The document discusses conventional and non-conventional machining processes. It defines machining as the process of removing excess material from a workpiece to obtain the desired shape and size. Conventional machining uses hard, sharp cutting tools while non-conventional machining uses various energy sources like light, sound, magnetism, plasma, or electricity to remove material without contact between the tool and workpiece. The document goes on to classify and describe various non-conventional machining processes based on the type of energy they use and discusses factors to consider when selecting a machining process.
The document provides an overview of non-traditional machining (NTM) processes, including:
- The need for NTM processes due to limitations of conventional machining processes.
- A classification of NTM processes into mechanical, electrical, thermal, chemical, and hybrid categories.
- Descriptions of various NTM processes like EDM, LBM, ECM, discussing their operating parameters, material removal mechanisms, applications, advantages, and limitations.
- Comparisons of NTM processes in terms of suitable materials, achievable shapes, and process variants.
Broaching is a machining process that removes material in a single stroke using a broach tool with gradually rising teeth. It can machine internal and external surfaces and is well-suited for mass production. The appropriate broach type and broaching machine must be selected based on the workpiece material, size, and desired machining operation. Broaching provides high production rates, accuracy, and surface finish compared to other machining methods.
Electro-chemical grinding (ECG) is a process that uses both mechanical grinding and electrochemical removal to shape electrically conductive materials. In ECG, a negatively charged grinding wheel with abrasive particles contacts the positively charged workpiece in the presence of an electrolyte fluid. This sets up an electrochemical reaction that dissolves metal from the workpiece, with around 90% of material removed electrochemically and 10% by abrasion. ECG produces very smooth, burr-free surfaces with little heat, making it suitable for grinding fragile or heat-sensitive parts. Applications include shaping tungsten carbide cutting tools, sharpening needles, grinding turbine blades, and removing cracks from steel structures.
CNC machines and their components are discussed. CNC machining uses computer-controlled machine tools to precisely cut metal or other materials. Key components of a CNC system include the machine control unit, machine tool, driving system, feedback devices, and display unit. CNC machines offer advantages like higher accuracy, reduced lead times, and increased productivity compared to conventional machine tools. Common types of CNC machines are CNC lathes for turning cylindrical parts and machining centers for milling complex shapes.
Water jet machining is a non-traditional machining process that uses high-pressure water jets to cut soft materials without direct contact between the tool and workpiece. It involves pumping water into an intensifier to pressurize it up to 400 MPa before passing through a nozzle, where it gains tremendous kinetic energy and is able to cut the workpiece. Only soft materials can be cut using this eco-friendly process, which provides high precision cutting without heat damage and automatically cleans the surface.
This document discusses advanced machining processes, which utilize chemical, electrical, or high-energy beams to remove material as they are needed for difficult-to-machine materials or complex part geometries. It introduces various advanced processes like chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, and others. These processes allow machining of very hard materials, brittle materials, or parts that are too small, complex, or fragile for traditional machining techniques.
This document discusses various unconventional metal forming processes including high energy rate forming processes like explosive forming, magnetic forming, and electro hydraulic forming. It explains that these processes use large amounts of energy applied very quickly to deform metals. Some advantages are low die costs, easy maintenance of tolerances, and the ability to form difficult metals. The document also covers powder metallurgy and describes the production and applications of parts formed by this process.
Nanofinishing techniques have been developed to achieve surface finishes on the nanometer scale for applications in electronics, optics, and other industries. Some key nanofinishing processes include magnetic abrasive finishing, magnetorheological finishing, elastic emission machining, magnetic float polishing, and ion beam machining. These processes use techniques such as magnetic fields, abrasives, and ion bombardment to remove material from surfaces at the atomic level and achieve roughness in the range of 0.1 to 7.6 nm. Nanofinishing enables high-precision machining for applications such as medical devices and computer components.
The document provides an overview of non-traditional machining (NTM) processes, including:
- The need for NTM processes due to limitations of conventional machining processes.
- A classification of NTM processes into mechanical, electrical, thermal, chemical, and hybrid categories.
- Descriptions of various NTM processes like EDM, LBM, ECM, discussing their operating parameters, material removal mechanisms, applications, advantages, and limitations.
- Comparisons of NTM processes in terms of suitable materials, achievable shapes, and process variants.
Broaching is a machining process that removes material in a single stroke using a broach tool with gradually rising teeth. It can machine internal and external surfaces and is well-suited for mass production. The appropriate broach type and broaching machine must be selected based on the workpiece material, size, and desired machining operation. Broaching provides high production rates, accuracy, and surface finish compared to other machining methods.
Electro-chemical grinding (ECG) is a process that uses both mechanical grinding and electrochemical removal to shape electrically conductive materials. In ECG, a negatively charged grinding wheel with abrasive particles contacts the positively charged workpiece in the presence of an electrolyte fluid. This sets up an electrochemical reaction that dissolves metal from the workpiece, with around 90% of material removed electrochemically and 10% by abrasion. ECG produces very smooth, burr-free surfaces with little heat, making it suitable for grinding fragile or heat-sensitive parts. Applications include shaping tungsten carbide cutting tools, sharpening needles, grinding turbine blades, and removing cracks from steel structures.
CNC machines and their components are discussed. CNC machining uses computer-controlled machine tools to precisely cut metal or other materials. Key components of a CNC system include the machine control unit, machine tool, driving system, feedback devices, and display unit. CNC machines offer advantages like higher accuracy, reduced lead times, and increased productivity compared to conventional machine tools. Common types of CNC machines are CNC lathes for turning cylindrical parts and machining centers for milling complex shapes.
Water jet machining is a non-traditional machining process that uses high-pressure water jets to cut soft materials without direct contact between the tool and workpiece. It involves pumping water into an intensifier to pressurize it up to 400 MPa before passing through a nozzle, where it gains tremendous kinetic energy and is able to cut the workpiece. Only soft materials can be cut using this eco-friendly process, which provides high precision cutting without heat damage and automatically cleans the surface.
This document discusses advanced machining processes, which utilize chemical, electrical, or high-energy beams to remove material as they are needed for difficult-to-machine materials or complex part geometries. It introduces various advanced processes like chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, and others. These processes allow machining of very hard materials, brittle materials, or parts that are too small, complex, or fragile for traditional machining techniques.
This document discusses various unconventional metal forming processes including high energy rate forming processes like explosive forming, magnetic forming, and electro hydraulic forming. It explains that these processes use large amounts of energy applied very quickly to deform metals. Some advantages are low die costs, easy maintenance of tolerances, and the ability to form difficult metals. The document also covers powder metallurgy and describes the production and applications of parts formed by this process.
