UNCONVENTIONAL MACHINING

1. 1
Outline
 AJM
 LBM
 EDM
 USM
 EBM
 ECM

2. 2
Machining Process
 Manufacturing processes can be broadly divided into
two groups:
a) Primary manufacturing processes : Provide basic
shape and size
b) Secondary manufacturing processes : Provide final
shape and size with tighter control on dimension,
surface characteristics
 Material removal processes once again can be
divided into two groups
1. Conventional Machining Processes
2. Non-Traditional Manufacturing Processes or non-
conventional Manufacturing processes

3. 3
Classification
 1. Mechanical Processes
• Abrasive Jet Machining (AJM)
• Ultrasonic Machining (USM)
• Water Jet Machining (WJM)
• Abrasive Water Jet Machining (AWJM)
 2. Electrochemical Processes
• Electrochemical Machining (ECM)
• Electro Chemical Grinding (ECG)
• Electro Jet Drilling (EJD)
 3. Electro-Thermal Processes
• Electro-discharge machining (EDM)
• Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)
 4. Chemical Processes
• Chemical Milling (CHM)
• Photochemical Milling (PCM)

4. 4
Needs for Non Traditional Machining
• Extremely hard and brittle materials or Difficult to
machine materials are difficult to machine by
traditional machining processes.
• When the work piece is too flexible or slender to
support the cutting or grinding forces.
• When the shape of the part is too complex.
• Intricate shaped blind hole – e.g. square hole of 15
mmx15 mm with a depth of 30 mm
• Deep hole with small hole diameter – e.g. φ 1.5 mm
hole with l/d = 20
• Machining of composites.

5. 5
Conventional Machining VS Unconventional Machining
 In Conventional machining process, the cutting
tool and work piece are always in physical
contact, with a relative motion against each
other, which results in friction and a significant
tool wear.
 In Unconventional machining processes, there
is no physical contact between the tool and
work piece. Although in some non-traditional
processes tool wear exists, it rarely is a
significant problem.

6. 6
Outline of AJM
 Definition
 Schematic Diagram of AJM
 Typical AJM parameters
 Applications
 Limitations
 Advantages
 Disadvantages
 Video of Cutting Process

7. Definition of AJM :-
 In AJM, the material removal takes place due to
impingement of the fine abrasive particles. These
particles move with the high speed air (or gas)
stream.
 The abrasive particles are typically of 0.025 mm
diameter and the air discharges at a pressure of
several atmosphere.
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8. Schematic Diagram of AJM
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Aluminum oxide
Boron Nitride
Diamond Dust
Dry
air,
nitrogen
or
co2

9. Working of Abrasive jet machining: (AJM):
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 The nozzle is made of a hard material like
Tungsten Carbide here fine grained abrasive
particles are fed from the Hooper into the
mixing chamber.
 High pressure air is forced in to the mixing
chamber.
 The stream of abrasive particles bombards the
work piece at a very high speed and removes
the work material due to erosion.
 The abrasive particle feed rate is controlled by
the amplitude of vibration of the mixing
chamber.

10. Typical AJM Parameters
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 Abrasive
 Aluminum oxide for Al and Brass.
 SiC for Stainless steel and Ceramic
 Bicarbonate of soda for Teflon
 Glass bed for polishing.
 Size
 10-15 Micron
 Quantity
 5-15 liter/min for fine work
 10-30 liter/min for usual cuts.
 50-100 liter/min for rough cuts

11. Typical AJM Parameters
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 Medium
 Dry air, CO2, N2
 Quantity: 30 liter/min
 Velocity: 150-300 m/min
 Pressure: 200-1300 KPa
 Nozzle
 Material: Tungsten carbide
 Stand of distance: 2.54-75 mm
 Diameter: 0.13-1.2 mm
 Operating Angle: 60° to vertical

12. Typical AJM Parameters
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 Factors affecting MRR:
 Types of abrasive and abrasive grain size
 Flow rate
 Stand off distance
 Nozzle Pressure

13. Nozzle
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 The nozzle is one of the most vital elements
controlling the process characteristics. Since it is
continuously in contact with the abrasive grains
flowing at a high speed, the material must be
hard to avoid any significant wear.
 One of the most important factors in AJM is the
distance between the work surface and the tip of
the nozzle, normally called the nozzle distance

