MMM

2. Characteristics of Modern Manufacturing Methods / NTM
1. Material removal may occur with chip formation or even no chip formation may take place. For example, in AJM, chips
are of microscopic size and in case of Electrochemical machining material removal occurs due to electrochemical
dissolution at atomic level.
2. In NTM, there may not be a physical tool present. For example, in laser jet machining, machining is carried out by laser
beam. However, in Electrochemical Machining there is a physical tool that is very much required for machining
3. In NTM, the tool need not be harder than the work piece material. For example, in EDM, copper is used as the tool
material to machine hardened steels.
4. Mostly NTM processes do not necessarily use mechanical energy to provide material removal. They use different
energy domains to provide machining. For example, in USM, AJM, WJM mechanical energy is used to machine
material, whereas in ECM electrochemical dissolution constitutes material removal
Continued………..

3. Characteristics of Modern Manufacturing Methods / NTM
5. In many processes, material removal rate is independent of the hardness of the work piece.
6. Cutting forces are independent of the hardness of the work material.
7. Generally, tool wear is negligible hence tool wear is not a problem
8. No burr is left on the work piece
9. Generally, no residual stresses are left on the surfaces machined
10.In most of the cases entire shape can be obtained in one stage or in one setting. This is possible
since material removal takes place uniformly over the entire area below the tool simultaneously.
11.Modern machining methods can be integrated easily with micro-processors and numeric
controls for better control of the processes and for improving the versatility and productivity of
the machines
12.Intricately shaped contours and fine machining of precision holes are possible.
Continued………..

4. Advantages of Modern Manufacturing Methods / NTM
1. Complex geometries beyond simple planar or cylindrical features
2. Parts with extreme surface finish and tolerance requirements
3. Delicate components that cannot withstand large cutting forces
4. Parts without producing burrs or inducing residual stresses
5. Brittle materials or materials with very high hardness.

5. Need For Modern Manufacturing Methods / NTM
1. With the development of technology more & more challenging problems are face by the
scientist & technologists in the field of manufacturing
2. Technologically advanced industries like aeronautics, nuclear reactors, automobiles etc,
have been demanding materials like “high strength temperature resistant (HSRT) alloy
having “strength to weight “ratio
3. Extremely hard and brittle materials or Difficult to machine materials are difficult to
machine by traditional machining processes.
4. When the work piece is too flexible or slender to support the cutting or grinding forces.
5. When the shape of the part is too complex

6. Need For Modern Manufacturing Methods / NTM
6. Researchers in the area of materials science are developing materials having high
strength, hardness, toughness etc.
7. The difficulty in adopting the traditional manufacturing process can be attributed
mainly to the following three basic sources
i. New materials with low machinability
ii.Dimensional and accuracy requirements
iii.A high production rate & economy

7. Basic Principle Of Modern Manufacturing Methods :
The basic principle of machining by these new methods is to apply some form of energy
to the work piece directly without almost any physical contact between the tool and the
work piece and have the desired shape by material removal from the work piece.
Different forms of energy applied to the work piece are: Mechanical Energy, Electrical
(Electro-chemical energy), Thermal Energy, Chemical Energy.

8. Classification of Modern Manufacturing Methods :
1. Mechanical Energy
2. Electrical Energy (Electro-chemical energy)
3. Thermal Energy (Thermo- electric energy)
4. Chemical Energy

9. Classification of Modern Manufacturing Methods :
1. Mechanical Energy
 Conventional machining
 Abrasive Jet Machining (AJM)
 Water Jet machining (WJM)
 Ultrasonic machining (USM)
2. Electrical Energy
 Electro-chemical machining
 Electro-chemical grinding
 Electro-chemical Deburring
 Electro-chemical Honing

10. Classification of Modern Manufacturing Methods :
3 Thermal Energy
 Spark erosion machining or Electro-
discharge machining (EDM)
 Electron-Beam machining (EBM)
 Ion-Beam machining
 Laser-Beam machining
 Plasma-Arc machining
4. Chemical Energy
 Chemical machining
 Electro-polishing
 Photo-chemical machining

11. Energy type Mechanics of
material removal
Energy source Process
Mechanical
Plastic shear Mechanical
motion of tool/job
Conventional
machining
Erosion Mechanical fluid motion Abrasive jet machining (AJM)
Ultrasonic
machining (USM) ,WJM, AWJM
Electrochemical Ion displacement Electric current Electrochemical
machining (ECM)
Mechanical & Electro chemical
Plastic shear & Ion
displacement
Electric current & Mechanical motion Electrochemical and mechanical
grinding(ECG) Electro Jet Drilling (EJD)
Chemical
Corrosive agent Corrosive agent Chemical machining
(CHM)
Fusion reaction Electric spark Electric discharge
machining (EDM)
High speed
electrons
Electron beam machining
(EBM)
Thermal
Powerful radiation Laser beam Machining
(LBM)
Ionized substance Ion beam machining(lBM)
Plasma arc machining
(PAM) ,

12. Machining Characteristics of Modern Manufacturing Methods :
The machining characteristics of different non-conventional processes can be analyzed with
respect to:
 Metal removal rate
 Tolerance maintained
 Surface finish obtained
 Depth of surface damage
 Power required for machining

13. Econmics of Modern Manufacturing Methods :
The economics of the various processes are given below
 Tooling cost
 Consumed power cost
 Metal removal rate efficiency
 Tool wear.