This document discusses various non-traditional machining (NTM) processes, including their need, classification, parameters, advantages, limitations, and applications. It covers mechanical processes like ultrasonic machining, abrasive jet machining, and water jet machining. It also discusses chemical/electrochemical processes like electrochemical machining, thermal/electrothermal processes like laser beam machining and plasma arc machining, and electrical discharge machining. Each process is explained along with diagrams and tables of parameters for different materials.
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MP-II-UNIT 8-JSS.pptx
1. NEED FOR NTM
Machining hard work piece materials like
carbides, stainless steels, heat resistance
steels
Machining of small hole diameter and
complex shapes
Work piece is too flexible to support or
withstand cutting forces
High tolerance and surface finish is required
2. Classification of NTM
a) Mechanical Energy
Ultrasonic Machining (USM)
Water Jet Machining (WJM)
Abrasive Jet Machining (AJM)
b) Chemical or Electrochemical Energy
Electrochemical Machining (ECM)
Electrochemical Grinding (ECG)
3. Classification of NTM
Electrochemical Honing (ECH)
Electrochemical Deburring (ECD)
Chemical Machining (CM) – Milling and Blanking
c)Thermal or Electro thermal Energy
Laser Beam Machining (LBM)
Plasma Arc Machining (PAM) Electrical
Discharge Machining (EDM)
Electron Beam Machining (EBM)
Ion Beam Machining (IBM)
6. Process parameters of USM
Amplitude and frequency of vibration of tool
15-30 khz and 25-100 micrometer
Slurry
Tool material
Type of abrasive
Abrasive size
7. Advantages and limitations
Non conductive materials like ceramics
Non thermal non chemical
No burrs and no destruction of work
Suitable for Hard and brittle materials
Low material removal rate
Small holes and cavities
Tool wear is more
Not suitable for soft work materials
9. Process parameters of AJM
Abrasive flow rate and velocity
Material removal rate increase with abrasive
flow rate and velocity
Min jet velocity is 150 m/s
Nozzle tip and distance 7-13 mm
Abrasive grain size – 10 – 50 micrometer
10. Advantages and Limitations
Ability to cut intricate shapes in hard brittle
and heat sensitive materials
Uniform loading part
No work piece chatter or vibration
o Slow process
o Abrasive may embed in to work
o Rubber and plastic can not be machined
13. Process parameters of WJM
Pressure of water
Nozzle diameter
Stand off distance
14. Advantages and limitations
Dust free process – no toxic gasses or liquid
No heat affected zones or mechanical
stresses
Health hazards associated with cutting
materials like asbestos and fiberglass
minimized
Complex shapes with any radius can be
machined
Clean and sharp cut, up to 250 mm thick can
be machined
15. Advantages and limitations
Equipment is quite expensive
Inefficient for hard materials
Water should be filtered
Damages to nozzle tip
Safety equipments required – high pressur
and noise
Change in chemistry of water affects the
erosion resistance of work material
16. Application of WJM
Aerospace
Automobiles
Cutting whispers
Glass and metals
Rapid hole drilling of titanium
Killing of pathogens in beverages and drips
18. Process parameters of ECM
Current density – 50 – 1500 A/in2
Directly proportional
Gap between work piece and tool – o.25 mm
Small gap results in high current densities
Type of electrolyte
Velocity of electricity flow -15-60 m/s
19. Electrolyte for different work piece
materials
S No Electrolyte Work piece materials
1 Sodium chloride (Na Cl), Potacium
chloride (KCl) , Sodium Nitrate
(NaNO3)
Steels, iron based alloys and
steel alloys with nickel and
cobalt base
2 Sodium chloride (Na Cl), Potassium
chloride (KCl) , Sodium hydroxide
(NaOH)
Aluminum and aluminum
alloys, copper and copper
based alloys
3 Sodium chloride (Na Cl), Sodium
Nitrate (NaNO3)
Gray cast iron
4 Sodium chloride (Na Cl), Potacium
chloride (KCl) ,
Titanium alloys
20. Advantages of ECM
Accurate shape with good surface finish
No tool wear, No burr
Capable to machine any hard material
No thermal effect on the work piece
Easily automated
21. Limitation of ECM
Suitable only for conductive materials
Inability to machine sharp interior edges and
corners
More floor space
High electrical power is consumed
Post machining and cleaning is must
Limited to mass production as set up cost is
high
22. Application of ECM
Tool and die making industries
Automotive
Aerospace
Power generation
Oil and Gas generation
Complex shapes
Deburring, grinding, honing, cutting – off
Die sinking, profiling, broachining,
24. Process parameters of LBM
Power density
1.5 x 102 -1.5 x 104 W/cm2 - for heating of
surface
1.5 x 104 -1.5 x 105 W/cm2 - for welding
1.5 x 106 -1.5 x 108 W/cm2 - cutting and drilling
Laser beam – work piece interaction time
25. Advantages of LBM
Any material with respect of hardness and
brittleness can be machined
Easily automated
Remove material in small amount
Force less machining
Allows thin and fragile parts to be easily cut
26. Limitations of LBM
Costlier
Low thermal efficiency
Low material removal rate
Limited to thin parts
High reflectivity material difficult to cut
Difficult to drill exact round holes
27. Application of LBM
Precision micro machining on materials like
steel, ceramic, glass, diamond, Graphite
Cutting, drilling
Welding
Marking scribing
Heat treatment of surfaces
29. Gas mixtures for PAM
S No Material to be cut Gas mixture
1 Aluminum and
Magnesium
Nitrogen, N itrogen – hydrogen
mixture, argon -hydrogen mixture
2 Stainless steel and Non
ferrous materials
N itrogen – hydrogen mixture,
argon -hydrogen mixture
3 Carbon and alloy steels,
cast iron
N itrogen – hydrogen mixture,
Compressed air
30. PAM Process parameter
Voltage and current
Torch-work distance
Gas flow rate
S No Material Thickness in
mm
Torch – work
distance
Current
1 Titanium 13
25
6
10
400
550
2 Copper/Nickel 13
25
6
10
400
550
3 Cast iron 16 6 400
31. Advantages of PAM
Hard and refractory materials can be
machined
Faster machining process
Less operator training
Process variables like type of gas, power,
cutting speed can be adjusted for each metal
type
32. Limitation of PAM
Metallurgical alterations in the work because
of high temperature and high velocity
Operators safety is difficult – investment
High equipment cost
35. Process parameter of EDM
Influence of current – direct
Influence of spark frequency- surface finish
Spark gap – 0.01-0.05 mm
36. Advantages of EDM
Extremely hard materials can be machined
with close tolerance
Thin and small sized work piece can be
machined
No distortion as no direct contact between
tool and work piece
Fine holes can be drilled
37. Limitations of EDM
Conductive materials only
Slow material removal rate
Inability to machine sharp corners
Specific power consumption is high
Overcut is formed due to side cut
Tool wear occurs during machining
38. Application of EDM
Aerospace
Mold making
Die casting to produce die cavities
Small deep holes
Narrow slots
Turbine blades
Re sharpening of cutting tools and
broachining
40. Advantages of EBM
Any materials can be machined
No tool wear problems
Heat can be concentrated on a particular spot
No physical or metallurgical damage to work
piece
41. Limitation of EBM
High investment
Skilled operator is required
Vacuum requirement tend to limit the work
piece size and production rate
Small and fine cut only
Low metal removal rate
High power consumption
Not suitable for producing perfect deep holes
42. Application of EBM
Micro –finishing of thin sections
Dies for wire drawing parts of electron
microscope
Fibers spinners
Injector nozzles for diesel engines