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.

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)

4. Ultrasonic Machining (USM)

5. Ultrasonic Machining (USM)

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

8. Abrasive Jet Machining (AJM)

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

11. Application
 Glass quartz Semiconductor materials mica
 Drilling holes, cutting slots, deburring,
trimming

12. Water Jet Machining (WJM)

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

17. Electrochemical Machining (ECM)

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,

23. Laser Beam Machining (LBM)

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

28. Plasma Arc Machining (PAM)

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

33. Application PAM
 Transportation , Agricultural equipments
 Heavy machinery
 Aircraft components
 Sawing ,Milling
 Drilling
 Punching, cutting

34. Electrical Discharge Machining (EDM)

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

39. Electronic Beam Machining (EBM)

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