tasks e.g. Turning, Drilling, Boring, Milling,
Shaping, Sawing, Slotting, & Grinding etc.
Main Characteristics of Conventional Machining:
* Material removal by chip formation
* Material removal by mechanical force
* Cutting tool – harder than work piece under machining condition
* Direct mechanical contact - residual mechanical & thermal stress.

12. Demand for Products with
 New exotic work materials: Improved mechanical, thermal, & chemical
properties
Super alloys, ceramics and composites
* Too hard / brittle to machine with traditional process
* Materials too flexible / slender to cut or clamp
Ex: Machining Polycrystalline diamond
- fast wear of grinding wheel;
Silicon wafer, Ceramic – Damage during machining
60m square hole in Si Curved slot in SS
Micro-lenses
Quartz
Need of Modern Manufacturing Processes !
Challenges & Competition in manufacturing industries:
New Products - Better Performance, More Features, More Durable, Less Production
Time, Energy Efficient, Low cost,
 Innovative designs, complex shapes, high precision & high surface quality
* Stringent design requirements * Micro- Nano Sizes

13. Other requirements of the New Manufacturing Process
 Low machining cost
* Automated processing, Fast production
Photochemical Machining Electro-Discharge Machining
 Rapid change of Product design
* Elimination of Traditional tooling to reduce time & cost
 Less Temperature rise or residual stresses

14. Modern / Nontraditional Manufacturing processes employing
New tools and
New forms of energy
Developed as
Efficient and economic alternatives to conventional ones
Often the first choice for certain technical requirements.
Modern / Nontraditional Manufacturing Processes differ to Traditional Mfg.
Processes in following aspects 
 Unconventional Energy Sources : Thermal, Chemical, Kinetic Energy ----
 Processing usually not by direct MECHANICAL contact: Nontraditional
mechanism of interaction between the tool and the work piece: Evaporation,
Ablation, Melt Ejection, Dissolution, Erosion----
 Nontraditional media to transfer energy from the tool to the work piece :
Photons, E-beam, Dielectric media, Electrolytic media, Water, Abrasive slurry.

15. Basic NTM Process Groups:
* Thermal NTM Processes
- Laser Beam Machining (LBM)
- Electron Beam Machining (EBM)
- Plasma Arc Machining (PAC)
- Electrical Discharge Machining (EDM)
* Mechanical NTM Processes( Plastic deformation / Abrasive Erosion)
- Abrasive Jet Machining (AJM)
- Ultrasonic Machining (USM)
- Water Jet Machining (WJM)
- Abrasive Water Jet Machining (AWJM)
* Electrochemical NTM Processes
- Electrochemical Machining (ECM)
- Electrochemical Grinding (ECG)
* Chemical NTM Processes
- Chemical Machining (CHM)
- Thermo chemical Machining (TCM)
* Kinetic Energy ( Atom by atom knocking)
- Ion beam

16. Examples where NTM processes is the first choice
 Intricate shaped blind holes- e.g. square holes of say 10x10mm with a depth of
20mm  EDM / ECM
 Machining hard materials- e.g. Diamond, Inconel, Ti-Alloys, Composites,
Ceramics or Carbides  EDM, ECM, LBM
 Small diameter holes with large aspect ratio (0.5mm , 10mm l)
LBM, EBM, EDM
 Flexible , Brittle materials  WJ, AWJ, EDM, PCM, LBM, EBM
Laser Cutting
Abrasive Machining

17. Characteristics of Modern / Non Traditional Machining (NTM) Processes:
 Mostly NTM processes do not use mechanical energy for material removal.
They use different forms of energy for machining.
Example, USM, AJM, WJM - Mechanical energy
ECM- Electrochemical dissolution
Laser, EDM, EB - Thermal
 Material removal with chip formation or even without chip formation
Example: AJM - Microscopic size chips
ECM - Electrochemical dissolution at atomic level
 In NTM, Physical tool may or may not be present.
Example: Laser beam machining- No tool,
Electrochemical Machining- Physical tool needed
 In NTM, Tool need not be harder than the work piece material.
Example, EDM, copper tool to machine hardened steels.
 Nontraditional media for energy transfer:
EDM: Dielectric fluid,
Laser: Coherent photon beam

18. Attributes of Nontraditional Machining Processes:
Increased Productivity: Faster operation
Reduction in the number of overall operations;
Reduced Rejection: Improved repeatability
Reduction in in-process breakage of fragile work piece.
Perform operation not feasible by traditional Manufacturing Processes,
Example drilling holes of very high depth to width aspect ratio, 100:1
Easy automation, On-line Process Monitoring & Control: Increased reliability,
repeatability; reduced human involvement
Versatile & Virtually unlimited Capability: Ex.- Laser can cut most materials of
any hardness: diamond, metals, concrete, glass, plastics, textiles, wood etc.
Drill holes of any diameter

