This document discusses non-conventional machining processes. It introduces abrasive jet machining and ultrasonic machining. Abrasive jet machining uses abrasives propelled by high-velocity gas to erode material from hard or heat-sensitive workpieces. Ultrasonic machining involves a vibrating tool that oscillates at ultrasonic frequencies to remove material from the workpiece with help from an abrasive slurry. Both processes allow machining hard materials with less heat and damage compared to conventional processes. They are often used for intricate shapes or specific edge shapes due to their flexibility and ability to machine difficult materials.

1. NON-CONVENTIONAL
MACHINING PROCESS
By
MOHD JALEEL UDDIN
Roll.No:160411736105
MECHANICAL-B

2. CONTENTS
•INTRODUCTION AND IMPORTANCE
•DEVELOPMENT
•APPLICATION
•CLASSIFICATION OF NCM
•ABRASIVE JET MACHINING
•ULTRASONIC MACHINING
•REFERENCES

3. INTRODUCTION AND IMPORTANCE
•Hard and brittle materials like tungsten carbide, high
speed steels are machined with the help of
conventional machining processes, either the tool
undergoes extreme wear (while machining hard work
piece) or the work piece material is damaged (while
machining brittle work piece).
•To overcome all these drawbacks, we use
unconventional machining processes to machine hard
and brittle materials. We also use unconventional
machining processes to machine soft materials, in
order to get better dimensional accuracy.

4. DEVELOPEMENT
 Development of harder and difficult to
machine materials such as hastalloy, nitra
alloy and many other HSTR alloys.
 Used in aerospace industry, nuclear
engineering and other industries owing to
their high strength to weight ratio, hardness
and heat resisting quality.

5. COMPONENTS MADE BY NCM

6. The broad classification is
given as follows:
 Thus classification of NCM processes is
carried out depending on the nature of
energy used for material removal.
 Mechanical Processes
◦ ⎯ Abrasive Jet Machining (AJM)
◦ ⎯ Ultrasonic Machining (USM)
 Electrochemical Processes
◦ ⎯ Electrochemical Machining (ECM)
◦ ⎯ Electro Chemical Grinding (ECG)
◦ ⎯ Electro Jet Drilling (EJD)

7.  Electro-Thermal Processes
◦ ⎯ Electro-discharge machining (EDM)
◦ ⎯ Laser Beam Machining (LBM)
◦ ⎯ Electron Beam Machining (EBM)
 Chemical Processes
◦ ⎯ Chemical Milling (CHM)
◦ ⎯ Photochemical Milling (PCM) etc.

8. Abrasive Jet Machining
•Abrasive Jet Machining
(AJM) is an abrasive
blasting machining process that
uses abrasives propelled by a
high velocity gas to erode
material from the work piece.
• Common uses include cutting
heat-sensitive, brittle, thin, or
hard materials. Specifically it is
used to cut intricate shapes or
form specific edge shapes.

9. PROCESS
 Material is removed by fine abrasive particles, usually
about 0.001 in (0.025 mm) in diameter, driven by a high
velocity fluid stream; common gases are air or inert gases.
Pressures for the gas range from 25 to 130 psig (170–
900 kPa) and speeds can be as high as 300 m/s.
 AJM machines are usually self-contained bench-top units.
First it compresses the gas and then mixes it with the
abrasive in a mixing chamber. The gas passes through a
convergent-divergent nozzle before entering the mixing
chamber, and then exits through a convergent nozzle.

10. MERITS AND DEMERITS
MERITS :
The main advantages are its flexibility, low heat production,
and ability to machine hard and brittle materials. Its
flexibility owes from its ability to use hoses to transport the
gas and abrasive to any part of the work piece.
DEMERITS :
One of the main disadvantages is its slow material removal
rate for this reason it is usually used as finishing process.
Another disadvantage is that the process produces a
tapered cut.

11. Ultrasonic Machining (USM)
Ultrasonic machining, also
known as ultrasonic impact
grinding, is a machining
operation in which a vibrating
tool oscillates
at ultrasonic frequencies is used
to remove material from the
work piece, aided by
an abrasive slurry that flows
freely between the work piece
and the tool.
The tool never contacts the work
piece and as a result
the grinding pressure is rarely
more than 2 pounds.

12. PROCESS
The tool that does the cutting is made of a softer material
than the work piece. As the tool vibrates, it pushes down
on the abrasive slurry, a liquid containing abrasive grains,
until the grains impact the work piece. Under the impact of
the abrasive particles its surface abrades, while the softer
tool material simply deforms slightly.
Machine time depends upon the frequency at which the
tool is vibrating, the grain size and hardness and the
viscosity of the slurry fluid. The less viscous the slurry
fluid, the faster it can carry away used abrasive.

13. MERITS AND DEMERITS
MERITS :
•Virtually any hard material can be machined
•Little heat is produced
• The holes cut are not just circular shapes but can be any
shape
•Good surface finish and higher structural integrity is obtained
DEMERITS :
•It has low material removal rate (3-15mm^3/min).
•Tool wear rate is fast.
•Machining area and depth are restraint.

14. REFERENCES
•Metal cutting and machine tool by B.L Juneja and Sekhon.
•Metal cutting by PN Rao.
•http://en.wikipedia.org/wiki/Abrasive_jet_machining
•http://en.wikipedia.org/wiki/Ultrasonic_machining

15. THANK YOU