14. Nozzle Tip Distance
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15. Applications:-
 For drilling holes of intricate shapes in hard and
brittle materials
 For machining fragile, brittle and heat sensitive
materials.
 AJM can be used for drilling, cutting, deburring,
cleaning and etching.
 Micro-machining of brittle materials
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16. Limitations:-
 MRR (Material removal rate) is rather low
(around ~ 15 mm^3/min for machining glass).
 Abrasive particles tend to get embedded
particularly if the work material is ductile.
 Tapering occurs due to flaring of the jet.
 Environmental load is rather high.
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17. Advantages:-
 Extremely fast setup and programming.
 No start hole required.
 There is only one tool.
 Low capital cost.
 Less vibration.
 No heat generation in work piece.
 Environmentally Friendly.
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18. Disadvantages:-
 Low metal removal rate.
 Abrasive powder cannot be reused.
 Tapper is also a problem.
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19. 19
Outline of LBM
 Definition
 Schematic Diagram of LBM
 Working of LBM
 Applications
 Limitations
 Advantages
 Disadvantages
 Video of Cutting Process

20. Definition of LBM :-
 Laser-beam machining is a thermal material-
removal process that utilizes a high-energy,
coherent light beam to melt and vaporize
particles on the surface of metallic and non-
metallic work pieces.
 Lasers can be used to cut, drill, weld and mark.
LBM is particularly suitable for making accurately
placed holes.
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21. Principle of Laser beam machining (LBM):
 Conversion of electrical energy into heat energy
to emit laser beam energy.
 Laser beam is focused on lance then create high
energy the high energy concentration on work
piece then work piece is melt and vaporized of
metal.
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22. Working of LBM
 The diagram of LBM is
shown in figure.
 Laser is stand for Light
Amplification by
Simulated Emulsion of
Radiation.
 The work piece is
placed on the
aluminum work table
which material is hard
not cut by laser beam.
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<slide Title> | CONFIDENTIAL 2011

23. Working of LBM
 Ruby rod is used into
form of cylindrical
crystal both ends of
ruby rod are finished to
optical tolerance.
 The flash lamp wound
around the ruby rod
and connected to
power supply.
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<slide Title> | CONFIDENTIAL 2011

24. Working of Laser beam machining (LBM):
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 The ruby rod becomes high efficient on low
temperature and low efficient on high
temperature. It is thus continuous cooled with
water, air or liquid nitrogen.
 When the light beam has been amplified
sufficiently and intensity beam of light comes out
form partially reflected end it is focused on the
work piece at the focused very high temperature
which vaporized and removes the metal on work
piece.

25. Applications:-
 LBM can make very accurate holes as small as
0.005 mm in refractory metals ceramics, and
composite material without warping the work
pieces.
 It is used for welding of thin metal sheet.
 Leaser can be used for cutting as well as drilling.
 Heat treatment.
 It is used for cutting complex profile.
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26. Limitations:-
 Uneconomic on high volumes compared to
stamping
 Limitations on thickness due to taper
 High capital cost
 High maintenance cost
 Assist or cover gas required
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27. Advantages:-
 Very hard and abrasive material can be cut.
 Sticky materials are also can be cut by this
process.
 It is a cost effective and flexible process.
 High accuracy parts can be machined.
 No cutting lubricants required
 No tool wear
 Narrow heat effected zone
 No contact between tool and work piece.
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28. Disadvantages:-
 Investment cost is more.
 Skilled operator is required.
 Operating cost is more.
 Flash lamp life is too short.
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29. Summary:-
 Mechanics of material removal : Melting, Vaporization
 Medium : Normal atmosphere
 Tool : Higher power laser beam
 Maximum material removal rate: 5 mm^3/min
 Specific power consumption : 1000 W/mm^3/min
 Materials application : All materials
 Shape application : Drilling fine holes
 Limitations : Very power consumption, cannot cut
materials with high heat conductivity and high reflectivity
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30. 30
Outline of EDM
 Definition
 Schematic Diagram of EDM
 Working of EDM
 Applications
 Advantages
 Disadvantages
 Video of Cutting Process

