This document introduces unconventional machining processes. It defines conventional machining and its limitations in machining advanced materials. Unconventional processes are classified based on energy type (thermal, electrical, electrochemical, chemical, mechanical). Examples are given for machining different materials like metals, ceramics, plastics. Process selection depends on part geometry, capabilities, economics. Advantages include machining hard materials close tolerance with less residual stress, while limitations are lower material removal rates and higher costs compared to conventional machining.
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Unconventional machining Process – Need – classification – merits, demerits and applications.
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An **unconventional machining process** (or **non-traditional machining process**) is a special type of **machining process**in which there is no direct contact between the tool and the workpiece
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An **unconventional machining process** (or **non-traditional machining process**) is a special type of **machining process**in which there is no direct contact between the tool and the workpiece
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2. CONTENTS
History and Development.
Conventional Machining Processes
Limitations Of Conventional Processes
Classification Of Unconventional Manufacturing
Processes
Unconventional Machining Processes
Unconventional Forming Processes
Classification of Unconventional machining processes
Method of Machining Suitable for Different Materials
Process selection parameters
Advantages & limitations of Unconventional machining
3. Conventional machining
process
Metal is removed – Tool harder than work
piece & subjected to Wear.
Direct contact – Tool and work piece.
Compression – shear chip formation.
4. Limitations of Conventional
machining
Metal is removed by chip formation which is
expensive and difficult process.
Chips produced during this process are unwanted
by products.
Removal of these chips and their disposal and
recycling is a very tedious procedure, involving
energy and money.
Very large cutting forces.
Greater amount of heat generated resulting in
undesirable deformation and residual stresses.
Delicate components cannot be produced – semi
conductor.
5. Unconventional manufacturing
processes
Unconventional manufacturing processes can
be divided into the following categories:
Unconventional machining processes(UCMP) or
Non- Traditional machining processes.
Unconventional forming processes.
6. Unconventional manufacturing
processes
Unconventional machining processes(UCMP)
or Non- Traditional machining processes.
No traditional tool for metal removal.
Utilises some form of energy for metal machining.
No direct physical contact between the tool and
work piece.
Tool material need not to be harder than work
piece material.
8. Need for unconventional
machining
Technological advanced industries requirement for
HSTR (High strength temperature resistant
material).
Material to high strength to weight ratio.
Productivity is not be hampered because of high
strength, hardness, toughness and other diverse
property materials.
Economic cutting speed.
Production of complex shaped products.
Better surface finish and tolerances, high
production rates.
9. Classification of UCMP
Medium of transfer of energies.
High voltage
particles Electrolyte Electron Hot gases
Source of energy required for material removal
Hydrostatic
pressure
High current
density
High voltage
Ionised
material
Based on mechanism involved in the process
Erosion Ionic dissolution vaporisation
Based on type of energy required to shape the material
Thermal Electrical
Electro
chemical
Chemical Mechanical
10. Classification of UCMP – Energy
Methods
Thermal Energy Methods.
Laser Beam, plasma arc, Electron Beam, Ion Beam
Electrical Energy Methods.
Electro discharge Machining, wire cut electrical
discharge machining
Electro chemical Energy Methods.
Electro chemical machining, Electro chemical grinding,
electro chemical honing, electrical chemical deburring.
Chemical Energy Methods.
Chemical machining.
Mechanical Energy Methods.
Ultrasonic machining, abrasive jet machining, water jet
machining.
11. Method of Machining Suitable
for Different Materials
Sl.N
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Material Method of Machining
1 Non – Metals like
ceramics, plastics, glass
USM, AJM, EBM, LBM
2 Refractories USM, AJM, EDM, EBM
3 Titanium EDM
4 Super alloys AJM, ECM, EDM, PAM
5 Steel ECM, CHM, EDM,
PAM
12. Process selection
The following point must be considered for
the selection of the unconventional
machining processes:
Physical parameters
Shapes to be machined
Process capability or machining
characteristics
Economic consideration.
15. Process selection – Process
capability
The machining
characteristics can be
analyzed with respect to
:
Metal removal rate
obtained
Tolerance maintained
Surface finish obtained
Depth of surface
damage
Power required for
16. Process selection – Process
economy
The economics
of various
processes are
analyzed by
considering the
following points:
Capital cost
Tooling cost
Power
requirement
Metal removal
rate efficiency
17. Advantages and limitations
Advantages
It increases productivity
It reduces no. of rejected components
Close tolerance is possible
Tool need not to be harder than work piece
Harder material can be machined.
The machined surface do not have any residual
stresses.
Limitations
Expensive
Metal removal rate is low
AJM, CHM, PAM, EBM are not commercially
economical processes.