19. Modern Manufacturing Processes
1. Laser Beam Machining ((Processing) (LBM)
2. Electron Beam Machining (EBM)
3. Plasma Arc Machining (PAC)
4. Ion Beam Machining (IBM)
5. Physical Vapour Deposition (PVD)
6. Chemical Vapour Deposition (CVD)
7. Abrasive Jet Machining (AJM)
8. Water Jet Machining (WJM)
9. Abrasive Water Jet Machining (AWJM)
10. Ultrasonic Machining (USM)
11. Electro- Discharge Machining (EDM)
12. Electrochemical Machining (ECM)
13. Chemical Machining (CHM)
14. Hybrid & Other Advanced Manufacturing Processes

20. Hybrid

21. Comparison - Parameters

22. Comparison - Shapes
Through cavities Through cutting

23. Comparison - Shapes

24. Comparison - Materials
Tungsten,
Molybdenum,
Niobium, Tantalum
and Rhenium

25. Comparison – Capability & Cost
CLA = Center Line average

27. Advantages of NTMT
 Complex geometries
 Extreme surface finish
 Tight tolerances
 Delicate components and features
 Easy adaptability for automation
 Little or no burring or residual stresses
 Easy to machine brittle materials with high hardness
 Mass production possible for micro electronics & Integrated circuits
 Intricate machining

28. Abrasive Jet Machining (AJM)

29. AJM
• Material removal takes place due to the impingement of the fine abrasive
particles.
• Particles moves with high speed air (or gas) steam.
• The kinetic energy of the abrasive particles is sufficient to provide material
removal due to brittle fracture of the workpiece or even micro-cutting by
the abrasives.
• AJM is inherently free from chatter and vibration problems. The cutting
action is cool because the carrier gas serves as a coolant.
• AJM is mainly used
• To cut intricate shapes in hard and
brittle materials which are sensitive to
heat and chip easily.
• For deburring and cleaning operations.

30. Mechanics of AJM
Stages
Gas supply pressure
is on the order of 850
kPa (~8bar)

31. Process Parameters
Major Parameters which controls MRR, geometry of cut, SF and Nozzle wear are
• Abrasive (composition, strength, size and mass flow rate)
• Gas (composition, pressure and velocity)
• Nozzle (geometry, material, distance from and inclination to the work
surface)

33. Process Parameters
• Abrasive
• Aluminium oxide (Al2O3) silicon carbide (SiC) glass beads,
crushed glass and sodium bicarbonate.
• Should have sharp edges
• Reuse is not recommended

34. Process Parameters
• Abrasive
Mixing ratio: Mass fraction of the
abrasives in the jet.

35. Process Parameters
• Nozzle: Shapes

36. Process Parameters
• Nozzle: Effect of nozzle tip distance on shape and size of cut.

37. Process Parameters
• Nozzle: Effect of nozzle tip distance on shape and size of cut.

38. AJM Characteristics

39. Adv. And Dis Adv.
Advantages:
• There is no direct contact between the tool and the workpiece
(Ability to cut fragile materials).
• Good surface finish can be obtained.
• No heat damage to the workpiece (Ability to cut heat-sensitive
material).
• Hard materials can be easily machined.
• Complex shapes can be produced on the workpiece.
• Low initial cost.
Disadvantages:
• The material removal rate is low.
• Poor machining accuracy.
• High nozzle wear rate.
• The soft material cannot be machined.
• Additional cleaning of the work surface is required due to
the sticking of abrasive grains in softer material.

40. Applications
• Cutting slots and thin sections.
• Contouring and drilling operation.
• Producing shallow crevices and deburring.
• Producing intricate hole shapes in a hard and brittle material.
• Machining of semiconductor materials.
• Cleaning and polishing the plastic, nylon and Teflon component.
• Frosting of the interior surface of glass tubes.
• Etching of marking of glass cylinders.
• Machining super-alloys and refractory material.

41. Mechanics
Assumptions:
1. Abrasives are spherical in shape and rigid.
2. Kinetic energy of particle is used to cut the material.
3. For brittle Materials, fracture of volume is considered to be
hemispherical with diameter equal to chordal length of indentation.
4. For ductile material, volume of material removal is assumed to be
equal to the indentation volume due to particulate impact.

42. Mechanics
From the geometry,

47. Thank you
for
your patience
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