31. Principle of EDM:
 Electrical discharge machining (EDM), sometimes also
referred to as spark machining, spark
eroding, burning, die sinking, wire burning or wire
erosion, is a manufacturing process whereby a desired
shape is obtained using electrical discharges (sparks).
 Material is removed from the work piece by a series of
rapidly recurring current discharges between two
electrodes , separated by a die-electric liquid and
subject to an electric voltage. One of the electrodes is
called the tool-electrode, or simply the "tool" or
"electrode", while the other is called the workpiece-
electrode, or "workpiece".
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32. Working of EDM
 The diagram of electro
discharge machining shown
in figure.
 EDM is thermal erosion
process whereby material is
melted and vaporized from
an electrically conductive
work piece immerse in a
liquid dielectric with a series
of spark discharge between
the tool electrode and the
work piece created by a
power supply.
30 August 2023
<slide Title> | CONFIDENTIAL 2011

33. Working of EDM
 The electrode and the work
piece are separated by a
dielectric medium.
 The dielectric medium is like
as kerosene, paraffin or light
oil.
 The strong electrostatic field
between the electrode and
work piece produce
emission of electrons from
the cathode.
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<slide Title> | CONFIDENTIAL 2011

34. Working of EDM
 In this gap between tool
and work piece get
ionized. The liquid is force
to sparking zone.
 Due to high temperature,
the metal at the sparking
zone melts
instantaneously.
 The material of the tool is
usually a material which
conduct electricity and
which can be easily
shaped.
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<slide Title> | CONFIDENTIAL 2011

35. Advantages:-
 Smaller holes can be easy machined.
 No contact between tool and work piece then
tool life is increase.
 Any complex shape can be machined.
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36. Disadvantages:-
 Tool life is not longer.
 Power consumption is high.
 Cycle time is more
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37. Summary:-
 Mechanics of material removal : Electrolysis
 Medium : Conducting electrolyte
 Tool : Cu, Brass, Steel
 Gap : 50-300 µm
 Maximum material removal rate: 15*10^3 mm^3/min
 Specific power consumption : 7 W/mm^3/min
 Materials application : All conducting metals and alloys
 Shape application : Blind complex cavities, curved
surfaces, through cutting, large through cavities
 Limitations : High speed energy consumption, not
applicable with electricity non-conducting materials
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38. Video
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<slide Title> | CONFIDENTIAL 2011

39. Any Questions ???
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40. 40
Outline of USM
 Definition
 Schematic Diagram & working of USM
 Applications
 Advantages
 Disadvantages
 Summary
 Video

41. Principle of Ultrasonic machining(USM):
 In this method with the help of piezoelectric
transducer tool is vibrate at high frequency in a
direction normal to the surface being machined
abrasive slurry are used for the remove the metal
from work piece.
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42. Working of USM
 The USM diagram shown
in figure.
 In ultrasonic machining a
tool vibrate longitudinally
at 20 to 30 kHz with
amplitude between 0.01
to 0.06 mm is pressed on
to the work surface with
light force.
 The electronic oscillator
and amplifier is also
known as generator.
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<slide Title> | CONFIDENTIAL 2011

43. Working of USM
 It converts the
electrical energy of low
frequency to high
frequency.
 At the time high
frequency current is
passed through the
coil therefore change
in electromagnetic field
which produces
longitudinal strain.
30 August 2023
<slide Title> | CONFIDENTIAL 2011

