This document discusses various unconventional machining processes, including abrasive jet machining (AJM), water jet machining (WJM), and ultrasonic machining (USM). It outlines the key parameters that affect the material removal rate for each process, such as standoff distance, nozzle pressure, abrasive size, and vibration amplitude. The document also provides diagrams of typical system setups for AJM, WJM, and USM.

1. ME 8073 Unconventional
Machining Process
UNIT-I
INTRODUCTION AND MECHANICAL
ENERGY BASED PROCESSES

3. What is Conventional Machining Process?
• Conventional Machining process- Metal is removed by using some
sort of tool which is harder than work piece which is harder than the
work piece and it is subjected to wear and tear.
• Demerits-
1. Metal is removed by chip formation process and it is expensive and
difficult process.
2. Chips produced during this process is by-products.
3. Removal of these chips and their disposal and recycling is very
tedious procedure involving energy.

4. What is Unconventional Machining process?
• A unconventional machining process can be defined as a material
removal process in which no direct contact between tool and work
piece occurs.
• In this type of Machining process, a form of energy is used to remove
unwanted materials from a given work piece.

5. Types of Unconventional Manufacturing
Process
• There are namely two types of Process as they are-
1. Unconventional Machining Process.
2. Unconventional Forming Process.

29. Abrasive Machining Setup
• Gas Propulsion System.
• Abrasive Feeder.
• Machining Chamber.
• AJM Nozzle.
• Abrasives.

32. Parametric Analysis
• Important Parameter that affects the material removal rate during
AJM are .
1. Stand of Distance.
2. NTD or Nozzle tip Distance.
3. Types and Size of Abrasive particles.
4. Flow rate of abrasives,
5. Gas Pressure.
6. Work material and Feed rate.

33. Mass Flow Rate

34. Abrasive Grain Size

35. Gas Pressure

36. Velocity of Abrasive Grains

37. Mixing Ratio

38. Nozzle Tip Distance or SOD

39. Parametric Analysis
• Stand Off Distance .
• Mixing Ratio.

40. Stand Off Distance

41. Stand Off Distance

43. Mixing Ratio

44. Change in Abrasive Flow Rate

45. Nozzle Pressure

46. Stand off Distance of M=0.208

47. Characteristics of AJM

50. Water Jet Machining Process.

53. Intensifer

54. Equipments
• Nozzle.
• Catchers

55. Process Parameter
• Metal Removal Rate.
• Geometry and Surface Finish.
• Wear Rate of the Nozzle.

56. Metal Removal Rate
• In WJM the Metal removed is Directly proportional to the the Jet
velocity. Or the relative force.

57. Geometry and Surface of Work Material
• Geometry and Surface Finish of Work Material mainly depends upon
the following parameters.
1. Nozzle Design.
2. Jet Velocity.
3. Cutting speed.
4. Depth of Cut and
5. Properties of the Materials to be machined.

58. Wear Rate of the Nozzle
• Nozzle wear Rate depends upon the following Factors-
1. Hardness of the Nozzle material.
2. Pressure of the Jet.
3. Velocity of the jet and
4. Nozzle Design.

59. Ultrasonic Machining (USM)

71. Horn or Concentrator

72. Feed Mechanism- Gravity feed Mechanism

73. Spring Loaded Feed Mechanism

74. Pneumatic Feed Mechanism

75. MRR- Grain Size

76. Abrasive Concentration

77. Amplitude of Vibration

78. Frequency

79. Process parameter