ADVANCED MANUFACTURING PROCESSES

[BTME14616]

Ch-2
Non-Conventional Machining
Processes

1
Table of Content
• Introduction,
• Different non-conventional machining process principal, material
removal mechanism, parametric analysis and applications of
processes such as ultrasonic machining (USM), abrasive jet
machining (AJM), water jet machining (WJM), electrochemical
machining (ECM), electro discharge machining (EDM), electron
beam machining (EBM), laser beam machining (LBM) processes.

2
Introduction
Traditional Machining:
• Machining removes certain parts of the workpieces to change them to
final parts.
• Traditional, also termed conventional, machining requires the
presence of a tool that is harder than the workpiece to be machined.
• This tool should be penetrated in the workpiece to a certain depth.
• Moreover, a relative motion between the tool and workpiece is
responsible for forming or generating the required shape.
• The absence of any of these elements in any machining process such
as the absence of tool- workpiece contact or relative motion, makes
the process a nontraditional one.

3
Requirement of Non Traditional Machining
• The greatly improved thermal, chemical, and mechanical
properties of the new engineering materials made it impossible
to machine them using the traditional machining processes of
cutting and abrasion.
• This is because traditional machining is most often based on the
removal of material using tools that are harder than the
workpiece.
• The high cost of machining ceramics and composites and the
damage generated during machining.
• In addition to the advanced materials, more complex shapes,
low-rigidity structures, and micromachined components with
tight tolerances and fine surface quality are often needed.
Traditional machining methods are often ineffective in
machining these parts. To meet these demands, new processes
are developed.
• These methods play a considerable role in the aircraft,
automobile, tool, die, and mold making industries.
4
Comparison between conventional and Non Conventional
Machining
Conventional Machining Non Conventional Machining

Tools are made with non-conventional

Direct contact of tool and workpiece.
technique like Laser beam, electric arc etc.
Tool may not be harder and it may not be
Cutting tool is always harder than work piece. physical
presence.

Tool life is less due to high wear. Tool life is more.

Material removal occur with or without chip

Generally Macroscopic chip formation.
formation.

Material removal takes place due to application It uses different energy like electrical, Thermo-
of cutting force. Chemical etc. to provide machining.

Capital cost and maintenance cost is low. Capital cost and maintenance cost is High.

It cannot be used to make prototype parts very It can be used to produce prototype parts very
effectively. effectively. 5
Classification of Unconventional Machining Process
• Mechanical Energy Based Process: In this Process metal
is remove by mechanical erosion of workpiece material.
 Abrasive Jet Machining
 Water Jet Machining
 Abrasive Water Jet Machining
 Ultrasonic Machining

• Electrical Energy Based Process: With the aid of current a

high power spark is produced between wire- electrode and
work piece. Due to this high amount of heat is produced this
heat energy used to melt and vaporize the work material.
 Electric Discharge Machining
 Wire Cut EDM
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Cont….
• Chemical and Electro Chemical Process: Material is
removed by microscopic electrochemical cell action, as
occurs in corrosion or chemical dissolution of a metal.
 Chemical and Electrochemical Machining
 Electro Chemical Grinding
 Electro Chemical Honing

• Thermal Energy Based Process: Thermal machining

removes the machining allowance by melting or vaporizing
the workpiece material.
 Laser Beam Machining
 Plasma Arc Machining
 Electro Beam Machining
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Abrasive Jet Machining (AJM)
• In abrasive jet machining (AJM) a focused stream of abrasive grains
of Al2O3 or SiC carried by high- pressure gas or air at a high velocity
is made to impinge on the work surface through a nozzle of 0.3- to
0.5-mm diameter.
• The process differs from sandblasting (SB) in that AJM has smaller
diameter abrasives and a more finely controlled delivery system.
• AJM machining is best suited for machining holes in super hard
materials. It is typically used to cut, clean, peen, deburr, deflash, and
etch glass, ceramics, or hard metals

Working Principal
• The workpiece material is removed by the mechanical abrasion (MA)
action of the high-velocity abrasive particles.

8
Cont….
Construction:
• It consist of Compressor (To pressurize the gas), Filter, mixing
chamber, Hopper, Vibrator, Nozzle, Pressure gauge and flow
regulator.
• The nozzle is made of a hard material like tungsten carbide.
• Abrasive used are aluminum oxide, Silicon carbide, or Sodium
bicarbonate.
• The gases commonly used are air, N2, CO2.
• Hopper is placed above mixing chamber for feeding purpose.
• Vibrating device placed below mixing chamber to vibrate mixture of
abrasive and gas.