Nanofinishing techniques have been developed to achieve surface finishes on the nanometer scale for applications in electronics, optics, and other industries. Some key nanofinishing processes include magnetic abrasive finishing, magnetorheological finishing, elastic emission machining, magnetic float polishing, and ion beam machining. These processes use techniques such as magnetic fields, abrasives, and ion bombardment to remove material from surfaces at the atomic level and achieve roughness in the range of 0.1 to 7.6 nm. Nanofinishing enables high-precision machining for applications such as medical devices and computer components.
This document discusses various chemical and electrochemical machining processes. It describes chemical machining (CHM) which uses chemical etching to remove material from a workpiece. It involves using etchants and maskants to selectively remove material. Electrochemical machining (ECM) uses electrolysis principles to remove material from a workpiece submerged in an electrolyte solution. Variations include electrochemical grinding (ECG) which combines ECM with conventional grinding, and electrochemical honing (ECH) which uses non-conductive honing stones instead of a grinding wheel. These processes allow burr-free machining of complex shapes in hard and brittle materials with good surface finish and accuracy.
Plasma arc machining (PAM) is a process that uses ionized gas called plasma to remove material from a workpiece. A gas like nitrogen or hydrogen is heated to over 5000°C to become ionized plasma through an electric arc between an electrode and nozzle. This high-velocity plasma jet, which reaches temperatures over 11,000°C, is directed at the workpiece to melt and blow away the material. PAM can machine hard and brittle metals with good accuracy and is used to repair jet engine blades and cut profiles for applications like nuclear submarines and rocket motors.
Ultrasonic machining (USM) is a mechanical process that uses high frequency vibrations and an abrasive slurry to erode fine holes and cavities in hard or brittle materials. It is well-suited for machining brittle materials like glass, ceramics, and semiconductors. The material removal occurs through abrasion by the particles in the slurry, with no thermal or chemical changes to the workpiece. USM produces intricate shapes and profiles with good surface finish and integrity.
Micro machining and classification, and Electro chemical micro machining Elec...Mustafa Memon
A detail description of Micro machining, its classification
Electro chemical micro machining
Electric Discharge Micro machining
micro turning
their resource and application
By Muhammad Mustafa memon
BE Qucest larkana
ME MUET jamshoro
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
Electrical discharge machining (EDM) is a machining process that uses electrical sparks to remove material from a conductive workpiece. EDM works by producing sparks between an electrode tool and the workpiece submerged in a dielectric fluid, which erodes away tiny amounts of material. This allows EDM to machine very hard or brittle materials and create complex shapes regardless of material hardness. EDM provides a high-precision, burr-free finish and can machine thin walls and small features. Wire cut EDM is a similar process that uses a continuously moving thin wire as the electrode to cut intricate shapes.
UNIT 4 ADVANCED NANO FINISHING PROCESSES.pptxDineshKumar4165
Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, magneto rheological abrasive flow finishing their working principles, equipments, effect of process parameters, applications, advantages and limitations
This document provides an introduction to non-traditional machining processes. It defines non-traditional machining as processes that remove material using mechanical, thermal, electrical or chemical energy without using sharp cutting tools. The need for developing such processes is discussed, such as difficulties in machining new hard materials and complex geometries. A comparison is provided between traditional and non-traditional machining. The document outlines the classification and selection of various non-traditional machining processes and provides examples of when they may be preferable to traditional processes. It introduces several specific non-traditional machining techniques that will be covered in more depth later in the document.
machining operations and machine tools.Mihir Dixit
This document discusses various machining operations and machine tools used in manufacturing. It describes turning operations which use a single point cutting tool on a lathe to generate cylindrical parts. Milling operations employ a rotating cutting tool with multiple edges to cut planar surfaces. Other operations covered include drilling, boring, tapping and shaping. A variety of machine tools are discussed for performing these operations, including lathes, milling machines, drill presses, shapers and sawing machines. The document provides detailed explanations of each machining process along with example applications and illustrations.
Electro-chemical machining (ECM) is a non-traditional machining process that removes metal by dissolving it in an electrolyte with the use of electric current. In ECM, the workpiece acts as an anode and is dissolved by the electrolyte, while a tool with the desired shape acts as a cathode. Key factors in ECM include the electrolyte, which carries current and removes dissolved material, the tool and workpiece materials, and a DC power supply. ECM can machine hard metals and complex shapes with high accuracy and no tool wear. Common applications of ECM include machining turbine blades, aerospace components, and other difficult-to-machine metals.
RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSESravikumarmrk
This document discusses various hybrid and non-traditional machining processes. It describes electrochemical spark machining (ECSM) which is a hybrid process that combines ECM and EDM, allowing it to machine both conductive and non-conductive materials. The document outlines the principle, material removal mechanisms, and process parameters of ECSM. It also summarizes electric discharge diamond grinding (EDDG) and discusses its basic configuration, parameters, advantages, and applications. Finally, the document provides an overview of recent trends in micro-machining including various advanced mechanical and thermal micro-machining processes.
Abrasive jet machining (AJM) is a mechanical energy based unconventional machining process that uses a high velocity abrasive jet to remove material from hard metallic workpieces. It works by mixing compressed gas with abrasive particles in a mixing chamber and forcing the abrasive jet through a nozzle onto the workpiece. Key components include an abrasive jet, mixing chamber, compressor, nozzle, and various pressure and flow controls. AJM can be used to drill, bore, finish surfaces, cut, clean, deburr, etch, trim, and mill hard materials.
Water jet machining (WJM) is a similar non-traditional machining process that uses high pressure water instead of an
The document provides information about the Advanced Manufacturing Processes course taught by Dr. Manoj Kumar Pandey at BITS Pilani K. K. Birla Goa campus. It includes details about the instructor, office number, contact information, reference books, and course materials. The document then defines non-traditional manufacturing processes and provides examples of when these processes would be preferred over conventional machining. It discusses the need for non-traditional processes due to new materials, part geometries, and other factors. Finally, it provides overviews of several specific non-traditional processes including abrasive jet machining.
Selective Laser Melting versus Electron Beam MeltingCarsten Engel
This document summarizes research on additive manufacturing technologies for metal applications. It discusses Sirris, an organization that provides technology services to industry, and their expertise in additive manufacturing. Two key additive manufacturing technologies for metals are described - Electron Beam Melting (EBM) and Laser Beam Melting (LBM). EBM uses an electron beam to sinter metal powder in a vacuum environment, while LBM uses a laser beam under argon gas. Their differences in terms of process parameters, material properties, and advantages/disadvantages are summarized. Metallurgical analysis shows EBM produces a uniform fine-grained microstructure while LBM microstructure depends on build orientation. Mechanical properties are also compared between the two technologies.