44. Working of USM
 As the tool vibrate with
specific frequency the
abrasive slurry mix with
water and grain of definite
proportion is made to flow
under pressure through
the tool work piece
interface. The flow of slurry
through the work tool
interface actually causes
thousand of microscopic
grain to remove the work
material by abrasion.
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45. Applications:-
 USM is best suitable for hard, brittle material,
such as ceramics, carbides, glass, precious
stone etc.
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46. Advantages:-
 Any materials can be machined regardless of
their electrical conductivity.
 Especially suitable for machining of brittle
materials.
 Machined parts by USM possess better surface
finish and higher structural integrity.
 USM does not produce thermal, electrical and
chemical abnormal surface.
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47. Disadvantages:-
 Tool wears fast in USM.
 Machining area and depth is restraint in USM.
 High cost of tooling.
 MMR is low.
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48. Summary:-
 Mechanics of material removal : Brittle fracture caused by
impact of abrasive grains due to tool vibrating at high
frequency.
 Medium : Slurry
 Tool : Soft Steel
 Gap : 25-40 µm
 Frequency : 15-30kHz
 Amplitude : 25-100 µm
 Specific power consumption : 1000 W/mm^3/min
 Materials application : Metals and alloys,
semiconductors, non- metals
 Shape application : Round and irregular holes
 Limitations : Very low mrr, tool wear, depth of holes and
cavities small 30 August 2023

49. Video
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<slide Title> | CONFIDENTIAL 2011

50. 50
Outline
 Definition
 Schematic Diagram of EBM
 Working of EBM
 Applications
 Limitations
 Advantages
 Video of Cutting Process

51. Definition of EBM :-
 Electron Beam Machining (EBM) is a thermal
process. Here a steam of high speed electrons
impinges on the work surface so that the kinetic
energy of electrons is transferred to work
producing intense heating.
 Depending upon the intensity of heating the work
piece can melt and vaporize.
 The process of heating by electron beam is used
for annealing, welding or metal removal.
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52. EBM:
 During EBM process very high velocities can be
obtained by using enough voltage of 1,50,000 V
can produce velocity of 228,478 km/sec and it is
focused on 10 – 200 μM diameter.
 Power density can go up to 6500 billion
W/sq.mm. Such a power density can vaporize
any substance immediately.
 Complex contours can be easily machined by
maneuvering the electron beam using magnetic
deflection coils
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53. EBM:
 To avoid a collision of the accelerating electrons
with the air molecules, the process has to be
conducted in vacuum. So EBM is not suitable for
large work pieces.
 Process is accomplished with vacuum so no
possibility of contamination.
 No effects on work piece because about 25-
50μm away from machining spot remains at
room temperature and so no effects of high
temperature on work
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54. Working of EBM
 The EBM beam is
operated in pulse mode.
 This is achieved by
appropriately biasing the
biased grid located just
after the cathode.
 Switching pulses are
given to the bias grid so
as to achieve pulse
duration of as low as 50
μs to as long as 15 ms.
30 August 2023
<slide Title> | CONFIDENTIAL 2011

55. Working of EBM
 Beam current is directly
related to the number of
electrons emitted by the
cathode or available in
the beam.
 Beam current once
again can be as low as
200μ amp to 1 amp.
Increasing the beam
current directly
increases the energy
per pulse.
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<slide Title> | CONFIDENTIAL 2011

56. Working of EBM
 Similarly increase in pulse duration also
enhances energy per pulse.
 High-energy pulses (in excess of 100 J/pulse)
can machine larger holes on thicker plates.
 A higher energy density, i.e., for a lower spot
size, the material removal would be faster though
the size of the hole would be smaller.
 The plane of focusing would be on the surface of
the work piece or just below the surface of the
work piece.
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57. Applications:-
 Used for producing very small size holes like
holes in diesel injection nozzles, Air brakes etc.
 Used only for circular holes.
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58. Limitations:-
 Material removal rate is very low compared to
other convectional machining processes.
 Maintaining perfect vacuum is very difficult.
 The machining process can’t be seen by
operator.
 Work piece material should be electrically
conducting.
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59. Advantages:-
 Very small size holes can be produced.
 Surface finish produced is good.
 Highly reactive metals like Al and Mg can be
machined very easily.
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60. Summary:-
 Mechanics of material removal : Melting, Vaporization
 Medium : Vacuum
 Tool : Beam of electron moving at very high velocity
 Maximum material removal rate: 10 mm^3/min
 Specific power consumption : 450 W/mm^3/min
 Materials application : All materials
 Shape application : Drilling fine holes, cutting contours in
sheets, cutting narrow slots
 Limitations : Very high specific energy consumption,
necessity of vacuum, expensive machine
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61. Video
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<slide Title> | CONFIDENTIAL 2011

62. Any Questions ???
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63. CORE JAVA
THANK YOU