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Working
• First dry air or gas is filtered and then it compressed by compressor.
• A pressure gauge and flow regulator controls the pressure and regulate
the flow of the compressed air.
• Compressed air entered into the mixing chamber where it mixed with
abrasive particles.
• Then mixture passes through nozzle where high velocity fine abrasive
jet is produced.
• The nozzle increases
velocity about 200 to 400
m/s at the expense of it’s
pressure.
• As a result of repeated
impact material removed
from work due to erosion.
Again new surface
exposing and so on
material removed by
erosion. 10
Cont….
Process Parameter:
• Abrasive size: 25 mm
• Nozzle diameter: 0.13 to 1.2 mm
• MRR: 0.8 mm3/min
• Surface Finish: 0.5-1.2 mm

Application:
• Drilling, Cleaning, and polishing of hard surface.
• To machine intricate shapes which is difficult to machine.
• Aircraft fuel system, Medical appliances and Hydraulic valves.

Factors affecting performance of AJM :

• Abrasive grain size and It’s mass flow rate
• Mixing ratio.
• Velocity of abrasive particles.
• Gas pressure.
• Nozzle tip distance.
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Cont….
Advantage of Abrasive Jet Machining:
• No heat is generated in work. So it is suitable for heat
sensitive materials.
• No physical contact between tool and work.
• Thin and fragile materials also machined.
• Low investment.
• Smooth surface finish.

Disadvantage:
• Low MRR.
• Abrasive powder cannot be reused.
• Nozzle life is less and maintenance of nozzle required.
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Water Jet Machining
• Key element in WJM is a jet of water.
• Water jet travels at velocities as high as 900 m/s (approximately Mach 3).
• When the water stream strikes a work piece surface, the erosive force of
water removes the material rapidly.
• The water, in this case, acts like a saw and cuts a narrow groove in the work
piece material.
• True cold cutting process – no HAZ (Heat Affected Zones), mechanical
stresses or operator and environmental hazards

Working Principal
• The water jet machining involves directing a high pressure, high, velocity
water jet to the surface to be machined.
• The kinetic energy of water jet after striking the work surface is reduced to
zero.
• The bulk of kinetic energy of jet is converted into pressure energy. q
• If the local pressure caused by the water jet exceeds the strength of the
surface being machined, the material from the surface gets eroded and a
cavity is thus formed.
• Water is the most common fluid used, but additives such as alcohols, oil
products and glycerol are added when they can be dissolved in water to
improve the fluid characteristics.
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Cont….
Construction
• Typical work materials involve soft metals, paper, cloth, wood,
leather, rubber, plastics, and frozen food.
• If the work material is brittle it will fracture, if it is ductile, it will cut
well.
• Water jet Machining consists of,

14
Cont….
• Hydraulic Pump
• Intensifier
• Accumulator
• High Pressure Tubing
▫ Transports pressurized water to the cutting head.
▫ Typical tube diameters are 6 to 14 mm.
▫ The equipment allows for flexible movement of the cutting head.
▫ The cutting action is controlled either manually or through a remote-
control valve specially designed for this purpose.
• Jet Cutting Nozzle
• Catcher
• Jet Nozzle
• Jet Fluid
• Work Piece

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Cont….
Applications
• WJM is used on metals, paper, cloth, leather, rubber, plastics, food, and
ceramics.
• It completely eliminates heat-affected zones, toxic fumes, recast layers,
work hardening and thermal stresses.
• The process drills precision-angled and -shaped holes in a variety of
materials.
• Machining or cutting of fiber reinforce plastics.
• Cutting of Rocks.
• Deburring.
• Cutting of Printed circuit board.
• Surface treatments.

Limitations
• Hourly rates are relatively high.
• It is not suitable for mass production because of high maintenance
requirements.
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Cont….
Advantages
• It has multidirectional cutting capacity.
• No heat is produced.
• Cuts can be started at any location without the need for predrilled
holes.
• There is no deflection to the rest of the workpiece.
• The burr produced is minimal.
• The tool does not wear and, therefore, does not need sharpening.
• The process is environmentally safe.
• Hazardous airborne dust contamination and waste disposal problems
that are common when using other cleaning methods are eliminated.
• There is multiple head processing.
• Grinding and polishing are eliminated, reducing secondary operation
costs
• It is ideal for roughing out material for near net shape.
• It is ideal for laser reflective materials such as copper and aluminum.
• It allows for more accurate cutting of soft material.
• It cuts through very thick material such as 383 mm in titanium and
307 mm in Inconel. 17
Ultrasonic Machining
• It is mechanical material removal process in which material is
removed by repetitive impact of abrasive slurry on work surface, by
using high frequency oscillation of shaped tool.

