Ucmp

1. INTRODUCTION
TO
UNCONVENTIONAL
MACHINING PROCESSES

2. CONTENTS
 History and Development.
 Conventional Machining Processes
 Limitations Of Conventional Processes
 Classification Of Unconventional Manufacturing
Processes
 Unconventional Machining Processes
 Unconventional Forming Processes
 Classification of Unconventional machining processes
 Method of Machining Suitable for Different Materials
 Process selection parameters
 Advantages & limitations of Unconventional machining

3. Conventional machining
process
 Metal is removed – Tool harder than work
piece & subjected to Wear.
 Direct contact – Tool and work piece.
 Compression – shear chip formation.

4. Limitations of Conventional
machining
 Metal is removed by chip formation which is
expensive and difficult process.
 Chips produced during this process are unwanted
by products.
 Removal of these chips and their disposal and
recycling is a very tedious procedure, involving
energy and money.
 Very large cutting forces.
 Greater amount of heat generated resulting in
undesirable deformation and residual stresses.
 Delicate components cannot be produced – semi
conductor.

5. Unconventional manufacturing
processes
 Unconventional manufacturing processes can
be divided into the following categories:
 Unconventional machining processes(UCMP) or
Non- Traditional machining processes.
 Unconventional forming processes.

6. Unconventional manufacturing
processes
 Unconventional machining processes(UCMP)
or Non- Traditional machining processes.
 No traditional tool for metal removal.
 Utilises some form of energy for metal machining.
 No direct physical contact between the tool and
work piece.
 Tool material need not to be harder than work
piece material.

7. Unconventional manufacturing
processes
 Unconventional forming processes
 In this metals are formed through the release and
application of large amounts of energy in a very
short time interval.

8. Need for unconventional
machining
 Technological advanced industries requirement for
HSTR (High strength temperature resistant
material).
 Material to high strength to weight ratio.
 Productivity is not be hampered because of high
strength, hardness, toughness and other diverse
property materials.
 Economic cutting speed.
 Production of complex shaped products.
 Better surface finish and tolerances, high
production rates.

9. Classification of UCMP
Medium of transfer of energies.
High voltage
particles Electrolyte Electron Hot gases
Source of energy required for material removal
Hydrostatic
pressure
High current
density
High voltage
Ionised
material
Based on mechanism involved in the process
Erosion Ionic dissolution vaporisation
Based on type of energy required to shape the material
Thermal Electrical
Electro
chemical
Chemical Mechanical

10. Classification of UCMP – Energy
Methods
 Thermal Energy Methods.
 Laser Beam, plasma arc, Electron Beam, Ion Beam
 Electrical Energy Methods.
 Electro discharge Machining, wire cut electrical
discharge machining
 Electro chemical Energy Methods.
 Electro chemical machining, Electro chemical grinding,
electro chemical honing, electrical chemical deburring.
 Chemical Energy Methods.
 Chemical machining.
 Mechanical Energy Methods.
 Ultrasonic machining, abrasive jet machining, water jet
machining.

11. Method of Machining Suitable
for Different Materials
Sl.N
o
Material Method of Machining
1 Non – Metals like
ceramics, plastics, glass
USM, AJM, EBM, LBM
2 Refractories USM, AJM, EDM, EBM
3 Titanium EDM
4 Super alloys AJM, ECM, EDM, PAM
5 Steel ECM, CHM, EDM,
PAM

12. Process selection
 The following point must be considered for
the selection of the unconventional
machining processes:
Physical parameters
Shapes to be machined
Process capability or machining
characteristics
Economic consideration.

13. Process selection - Physical
Parameters

14. Process selection – Shapes to be
machined

15. Process selection – Process
capability
 The machining
characteristics can be
analyzed with respect to
:
 Metal removal rate
obtained
 Tolerance maintained
 Surface finish obtained
 Depth of surface
damage
 Power required for

16. Process selection – Process
economy
 The economics
of various
processes are
analyzed by
considering the
following points:
 Capital cost
 Tooling cost
 Power
requirement
 Metal removal
rate efficiency

17. Advantages and limitations
 Advantages
 It increases productivity
 It reduces no. of rejected components
 Close tolerance is possible
 Tool need not to be harder than work piece
 Harder material can be machined.
 The machined surface do not have any residual
stresses.
 Limitations
 Expensive
 Metal removal rate is low
 AJM, CHM, PAM, EBM are not commercially
economical processes.