Non-traditional machining processes like EDM, USM, and WEDM are useful for machining hard materials and complex shapes with precision. EDM works by using electrical sparks to erode material from a part placed close to an electrode tool, allowing intricate shapes to be produced. USM uses an abrasive slurry and vibrating tool to cut materials. WEDM is similar to EDM but uses a continuously moving wire as the electrode. These non-traditional processes are more precise than traditional machines and can machine tough materials that would be difficult to cut otherwise.

1. ADVANCED MANUFACTURINGADVANCED MANUFACTURING
PROCESSPROCESS
Mr. KONAL SINGHMr. KONAL SINGH
Director and Founder of
ProBotiZ Group, NagpurProBotiZ Group, Nagpur
1(W) - Probotizgroup.com (M) - 8862098889, 9423632068 (E) - probotizinfo@gmail.com

2. SYLLABUS
-Need and importance of nontraditional machining processes, its
classifications
-Electrical discharge Machining.
Principle of working, Setup of EDM, Dielectric fluid,
tools(electrodes), Process parameters, Output
characteristics,Applications e.g. micro hole drilling, curve hole
drilling.
-Wire cut EDM - Principle of working, Setup of WEDM,
controlling Parameters, Applications.
-Laser Beam Machining.
Physical principle of Laser, Laser action in ruby rod,
Types of Lasers. Set-up for LBM. Characteristics,
controlling Parameters, Applications, Application Of
Laser Beam for Welding (LBW)
-Other non traditional machines such as ECM, AJM,
USM, LBM, PAM etc. Principle of working, Applications
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3. LEARNING OBJECTIVE
-In this chapter we are going to learn different types of
non traditional machining process.
- How traditional and non traditional machines differs.
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4. Why Nontraditional Processes?
-New Materials (1940’s)
Stronger
Tougher
Harder
-Applications
Cut tough materials
Finish complex surface geometry
Surface finish requirements
texture, fine, etc.
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5. Processes
-Mechanical
-Chemical
-Electrochemical
-Thermoelectric
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6. Mechanical
-Ultrasonic Machining - Cutting action is
accomplished with an abrasive slurry which is
driven by a tool vibrating at high frequency. The
tool is the exact shape of the desired shape to be
cut into the work.
-Applications
slots, blind holes, irregular shapes, and
through holes
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7. Mechanical
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8. Mechanical
Abrasive Water-Jet Cutting
-Similar to sandblasting
-Process utilizes a high velocity stream of water
mixed with an -abrasive as the cutting tool
-Forces the mixture through a nozzle with a hole
diameter of .0040” - .012”
-System pressures range from 30,000 - 50,000
psi
-Used to cut a variety of materials from wood to
tool steel
-Cutting rate - ¼” Alum. Plate - 150 in/min.
-One disadvantage to note
Tolerances typically (+/- .01”) 8

9. Mechanical
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10. Chemical
Chemical Milling
-Controlled etching process
-MRR about .001” cu/in per min ~ .045”
cu/in hour
-Process
Sample part is tested for erosion rate
Part to be “chem” machined is cleaned
Mask area you do not want to machine
Dip part in chemical solution hot
alkaline
Remove part
Clean part
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11. Chemical
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12. Electrochemical
-Basically the same
principle as plating
-Differences
Part is the anode (+) and
the tool is the cathode (-)
Metal is “pulled” away
from work
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13. Electrochemical
Advantages
-Hard to soft materials made of
conductive material can be
machined
-Cutting tool can be made from soft
material
-Low heat generated during
process
-No cutting forces
-Excellent surface finish
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14. Thermoelectric
Electrical Discharge Machining (EDM)
This process is like a mini-thunderstorm.
Flashes of lightning in rapid succession (500 -
5,000 sparks per second) erode material from
the part being machined.
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15. EDM
-Machining action forms a gap between the
part and the electrode (tool) which causes a
spark which removes the material
-Electrode is (+) and the part is (-)
-Electrodes can be made from
Brass
Copper
Graphite-
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16. EDM
-Cutting action takes place in a dielectric fluid
which helps to contain the spark and flush away
chips
-Metal removal rates (MRR) are low compared to
other process like milling
EDM, MRR= 1 cu/in to 15 cu/in per hr.
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17. EDM
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18. types of machines
EDM
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19. EDM
Applications
-Finish geometry for molds ( die sinking)
Ram
-Punch & dies for blanking, shearing, and
progressive die tooling
Wire
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20. SUMMARY
Non Traditional machines more useful for hard materials
and complex shapes can be produced easily.
These machines are more precise.
USM,EDM,WEDM are the examples of non traditional
machines.
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REFERENCE:
ADVANCED MANUFACTURING PROCESS:
MP by S.L Gawale