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1. UNIT I INTRODUCTION

2. Syllabus
• Unconventional machining Process
• Need
• Classification
• Brief overview

3. WHAT IS UCM?

4. Conventional Machining
Process
• Metal Removal ?
• Nature of Contact ?
• Scrap ?

5. Demerits
• Disposal of Waste
• By products of chips
• Work holding Devices for larger cutting
force
• Heat Generation
• Not possible without chips

6. Unconventional Manufacturing
process
• Unconventional Manufacturing process
1. Unconventional Machining process
or
Non Traditional Machining Process
2. Unconventional Forming process

7. Unconventional
Manufacturing process
Machining process
• Metal Removal
• No Direct Contact b/w
tool and work piece
Forming process
• Metals are formed
• Releases large amount of
Energy in very short time
interval

8. NEED FOR UCM

9. Need
• Machining - produces finished products with high degree of
accuracy
• Conventional machining
• Utilizes cutting tools (harder than workpiece material).
• Needs a contact between the tool and workpiece.
• Needs a relative motion between the tool and workpiece.

10. Need
• The need for higher productivity, accuracy and surface quality
• Improve the capability of automation system and decreasing their
sophistication (decreasing the investment cost) requirements
• Very hard fragile materials difficult to clamp for traditional
machining
• When the work piece is too flexible or slender
• When the shape of the part is too complex
• Internal and external profiles, or small diameter holes.

11. CLASSIFICATION

12. Unconventional Machining Processes -
Based on Energy
12

13. Unconventional Machining Processes -
Based Mechanism
13

14. Unconventional Machining Processes -
Based on Energy used for Removal
14

15. Unconventional Machining Processes -
Based on Transfer of Energy
15

16. Mechanical Based Processes
1. Working principles
2. Equipment used
AJM
WJM
AWJM
USM
3. Process parameters
4. MRR
5. Variation in techniques used
6. Applications
16

17. Electrical Based Processes
Electrical
EDM
WEDM
1. Working principle
2. Equipment used
3. Process parameters
4. Surface finish & MRR
5. Electrode/Tool
6. Power & Control circuits
7. Tool wear
8. Dielectric
9. Flushing
10. Applications
17

18. Chemical & Electrochemical Based
Processes
1. Working principles
2. Etchants & Maskants
3. Techniques of applying maskants
CHM 4. Process parameters
ECM 5. Surface finish & MRR
ECG 6. Electrical circuits in case of ECM
ECH 7. Applications
18

19. Thermal Based Processes
1. Working principles
2. Equipment used
3. Types
LBM
4. Beam control techniques
PAM
5. Applications
EBM
19

20. SELECTION PROCESS

21. Selection Process
• Selection Process is based of following
parameters
- Physical Parameter
- Shapes to be Machined
- Process Capability
- Economic consideration

22. Physical Parameter
Parameter ECM EDM
Potential, V 5- 30 50-500
Current, A 40,000 15-500
Power, kW 100 2.70
Gap, mm 0.5 0.05
Medium Electrolyte Die electric
fluid
Work Tungsten
EBM LBM
200 x 103 4.5 x 103
0.001 2
0.15 20
100 150
Vacuum Air
PAM USM AJM
250 220 220
600 12 1.0
220 2.4 0.22
7.5 0.25 0.75
Abrasive
Argon Nitrogen grains
Tungsten
M/C diff All Mtl All Mtl All Mtl HSS
Material carbide carbide

23. Shapes to be Machined
Process
Holes ( Micro, Small,
deep,Shallow)
Precision Work
Horning
Etching
Grinding
Deburring
Threading
Profile Cut
Machines
LBM, EBM,ECM, USM & EDM
USM & EDM
ECM
ECM & EDM
AJM & EDM
USM & AJM
EDM
PAM

24. Process Capability or Machining
Characteristics
Process
LBM
EBM
EDM
ECM
PAM
USM
AJM
MRR
( mm3/s )
0.10
0.15 - 40
15 - 80
27
2500
14
0.014
Surface Finish
(μm)
0.4 - 6.0
0.4 - 6.0
0.25
0.2 -0.8
Rough
0.2 - 0.7
0.5- 1.2
Accuracy
(μm)
25
25
10
50
250
7.5
50
Power (kW/
cm3/ min
2700
450
1.8
7.5
0.90
9.0
312.5

25. Process Economy
Process
EDM
CHM
ECM
AJM
USM
EBM
LBM
PAM
Convention
al
Capital Cost
Medium
Medium
V. High
V. Low
High
High
Medium
V. Low
V. Low
Tool & Fixtures
High
Low
Medium
Low
High
Low
Low
Low
Low
Power
Requirement
Low
High
Medium
Low
Low
Low
V. Low
V. Low
Low
Efficiency
High
Medium
V. Low
Low
Medium
V. High
V. High
V. Low
V. Low

26. Limitation
• More Expensive
• Slow Process
• Commercial

27. Compiled By
D.Vasanth kumar