This document discusses electron beam machining (EBM), a thermal energy-based machining process. EBM works by accelerating electrons in a vacuum and focusing them into a beam that strikes and vaporizes small amounts of workpiece material. Key components of an EBM system include an electron gun, focusing lens, and deflector coil. Process parameters like beam current and spot size are controlled. EBM allows for precise micro-machining of hard, brittle, and electrically conductive materials but has high equipment costs and a slow material removal rate. Applications include drilling small holes in parts for industries like aerospace, electronics, and diesel engines.
Water jet machining uses a high-pressure stream of water to cut materials. It is a cold cutting process that produces no heat-affected zones. The water jet travels at supersonic speeds and erodes material when the local pressure exceeds the material's strength. Key components include a hydraulic pump to pressurize water, an intensifier to further pressurize it, and a nozzle to direct the jet. It can cut a variety of materials and offers advantages over other cutting methods like reduced burrs, flexibility of cutting complex shapes, and not producing heat or fumes. However, it is not suitable for high-volume production.
This document discusses adaptive control systems for machining. It defines adaptive control as a feedback system that automatically adjusts machining variables like cutting speed and feed rate based on actual process conditions. The three main functions of adaptive control are identification, decision, and modification. Adaptive control systems are classified as adaptive control with optimization, which uses a performance index, or adaptive control with constraints, which maximizes variables within set limits. Benefits include increased production and tool life, while limitations include lack of reliable tool sensors and standardized interfaces with CNC units.
This document provides an overview of advanced machining processes, also known as unconventional or non-traditional machining. It begins with an introduction and outlines the course objectives to understand these processes and their advantages over conventional techniques. These processes are classified based on the type of energy used, including mechanical, electrical, chemical/electro-chemical, and thermal. Examples of specific processes are described within each category, such as abrasive jet machining, electrical discharge machining, electrochemical machining, and laser beam machining. Diagrams are provided to illustrate key principles and applications for several of the machining methods.
This document provides an introduction to nontraditional manufacturing processes (NTMPs). It discusses how NTMPs were developed as efficient alternatives to conventional machining to address its limitations for new materials and complex part geometries. The document outlines various NTMP categories including thermal, mechanical, electrochemical, and kinetic processes. It provides examples of applications for different NTMPs and highlights attributes like increased productivity, versatility, and reduced part rejection. The course objectives are defined as developing understanding of NTMP theories, characteristics, process variables, capabilities and limitations.
This document discusses various chemical and electrochemical machining processes. It describes chemical machining (CHM) which uses chemical etching to remove material from a workpiece. It involves using etchants and maskants to selectively remove material. Electrochemical machining (ECM) uses electrolysis principles to remove material from a workpiece submerged in an electrolyte solution. Variations include electrochemical grinding (ECG) which combines ECM with conventional grinding, and electrochemical honing (ECH) which uses non-conductive honing stones instead of a grinding wheel. These processes allow burr-free machining of complex shapes in hard and brittle materials with good surface finish and accuracy.
Plasma arc machining (PAM) is a process that uses ionized gas called plasma to remove material from a workpiece. A gas like nitrogen or hydrogen is heated to over 5000°C to become ionized plasma through an electric arc between an electrode and nozzle. This high-velocity plasma jet, which reaches temperatures over 11,000°C, is directed at the workpiece to melt and blow away the material. PAM can machine hard and brittle metals with good accuracy and is used to repair jet engine blades and cut profiles for applications like nuclear submarines and rocket motors.
Ultrasonic machining (USM) is a mechanical process that uses high frequency vibrations and an abrasive slurry to erode fine holes and cavities in hard or brittle materials. It is well-suited for machining brittle materials like glass, ceramics, and semiconductors. The material removal occurs through abrasion by the particles in the slurry, with no thermal or chemical changes to the workpiece. USM produces intricate shapes and profiles with good surface finish and integrity.
Micro machining and classification, and Electro chemical micro machining Elec...Mustafa Memon
A detail description of Micro machining, its classification
Electro chemical micro machining
Electric Discharge Micro machining
micro turning
their resource and application
By Muhammad Mustafa memon
BE Qucest larkana
ME MUET jamshoro
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
Electrical discharge machining (EDM) is a machining process that uses electrical sparks to remove material from a conductive workpiece. EDM works by producing sparks between an electrode tool and the workpiece submerged in a dielectric fluid, which erodes away tiny amounts of material. This allows EDM to machine very hard or brittle materials and create complex shapes regardless of material hardness. EDM provides a high-precision, burr-free finish and can machine thin walls and small features. Wire cut EDM is a similar process that uses a continuously moving thin wire as the electrode to cut intricate shapes.
UNIT 4 ADVANCED NANO FINISHING PROCESSES.pptxDineshKumar4165
Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, magneto rheological abrasive flow finishing their working principles, equipments, effect of process parameters, applications, advantages and limitations
This document provides an introduction to non-traditional machining processes. It defines non-traditional machining as processes that remove material using mechanical, thermal, electrical or chemical energy without using sharp cutting tools. The need for developing such processes is discussed, such as difficulties in machining new hard materials and complex geometries. A comparison is provided between traditional and non-traditional machining. The document outlines the classification and selection of various non-traditional machining processes and provides examples of when they may be preferable to traditional processes. It introduces several specific non-traditional machining techniques that will be covered in more depth later in the document.
machining operations and machine tools.Mihir Dixit
This document discusses various machining operations and machine tools used in manufacturing. It describes turning operations which use a single point cutting tool on a lathe to generate cylindrical parts. Milling operations employ a rotating cutting tool with multiple edges to cut planar surfaces. Other operations covered include drilling, boring, tapping and shaping. A variety of machine tools are discussed for performing these operations, including lathes, milling machines, drill presses, shapers and sawing machines. The document provides detailed explanations of each machining process along with example applications and illustrations.
Electro-chemical machining (ECM) is a non-traditional machining process that removes metal by dissolving it in an electrolyte with the use of electric current. In ECM, the workpiece acts as an anode and is dissolved by the electrolyte, while a tool with the desired shape acts as a cathode. Key factors in ECM include the electrolyte, which carries current and removes dissolved material, the tool and workpiece materials, and a DC power supply. ECM can machine hard metals and complex shapes with high accuracy and no tool wear. Common applications of ECM include machining turbine blades, aerospace components, and other difficult-to-machine metals.
RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSESravikumarmrk
This document discusses various hybrid and non-traditional machining processes. It describes electrochemical spark machining (ECSM) which is a hybrid process that combines ECM and EDM, allowing it to machine both conductive and non-conductive materials. The document outlines the principle, material removal mechanisms, and process parameters of ECSM. It also summarizes electric discharge diamond grinding (EDDG) and discusses its basic configuration, parameters, advantages, and applications. Finally, the document provides an overview of recent trends in micro-machining including various advanced mechanical and thermal micro-machining processes.
Abrasive jet machining (AJM) is a mechanical energy based unconventional machining process that uses a high velocity abrasive jet to remove material from hard metallic workpieces. It works by mixing compressed gas with abrasive particles in a mixing chamber and forcing the abrasive jet through a nozzle onto the workpiece. Key components include an abrasive jet, mixing chamber, compressor, nozzle, and various pressure and flow controls. AJM can be used to drill, bore, finish surfaces, cut, clean, deburr, etch, trim, and mill hard materials.
Water jet machining (WJM) is a similar non-traditional machining process that uses high pressure water instead of an
The document provides information about the Advanced Manufacturing Processes course taught by Dr. Manoj Kumar Pandey at BITS Pilani K. K. Birla Goa campus. It includes details about the instructor, office number, contact information, reference books, and course materials. The document then defines non-traditional manufacturing processes and provides examples of when these processes would be preferred over conventional machining. It discusses the need for non-traditional processes due to new materials, part geometries, and other factors. Finally, it provides overviews of several specific non-traditional processes including abrasive jet machining.
Selective Laser Melting versus Electron Beam MeltingCarsten Engel
This document summarizes research on additive manufacturing technologies for metal applications. It discusses Sirris, an organization that provides technology services to industry, and their expertise in additive manufacturing. Two key additive manufacturing technologies for metals are described - Electron Beam Melting (EBM) and Laser Beam Melting (LBM). EBM uses an electron beam to sinter metal powder in a vacuum environment, while LBM uses a laser beam under argon gas. Their differences in terms of process parameters, material properties, and advantages/disadvantages are summarized. Metallurgical analysis shows EBM produces a uniform fine-grained microstructure while LBM microstructure depends on build orientation. Mechanical properties are also compared between the two technologies.
This document discusses electron beam machining (EBM), a thermal energy-based machining process. EBM works by accelerating electrons in a vacuum and focusing them into a beam that strikes and vaporizes small amounts of workpiece material. Key components of an EBM system include an electron gun, focusing lens, and deflector coil. Process parameters like beam current and spot size are controlled. EBM allows for precise micro-machining of hard, brittle, and electrically conductive materials but has high equipment costs and a slow material removal rate. Applications include drilling small holes in parts for industries like aerospace, electronics, and diesel engines.
Water jet machining uses a high-pressure stream of water to cut materials. It is a cold cutting process that produces no heat-affected zones. The water jet travels at supersonic speeds and erodes material when the local pressure exceeds the material's strength. Key components include a hydraulic pump to pressurize water, an intensifier to further pressurize it, and a nozzle to direct the jet. It can cut a variety of materials and offers advantages over other cutting methods like reduced burrs, flexibility of cutting complex shapes, and not producing heat or fumes. However, it is not suitable for high-volume production.
This document discusses adaptive control systems for machining. It defines adaptive control as a feedback system that automatically adjusts machining variables like cutting speed and feed rate based on actual process conditions. The three main functions of adaptive control are identification, decision, and modification. Adaptive control systems are classified as adaptive control with optimization, which uses a performance index, or adaptive control with constraints, which maximizes variables within set limits. Benefits include increased production and tool life, while limitations include lack of reliable tool sensors and standardized interfaces with CNC units.
This document provides an overview of advanced machining processes, also known as unconventional or non-traditional machining. It begins with an introduction and outlines the course objectives to understand these processes and their advantages over conventional techniques. These processes are classified based on the type of energy used, including mechanical, electrical, chemical/electro-chemical, and thermal. Examples of specific processes are described within each category, such as abrasive jet machining, electrical discharge machining, electrochemical machining, and laser beam machining. Diagrams are provided to illustrate key principles and applications for several of the machining methods.
This document provides an introduction to nontraditional manufacturing processes (NTMPs). It discusses how NTMPs were developed as efficient alternatives to conventional machining to address its limitations for new materials and complex part geometries. The document outlines various NTMP categories including thermal, mechanical, electrochemical, and kinetic processes. It provides examples of applications for different NTMPs and highlights attributes like increased productivity, versatility, and reduced part rejection. The course objectives are defined as developing understanding of NTMP theories, characteristics, process variables, capabilities and limitations.
This document provides an overview of unconventional machining processes. It begins with an introduction to conventional machining processes and then discusses the need for unconventional processes to machine advanced materials. The document categorizes unconventional processes as mechanical, electrical, chemical/electrochemical, or thermal based. Specific unconventional processes like ultrasonic machining and abrasive water jet cutting are then described in more detail.
The document discusses non-conventional machining processes. It begins by distinguishing between conventional machining processes, which use hard cutting tools to remove material, and non-conventional processes, which use other energies like mechanical, thermal, electrical, or chemical. Non-conventional processes are then classified based on the type of energy used, including mechanical, electrochemical, electro-thermal, and chemical processes. Examples of specific non-conventional machining techniques are provided within each classification.
Non-traditional machining processes are used to manufacture complex precision parts. They use indirect energy like sparks, lasers, heat or chemicals instead of direct tool contact. This allows machining of hard materials with complex shapes. Some common non-traditional processes include electrical discharge machining (EDM), electrochemical machining (ECM), laser beam machining, and abrasive jet machining. These processes remove material using techniques like electrical sparks, electrolysis, focused laser beams or high pressure abrasive jets. Non-traditional machining provides benefits like high accuracy, improved surface finish, less tool wear and greater design flexibility compared to traditional machining.
This document provides an overview of mechanical energy based unconventional machining processes. It discusses abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). For each process, it describes the basic working principles, key components, process parameters that influence material removal rate, advantages, disadvantages, and applications. It also compares different types of transducers used in USM and discusses factors affecting the machining performance of USM.
The document discusses various unconventional machining processes. It covers mechanical energy based processes like abrasive jet machining, water jet machining and ultrasonic machining in Unit 1. Unit 2 discusses thermal and electrical energy based processes. Key processes covered are electrical discharge machining and electrochemical machining. Unit 3 focuses on chemical and electrochemical energy based processes like electrochemical machining. The document provides details on the working, parameters, advantages and applications of these various unconventional machining processes.
