This document discusses various non-traditional machining processes. It begins by explaining that non-traditional machining is used when workpiece materials are too hard or complex shapes are required. It then classifies non-traditional machining into three categories: mechanical energy processes like ultrasonic machining; chemical/electrochemical processes like electrochemical machining; and thermal/electrothermal processes like laser beam machining. For each process, it provides a brief overview and discusses applications and key process parameters.

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2. Introduction
 Machining is a process of removing excess material
from the work piece to obtain the desired shape and size.
 The process is classified into two types:
i. Conventional or Traditional machining
 mechanical, abrasive.
ii. Non conventional or Non traditional machining
 electrical, chemical.
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3. Why Non-traditional Machining
 Workpiece material is too hard, strong, or tough.
 Part shape is very complex with internal or external
profiles or small holes.
 Requirements for surface finish and tolerances are
very high.
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4. Classification of Non-Traditional
Machining Process
1. Mechanical energy
 Ultrasonic Machining (USM)
 Water Jet Machining (WJM)
 Abrasive Jet Machining (AJM)
2. Chemical or Electrochemical energy
 Electro Chemical Machining (ECM)
 Electro Chemical Grinding (ECG)
 Electro Chemical Honing (ECH)
 Electro Chemical Deburring (ECD)
 Chemical Machining (CM)
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5. Cont.,
3. Thermal or electrothermal energy
 Laser Beam Machining (LBM)
 Plasma Arc Machining (PAM)
 Electrical Discharge Machining (EDM)
 Electron Beam Machining (EBM)
 Ion Beam Machining. (IBM)
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6. Ultrasonic Machining (USM)
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Cont.,

8. USM Parts
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9. Applications of USM
 Hard, brittle work materials such as ceramics, glass,
and carbides, precious stones, and hardened steels.
 Also successful on certain metals, such as stainless
steel and titanium
 Shapes include non-round holes, holes along a
curved axis
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10. Process parameter of USM
 Amplitude and frequency of vibrations of the tool
 Slurry
 Tool material
 Type of abrasive
 Abrasive size
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11. Abrasive Jet Machining (AJM)
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12. Cont.,
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13. Applications of AJM
 Normally used as a finishing process rather than
cutting process
 Applications: deburring, trimming and cleaning, and
polishing
 Work materials: thin flat stock of hard, brittle materials
(e.g., glass, silicon, mica, ceramics)
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14. Process parameter of AJM
 Abrasive flow rate and velocity
 Nozzle tip distance (NTD)
 Abrasive grain size
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15. Water Jet Machining (WJM)
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16. Cont.,
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17. WJM Parts
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18. Applications of WJM
 Used in mining, aerospace.
 Cutting thin details in stone, glass and metals.
 Drilling of titanium materials.
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19. Process parameter of WJM
 Pressure of water
 Nozzle diameter
 Stand-off distance
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20. Electrochemical Machining
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Fig: ECM equipment

22. Applications of ECM
 Used in tool & die making industries, automotive,
aerospace, power generation, and oil & gas industries.
 Facing & turning complex 3D surfaces, deburring,
grinding, honing, trepanning, broaching, multiple hole
drilling etc.
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23. Process parameter of ECM
 Current density
 Gap between workpiece and tool
 Type of electrolyte
 Velocity of electrolyte flow
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24. Types of electrolyte
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25. Laser Beam machining (LBM)
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26. Application of LBM
 LBM is used to perform precision micro-machining on
all materials such as steel, ceramic, glass, diamond,
graphite etc.
 It is used for cutting, drilling, marking, scribing etc.
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27. Process parameter of LBM
 Power density
 Without melting power densities 1.5×102 to 1.5×104 W/cm2
 If melting (welding or cladding) power densities 1.5×104 to
1.5×105 W/cm2
 Cutting and drilling - power densities 1.5×106 to 1.5×108
W/cm2
 Laser beam-workpiece interaction time
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28. Plasma Arc machining (PAM)
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29. Materials and gas mixture
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30. Application of PAM
 Manufacturers of transportation and agricultural
equipments, aircraft components etc.
 Used in sawing, cutting, drilling, machining and
punching.
 Also used in the heating, ventilating, air conditioning
industries to cut complex work.
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31. Process parameter of PAM
 Voltage and current
 Torch-work distance
 Gas flow rate
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32. Cont.,
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33. Electrical Discharge Machining (EDM)
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Di-electric
liquid

34. Enlarged view of metal removal
mechanism
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35. Electron Beam Machining (EBM)
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