E

1. Unconventional Machining Processes
COMPARISON
S. No Process
parameters
EDM ECM EBM LBM PAM USM AJM WJM
1.
Metal
removal
technique
By using
powerful
electric
spark
Based on
Faraday’s
law of
electrolysis
By using high
velocity beam
of electrons
By using
high
intensity of
laser beam
Heating,
melting and
vaporizing by
using plasma
Slurry of small
abrasive
particles is
forced against
work piece by
means of
vibrating tool
By using high
stream of
abrasive
particles mixed
with air
By using high
velocity of
water jet
2.
Work
material
Electrically
conductive
metals and
alloys
Difficult to
machine
materials
All materials
All
materials
except those
having high
thermal
conductivity
and high
reflectivity
All materials
which
conduct
electricity
Tungsten
Carbide,
Glass, Quartz,
Germanium,
Ceramics
Hard and brittle
materials like
Glass, Quartz,
Ceramics
Soft and non-
metallic
materials like
wood, plastic,
paper-board
3.
Tool
material
Copper,
yellow
Brass, alloy
of Zinc,
Copper
Tungsten
Copper,
brass,
Titanium,
Copper
Tungsten,
Stainless
Steel
Electron Beam Laser Beam Plasma
Low Carbon
Steels
Abrasives like
Aluminum
Oxide, Silicon
Carbide, Glass
Powder
Water jet
4.
Metal
Removal
Rare
(mm3
/S)
15 to 80 27 15 to 40 0.10 2500 14 0.014 0.6

2. Unconventional Machining Processes
5.
Surface
Finish in µm
0.25 0.2 to 0.8 0.4 to 6 0.4 to 6 Rough 0.2 to 0.7 0.5 to 1.2 0.5 to 0.8
6.
Power
Requirement
Low Medium Low Very Low Very low Low Low High
7. Capital Cost Medium High High High Low High Very Low High
8. Efficiency High Low Very High Very High Very low High High High
9. Applications
Production
of
complicated
and
irregular
shaped
profiles and
re-
sharpening
of cutting
tools
Machining
hard
materials
and
complex
shaped
parts
Micro
machining
operations on
thin materials
like drilling,
slotting,
scribing
Drilling
micro holes
(upto
250mm)
and cutting
very narrow
slots
Profile
cutting of
stainless
steel, monel
and super
alloy plates
Efficiently
applied to
machine glass,
ceramics,
tungsten
Intricate hole
shapes in hard
and brittle
materials
Machining non-
metallic
materials
10. Limitations
Not suitable
for non
conducting
materials
Not
suitable for
non
conducting
materials
Not suitable for
large work
pieces,
necessity of
vacuum
Taper of
0.05mm
when work
thickness is
more than
0.25 mm
Low
accuracy
Low metal
removal rate,
high rate of
tool wear
Low metal
removal rate,
low accuracy
Difficult to
machine hard
materials