The document discusses various unconventional machining processes. It covers mechanical energy based processes like abrasive jet machining, water jet machining and ultrasonic machining in Unit 1. Unit 2 discusses thermal and electrical energy based processes. Key processes covered are electrical discharge machining and electrochemical machining. Unit 3 focuses on chemical and electrochemical energy based processes like electrochemical machining. The document provides details on the working, parameters, advantages and applications of these various unconventional machining processes.
Modern manufacturing has seen the development of harder materials that are difficult to machine using conventional methods. This has driven the creation of unconventional machining methods that use various forms of energy without physical contact between tool and workpiece. Some key unconventional methods are electrical discharge machining, electrochemical machining, laser beam machining, and abrasive jet machining. These methods allow machining of any material, produce less tool wear and residual stress, and enable intricate shaping. However, they are generally more costly and have limitations such as requiring electrically conductive materials. Overall, unconventional machining methods expand what is possible in modern manufacturing.
This document provides an overview of various nontraditional machining processes, including abrasive jet machining (AJM), water jet machining (WJM), ultrasonic machining (USM), electrochemical machining (ECM), and electrochemical grinding (ECG). It discusses the working principles, typical parameters, advantages, and applications of these processes. The key advantages of nontraditional machining noted are the ability to machine hard, brittle, or heat-sensitive materials without causing mechanical or thermal damage like in conventional machining.
This document provides an overview of nontraditional machining processes, including their history, advantages over conventional machining, and classifications. Key nontraditional processes discussed include abrasive jet machining (AJM), water jet machining (WJM), electrochemical machining (ECM), electric discharge machining (EDM), plasma arc machining (PAM), and ultrasonic machining (USM). AJM uses abrasive particles mixed with pressurized gas or water to erode material, while WJM relies on the kinetic energy of high pressure water. ECM, EDM, and PAM use electrochemical, electric spark, or thermal energy respectively to remove material. USM works by micro
NON CONVENTIONAL MACHINING PRESENTATIONKunal Chauhan
This document provides an overview of non-conventional machining processes including electron beam machining (EBM), laser beam machining (LBM), and ultrasonic machining (USM). EBM uses a focused beam of high velocity electrons to melt and evaporate material. LBM uses a high power laser beam capable of high power density to melt and evaporate material. USM uses a tool that vibrates at ultrasonic frequencies in an abrasive slurry to erode material away. Non-conventional machining processes allow machining of materials that are difficult to machine with conventional methods and provide benefits like higher accuracy, less heat impact, and ability to machine complex shapes.
This document discusses non-traditional machining (NTM) processes. It defines NTM as processes that cut material using mechanical, thermal, electrical, or chemical energy without sharp cutting tools. NTM can machine extremely hard, brittle, or complex materials. The document classifies NTM into mechanical, electrochemical, electro-thermal, and chemical processes. It provides details on electrical discharge machining (EDM) and abrasive jet machining (AJM) processes, including their working principles, advantages, and disadvantages.
This document provides information about an Unconventional Machining Processes course. It includes the course code, regulation, instructor details, course outcomes, modules, and learning outcomes. Specifically, it outlines Module I which provides an introduction to unconventional machining processes, including ultrasonic machining. It discusses the history, principles, setup, mechanisms, materials used, applications, and limitations of ultrasonic machining.
This document provides an introduction to electrical discharge machining (EDM). EDM is an unconventional machining process where material is removed by electric sparks between an electrode tool and conductive workpiece, with no direct contact between them. Key aspects of EDM covered include the construction of EDM machines, the role of dielectric fluids, factors that affect the material removal rate such as capacitance and spark parameters, and electrode tool materials and wear characteristics. Graphite, copper, and copper-tungsten are commonly used as tool materials in EDM due to properties like machinability and erosion resistance.
Non conventional machining process - me III - 116010319119Satish Patel
This document discusses non-conventional machining processes and abrasive water jet cutting. It classifies non-conventional processes into thermal and electro-thermal, mechanical, and chemical and electro-chemical processes. It then describes abrasive water jet cutting, where a high pressure water jet mixed with abrasive particles is used to cut materials. Advantages include the ability to cut hard and brittle materials without generating heat, while disadvantages include low material removal rates and abrasive particles embedding in the workpiece.
This seminar presentation discusses conventional and non-conventional machining processes. It begins by dividing manufacturing processes into primary and secondary processes and further dividing material removal processes into conventional and non-conventional machining. Common conventional processes are described as turning, milling, and grinding. Non-conventional processes are defined as using thermal, chemical, or electrical energy and examples provided include EDM, laser beam machining, and ultrasonic machining. The presentation then compares conventional and non-conventional machining, describing advantages of non-conventional such as better accuracy and surface finish for hard materials where conventional machining is difficult.
UNIT 3 CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES.pptxDineshKumar4165
This document provides information on chemical and electro-chemical machining processes. It discusses chemical machining where metal is removed through controlled chemical attack. Key aspects of chemical machining include cleaning, applying a maskant, dipping in a chemical solution, stirring and heating for uniform removal, and washing. Electro-chemical machining is also covered, operating on the principles of electrolysis to anodically dissolve metal. The document outlines the basic setup and process parameters for electro-chemical machining, grinding, honing and deburring and their applications in precision machining of difficult-to-cut materials.
The document discusses electrochemical machining (ECM). ECM is an unconventional machining process where material is removed from a workpiece made of an electrically conductive material via an electrochemical reaction. In ECM, the workpiece acts as an anode in an electrolyte solution, and a tool acts as a cathode. A direct current is passed between them, causing metal ions from the workpiece to dissolve into the electrolyte solution. ECM can machine complex shapes with high accuracy and no tool wear. It has the highest material removal rate of any unconventional machining process but requires expensive equipment and a conductive workpiece material.
This document provides information on chemical and electro-chemical machining processes. It discusses chemical machining which removes metal through controlled etching using a chemical solution. Electro-chemical machining (ECM) removes metal through anodic dissolution when a workpiece is made the anode in an electrolytic cell. Electro-chemical grinding (ECG) and honing (ECH) combine electrochemical effects with conventional grinding/honing, removing mostly by chemical action and some by mechanical action. Process parameters like current density, electrolyte composition and feed rate affect the material removal rate and surface finish. ECM, ECG and ECH allow burr-free machining of difficult-to-cut materials.
The document discusses information technology infrastructure and its key components. It describes hardware components like servers and networking equipment. It also covers software components like operating systems and middleware. Additionally, it outlines different types of infrastructure like traditional IT infrastructure, cloud infrastructure, converged infrastructure, and hyper-converged infrastructure. Finally, it discusses the importance of IT professionals and backup/recovery systems as part of the overall IT infrastructure framework.
The document discusses the application of management information systems (MIS) in manufacturing, services, and various business functions. It explains that MIS helps optimize inventory, streamline production, and manage supply chains in manufacturing. In services, MIS aids customer relationship management, scheduling, and financial processes. The document also summarizes key components of manufacturing MIS and various ways MIS supports functions like human resources, financial management, and decision-making.
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Laser beam machining uses a high-energy, monochromatic light beam to melt and vaporize material on a workpiece's surface. It can be used to cut, drill, weld and mark materials. The document discusses the key components of laser beam and electron beam machining equipment, including the ruby crystal, xenon flash tube, cooling system, and focusing lens. It also explains the processes of how laser beams and electron beams generate and focus intense heat to remove material through melting and vaporization. Advantages include machining any material and producing precise, force-less cuts, while disadvantages include higher costs and lower removal rates compared to other processes.
Electrical discharge machining (EDM) is a machining process that uses electrical sparks to erode material from a workpiece. In EDM, a tool electrode is moved close to the workpiece and an electric current is applied, causing sparks that melt and vaporize small amounts of material. The sparks occur in a dielectric fluid which flushes away removed material. Process parameters like spark frequency, current, and spark gap influence the accuracy and surface finish of EDM.
Electrochemical machining (ECM) is a non-traditional machining process that removes metal by applying a high electrical current between an electrolyte-filled gap of the tool and workpiece. During ECM, the workpiece acts as the anode and the tool acts as the cathode. As current is passed, metal ions from the workpiece dissolve into the electrolyte solution. The tool is shaped to produce the desired shape in the workpiece. Key factors that affect the ECM process include the current density, gap size between tool and workpiece, electrolyte composition and flow rate, and process parameters such as tool feed rate. ECM can machine hard materials and produce complex shapes with a burr-free
Ultrasonic machining is a mechanical material removal process that uses a tool vibrating at high frequency to remove material from a workpiece. Small abrasive particles in a slurry are driven at high velocity by the vibrating tool against the workpiece, fracturing the surface and removing material. It can machine hard and brittle materials like ceramics, glass, and carbides. The tool is fed into the workpiece as it vibrates at amplitudes of a few thousandths of an inch and a frequency of 20 kHz, machining a negative of the tool profile into the workpiece. Ultrasonic machining provides a safe, non-thermal process for precision machining of brittle materials.
Abrasive jet machining is a non-traditional machining process that uses a high-pressure jet of abrasive particles suspended in a carrier gas or liquid to erode material from the workpiece surface. Key aspects of the process include:
- Material is removed via erosion caused by abrasive particles impacting the workpiece surface at high velocity. Common abrasives used are aluminum oxide and silicon carbide.
- Process variables that influence the material removal rate and quality of surface finish include the carrier gas, abrasive type and size, abrasive flow rate and velocity, stand-off distance between nozzle and workpiece, and mixing ratio of abrasives to carrier gas.
- The equipment used consists
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Low power architecture of logic gates using adiabatic techniquesnooriasukmaningtyas
The growing significance of portable systems to limit power consumption in ultra-large-scale-integration chips of very high density, has recently led to rapid and inventive progresses in low-power design. The most effective technique is adiabatic logic circuit design in energy-efficient hardware. This paper presents two adiabatic approaches for the design of low power circuits, modified positive feedback adiabatic logic (modified PFAL) and the other is direct current diode based positive feedback adiabatic logic (DC-DB PFAL). Logic gates are the preliminary components in any digital circuit design. By improving the performance of basic gates, one can improvise the whole system performance. In this paper proposed circuit design of the low power architecture of OR/NOR, AND/NAND, and XOR/XNOR gates are presented using the said approaches and their results are analyzed for powerdissipation, delay, power-delay-product and rise time and compared with the other adiabatic techniques along with the conventional complementary metal oxide semiconductor (CMOS) designs reported in the literature. It has been found that the designs with DC-DB PFAL technique outperform with the percentage improvement of 65% for NOR gate and 7% for NAND gate and 34% for XNOR gate over the modified PFAL techniques at 10 MHz respectively.
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Adaptive synchronous sliding control for a robot manipulator based on neural ...IJECEIAES
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3. “It is the process of removing excess
material from the work piece to obtain the
desired shape and size”
Classification
1. Conventional (Traditional machining process)
2. Non Conventional(Non Traditional machining
process)
TSN, JSSATEB
4. Conventional Machining
• Conventional machining makes use of a hard,
and sharp cutting tool to shape materials.
• There are different types of machine designed to
hold and move the cutting too against a rigidly
held work piece materials or vice versa, to
remove excess material from the work piece.
• Eg: Lathes, Drilling machine, Grinding Machine
etc TSN, JSSATEB
5. Non Traditional Machining
• Non Traditional machining makes use of various
forms energy sources in order to remove excess
materials from the work piece.
• There are a variety of non traditional process
based on the forms of energy sources like Light(
Laser), Sound( Ultrasonic Process), Magnetism,
Plasma, Electrical sparks, Chemical Dissolution
…
TSN, JSSATEB
6. Cont..
“Machining process where tool and work
piece does not make contact with each other
but the required machining process is done”
“ Group of process that removes the excess
material by various technique involving
mechanical, thermal, electrical and chemical
energy but do not uses sharp cutting tool “
TSN, JSSATEB
7. Cont…
Process that removes excess of material by
various techniques involving mechanical,
thermal, electrical or chemical energy.
Ex: EDM, ECM, AJM, PAM,
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8. NTM characteristics
• Material removal may occur with chip formation
or even no chip formation may take place.
Eg: In AJM, chips are of microscopic size and in case of
ECM material removal occurs due to electrochemical
dissolution at atomic level.
• In NTM, there may not be a physical tool present.
Eg: In laser jet machining, machining is carried out by
laser beam. However in Electrochemical Machining there
is a physical tool that is very much required for
machining. TSN, JSSATEB
9. Cont..
• In NTM, the tool need not be harder than the work
piece material.
Eg: In EDM, copper is used as the tool material to
machine hardened steels.
• NTM processes do not necessarily use mechanical
energy for material removal.
• They use different energy domains to provide
machining.
Eg: USM, AJM, WJM mechanical energy is
used to machine material. EDM,LBM
used other source of engery
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10. Need for Non Traditional Machining
• The strength of steel alloys has increased five
folds due to continuous R & D effort.
• In aero-space requirement of High strength at
elevated temperature with light weight leads to
development and use of hard titanium alloys,
nimonic alloys, and other HSTR alloys.
TSN, JSSATEB
11. Cont…
• The ultimate tensile strength has been improved
by as much as 20 times.
• Development of cutting tools which has
hardness of 80 to 85 HRC which cannot be
machined economically in conventional
methods
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12. Cont..
• Technologically advanced industries like
aerospace, nuclear power, wafer fabrication,
automobiles has ever increasing use of High –
strength temperature resistant (HSTR) alloys and
It is no longer possible to use conventional process
to machine these alloys.
• Production and processing parts of complicated
shapes (in HSTR and other hard alloys) is
difficult, time consuming and uneconomical by
conventional methods of machining.
TSN, JSSATEB
13. Cont..
• Innovative geometric design of products and
components made of new exotic materials with
desired tolerance, surface finish cannot be
produced Economically by conventional
machining.
• If Work piece material are too brittle like glass,
ceramics, heat treated alloys, it is no longer
possible to use conventional process to machine
these alloys.
TSN, JSSATEB
14. Cont..
• Intricate shaped blind hole – Eg: square hole of 15
mm x15 mm with a depth of 30 mm with a
tolerance of 100 microns.
• Difficult to machine material – Eg: Inconel, Ti-
alloys or carbides, Ceramics, composites , HSTR
alloys etc.,
• Low Stress Grinding – Electrochemical Grinding
is preferred as compared to conventional grinding
• Deep hole with small hole diameter – Eg: ϕ 1.5
mm hole with l/d = 20
• Machining of composites
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15. Comparison
Conventional Process
• The cutting tool and
work piece are always
in physical contact with
relative motion with
each other, which
results in friction and
tool wear.
Non Conventional
Process
• There is no physical
contact between the tool
and work piece, In
some non traditional
process tool wear
exists.
TSN, JSSATEB
16. Conventional Process
• Material removal rate is
limited by mechanical
properties of work
material.
Non Conventional
Process
• NTM can machine hard
to cut materials like
titanium, ceramics,
nimonics, SS,
composites,
semiconducting
materials
TSN, JSSATEB
17. Cont..
Conventional Process
• Relative motion
between the tool and
work is typically rotary
or reciprocating. Thus
the shape of work is
limited to circular or
flat shapes.
• In spite of CNC
systems, production of
3D surfaces is still a
Non Conventional
Process
• Many NTM are capable
of producing complex
3D shapes and cavities
TSN, JSSATEB
18. Cont..
Conventional Process
• Machining of small
cavities, slits , blind
holes or through holes
are difficult
Non Conventional
Process
• Machining of small
cavities, slits and
Production of non-
circular, micro sized,
large aspect ratio, shall
entry angle holes are
easy using NTM
TSN, JSSATEB
19. Cont..
Conventional Process
• Use relatively simple
and inexpensive
machinery and readily
available cutting tools
Non Conventional
Process
• Non traditional
processes requires
expensive tools and
equipment as well as
skilled labour, which
increase the production
cost significantly
TSN, JSSATEB
20. Cont..
Conventional Process
• Capital cost and
maintenance cost is low
• Traditional processes are
well established and
process is well
understood
• Conventional process
mostly uses mechanical
energy
Non Conventional Process
• Capital cost and
maintenance cost is high
• Mechanics of removal of
Material in some NTM
process are still under
research
• Most NTM uses energy
in direct form Eg: laser,
Electron beam in its
direct forms are used in
LBM & EBM
TSN, JSSATEB
21. Cont..
Conventional Process
• Surface finish and
tolerances are limited
by machining
inaccuracies
• High metal removal
rate.
Non Conventional
Process
• High surface finish(up
to 0.1 micron) and
tolerances (25
Microns)can be
achieved
• Low material removal
rate.
TSN, JSSATEB
22. Classification of NTM processes
Based on the nature of energy used for material
removal.
• Mechanical Processes
• Electrochemical Processes
• Electro-Thermal Processes
• Chemical Processes
TSN, JSSATEB
27. I. Mechanical Energy Processes
• Material removal is due to the application of
mechanical energy in the form of high frequency
vibrations or kinetic energy.
• Erosion of work material by a high velocity
stream of abrasives or fluid (or both) is the
typical form of mechanical action
• Ultrasonic machining
• Water jet cutting
• Abrasive water jet cutting
• Abrasive jet machining
TSN, JSSATEB
28. II. Electrochemical Machining Processes
• Electrical energy is used in combination with
chemical reactions, to remove material
• Reverse of electroplating
• Work material must be a conductor
–Electrochemical machining (ECM)
–Electrochemical deburring (ECD)
–Electrochemical grinding (ECG)
TSN, JSSATEB
29. III. Thermal Energy Processes
• The material is removed through the controlled,
localized heating of the work piece. It result into
material removal by melting and evaporation.
• Thermal energy is applied to small portion of work
surface, causing that portion to be removed by
fusion and/or vaporization
- EDM, Wire EDM
- EBM
- Laser beam machining
- Plasma arc machining
TSN, JSSATEB
30. IV. Chemical Machining (CHM)
Material removal through contact with a strong
chemical etchant.
Chemical etchants selectively remove material from
portions of work part, while other portions are
protected by a mask
–Chemical milling
–Chemical blanking
–Chemical engraving
–Photochemical machining
TSN, JSSATEB
31. Selection Of Process
To make efficient use of modern machining process,
it is necessary to know the exact nature of the
machining process
The correct selection of the NTM methods must be
based on the following aspects.
i) Physical parameters of the process
ii) Shape to be machined
iii) Process capability
iv) Economics of the processes
TSN, JSSATEB
32. Physical parameters of the process
• PAM and ECM require high power for fast
machining.
• EBM and LBM require high voltages and require
careful handling of equipment.
• EDM and USM require medium power .
• EBM can be used in vacuum and PAM uses oxygen
and hydrogen gas.
TSN, JSSATEB
34. Shape to be machined
The different shapes can be machined by NTM.
• EBM and LBM are used for micro drilling and
cutting.
• USM and EDM are useful for cavity sinking and
standard hole drilling.
• ECM is useful for fine hole drilling and contour
machining.
• PAM can be used for cutting and AJM is useful
for shallow pocketing
TSN, JSSATEB
36. Process capability
• EDM which achieves higher accuracy, has the
lowest specific power requirement.
• ECM can machine faster and has a low thermal
surface damage depth.
• USM and AJM have different material removal rates
combined with high tool wear and are used non
metal cutting.
• LBM and EBM are, due to their high penetration
depth, can be used for micro drilling, sheet cutting
and welding.
• CHM is used for manufacture of PCM and other
shallow components. TSN, JSSATEB
39. Advantages NTM
1. Difficult to machine the materials in
conventional machining, can be machined with
non conventional process.
2. Machining of materials for the complex shapes
is possible with non conventional process.
3. Economical for mass production for long
duration.
4. High strength, high hardness and heat resisting
materials can be machined with non
conventional process.
TSN, JSSATEB
40. Cont…
5. High accuracy and surface finish
6. Material removed without mechanical contact with the
work piece (ECM,EDM,LBM,CHM).
7. Material removal rate is independent of work piece
hardness (ECM,LBM,EDM)
8.Cutting forces are independent of work piece
hardness.(ECM,LBM,EDM,CHM)
9. Tool material need not be harder than the work piece
material.(ECM,LBM,EDM,CHM,USM)
TSN, JSSATEB
41. Cont…
10.Tool wear is not a problem (ECM,LBM,CHM)
11.Ability to machine any material. (LBM)
12. Burr-free machining (ECM,EDM,CHM)
13. Stress- free machining. (ECM,ECG,CHM)
14.Uniform material removal over the entire area
simultaneously.(ECM,CHM)
15.Superior surface integrity possible
(ECM,CHM,ECG)
TSN, JSSATEB
42. Cont…
16. Intricate shaped and fragile materials can be
machined.(USM)
17. Finely focused micro machining
18.Micro- hole drilling at shallow entrance angles
possible.(EDM,ECM,LBM,EBM)
19. Easy compatibility with numerical control and
mini- computer controls.(ECM,EDM,LBM,EBM)
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43. Limitations:
1. Work piece and tool must be electrically
conductive (e.g. EDM,ECM)
2. Depth of cut is limited(e.g. LBM)
3. Recast or heat affected zones(HAZ) of surfaces
produced may be troublesome(e.g.
EDM,LBM,EBM)
TSN, JSSATEB
44. Cont…
4. Compatibility of the process with the metallurgical
state of the work piece materials can be studied
before using a particular non-traditional
machining process for production work.
5. There may be taper in the sidewalls of holes or
cavities(e.g. EDM,LBM)
*Most of these limitations can be overcome and
controlled, so that the advantages can be obtained
with good product quality assurance.
TSN, JSSATEB
45. Applications
USM:
• Drilling and machining of cavities / holes in
conductive and non-conductive materials like
glass and ceramics etc.
• Threading of various glass and ceramic materials.
• Hard materials and precious stones such as
synthetic ruby for the preparation of jewels to
watches and timer are successfully machined by
this method.
TSN, JSSATEB
46. AJM
• Abrasive water jet cutting is highly used in
aerospace, automotive and electronics industries
(PCB cutting).
• In aerospace industries, parts such as titanium
bodies for military aircrafts, engine components
(aluminium, titanium, heat resistant alloys),
aluminium body parts and interior cabin parts are
made using abrasive water jet cutting.
TSN, JSSATEB
47. Cont…
• In automotive industries, parts like interior trim
(head liners, trunk liners, door panels) and fiber
glass body components and bumpers are made by
this process.
• Similarly, in electronics industries, circuit boards
and cable stripping are made by abrasive water jet
cutting.
TSN, JSSATEB
48. LBM
• Laser beam machining is used to perform
precision micro- machining on all materials
such as steel, ceramic, glass, diamond, graphite
etc.
• It is used for cutting, drilling, welding of
materials, marking, scribing, heat treating of
surfaces and selectively clad materials.
TSN, JSSATEB
50. EBM
• EBM is more popular in industries like aerospace,
insulation, food processing, chemical, clothing,
etc.
• It is very useful in those cases where number of
holes (simple as well as complex shaped) required
in a work piece may range from hundreds to
thousands (perforation of sheets, etc).
TSN, JSSATEB
51. Cont…
• This Process is also used for drilling thousands of
holes (diameter < 1.00 mm) in very thin plates
used for turbine engine combustion domes.
TSN, JSSATEB
55. EDM
• Useful in machining of small holes, orifices,
slots in diesel fuel injection nozzles, airbrake
valves and aircraft engines etc.
• Blind cavities and narrow slots in dies,
minimum diameter hole can be produced.
• Mold making
TSN, JSSATEB
57. CM
• Aviation Industries
• Printed Circuit Boards
• Jewellery
• Turbine Engines
• Pressure Vessel Bulkheads
• Chemical Milling => Production Of Blind
Holes, Pockets, Channels
TSN, JSSATEB
58. Questions
1.What is non-traditional machining/
unconventional machining/ modern machining
technique. How are they classified.
2.Differentiate between conventional (traditional)
and unconventional (non-traditional) or modern
machining processes. June/July 2016, June/July
2014, June/July 2013, Dec 2011
3.What are the applications of non-traditional
machining methods.
4. What are the advantages and disadvantages of
non-traditional machining.
TSN, JSSATEB
59. Cont…
5.Classify non-traditional machining processes
based on nature of energy employed in
machining.
6. Write a note on the source of energy harnessed
and mechanism of material removal in non-
traditional machining. June/July 2011
7. Explain the need for development of non-
traditional machining. June/July 2011
TSN, JSSATEB
60. Cont…
8. Classify the modern machining processes. Dec
2011)
9. Explain the principle of modern machining process.
10.What are the factors to be considered while
selecting a process? Dec 2011
11.Explain the need to develop modern machining
processes. Dec 2012
12.Explain parameter to select to employ the new
machining methods. Dec 2012
13.Give the broad classification of non-traditional
machining processes. Dec 2012)
TSN, JSSATEB
61. Cont…
14.Justify the need of unconventional
manufacturing process in today’s industries.
June/July 2013
15.What are the basic factors upon which the
unconventional manufacturing processes are
classified? Explain. June/July 2013
16.Explain how the non-traditional machining
processes are classified. June/July 2014
17.List the unconventional machining processes
under mechanical energy thermal and chemical
energy category. Dec 2014, Jan2015
TSN, JSSATEB
62. Cont…
18. Differentiate between conventional (traditional)
and non-traditional machining processes with
examples. Dec 2014,Jan 2015)
19.Make a comparison between traditional and non-
traditional machining process in terms of cost,
application, scope, machine time and limitations.
Dec 2014, Jan 2015
20. List and explain the various factors to be
considered for selection of machining processes.
June/July 2015
TSN, JSSATEB
63. Cont…
21.Classify various non-traditional machining
process based on energy source used with giving
suitable examples. June/July 2015
22. Based on the various parameters of machining,
compare the conventional and non-conventional
machining processes. June/July 2015
23.How modern machining processes are
classified? June/July 2016
TSN, JSSATEB
64. Cont…
24.What are the essential physical process
parameters for an efficient use of modern
machining processes ? June/July 2016
25.Why Non-traditional machining (NTM)
processes are selected for manufacturing?
June/July 2016
TSN, JSSATEB