18
Cont….
Construction:
• It consist of Ultrasonic generator and transducer, Concentrator, tool,
Abrasive slurry and it’s feed mechanism, and tool feed mechanism.
• Concentrator is tool cone which made from titanium or SS.
• Tool is attached to base of concentrator by mean of silver brazing or
screws. Tool is shaped as approximate mirror image of cavity desired.
• The gap between tool and work is about 0.02 to 0.1 mm.
• Abrasive slurry is mixture of abrasive grains and carrier fluid which is
provided between tool and work-piece. Generally water is used as
carrier fluid.

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Cont….
Working:
• The ultrasonic transducer converts electrical energy into ultrasonic
waves or vibrations using magnetostrictive effects.
• Tool vibrates longitudinally at 20 to 30 kHz with amplitude 0.02 mm
pressed on the work surface with light force.
• Concentrator increases the amplitude of vibration in order to give
required force amplitude ratio.
• The abrasive particle in form of abrasive slurry is continuous circulate
between tool and work. The tool performs hampering action on
abrasive particles.
• The vibration of tool tip accelerates the abrasive particles at high rate
and it imparts the necessary force for cutting action.
• The tool is gradually moves down by means of tool feed mechanism
to maintain constant gap.

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Cont….
Process Parameter:
• Vibration frequency: 15 to 30 kHz
• Vibration amplitude: 25 to 100 mm
• Gap: 0.02 to 0.1 mm
• Surface finish: 0.2 to 0.8 mm ( CLA)
• MRR: 300 mm3/min

Application:
• It is used for machining of hard and brittle material like ceramics,
boron carbide, titanium carbide.
• USM enables a dentist to drill a hole of any shape on teeth painlessly.

21
Cont….
Advantage:
• Non-conductive materials can also be machined.
• There is no any change in microstructures, physical or chemical properties.
• Better surface finish and higher structure integrity.
• Noiseless operation.
• Work piece harder than 60 HRC like carbide, Ceramics machined by USM.

Disadvantage:
• Low MRR.
• High power consumption.
• High tooling cost and it wears rapidly.
• Not suitable for soft materials

Factors affecting MRR and surface finish in USM:

• Tool amplitude and frequency.
• Tool shape.
• Abrasive grain size.
• Abrasive concentration.
• Work hardness-tool hardness ratio.
• Feed force.
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Electrical Discharge Machine
Principle of EDM:
• The main attraction of EDM over
conventional machining is that this
technique use thermoelectric process to
erode undesired material from the w/p.

Construction
• System consist of Shaped tool, Power
supply source, Dielectric fluid and its
circulation line, Servo controlled tool
feed mechanism and work.
• Tool: Cathode ( Negative terminal)
• Work: Anode ( Positive terminal)
• Terminals are connected to DC power
supply to create potential difference
between work and tool.
• Distance between work and tool is
known as Spark gap and it is filled by
dielectric fluid.
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Cont….
Working:
• High voltage is applied between terminals and it induce electrical field in
spark gap.
• Free electrons on tool are subjected to electrostatic force and hence they are
emitted from tool and accelerate towards work. There would be collision
between electrons and molecules in dielectric. It causes further generation of
electrons because of ionization of dielectric molecules.
• This cyclic process increase concentration of electrons in spark gap and
when potential difference is sufficiently high dielectric break down and
large no. of electrons will flow from tool to job and ions from job to tool.
• This movement of electrons visually seen as Spark and electrical energy is
dissipated as thermal energy of spark.
• With a very short duration of spark , temperature of electrodes raised locally
to more than their normal boiling point and this heat of spark melt a tiny bit
of metal from work.
• The melted metal cools and solidifies as tiny particles in dielectric.
• The metal is carried away due to circulation of dielectric by means of pump
and the process continues.
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Cont….
Process Parameter:
• Voltage: 40 to 300 V
• Current: 0.5 to 400 A
• Spark gap: 0.0125 to0.125 mm
• Pulse duration: 2 to 2000 microsecond
• MRR: 800 mm3 – 5000 mm3

Application:
• EDM Drilling to drill very small holes and EDM milling to machine
complex shapes.
• EDM can be used to make parts with irregular shape with precision for
forging press tool, extrusion dies, cutting tool dies etc.

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Wire Cut EDM
• Wire EDM use Electro thermal mechanism to cut electrically conductive
materials.

Construction:
• EDM consist NC unit to control counter movement of work, wire feeding
mechanism to move wire at constant tension, power supply and dielectric
fluid supply.
• Wire of 0.02 to 0.3 mm diameter
• Tool: Cathode (Negative terminal)
• Work: Anode ( Positive terminal)
• Dielectric is de-ionized water applied as localized steam rather than
submerging the whole work.
• Wire for EDM is made of Brass, copper, tungsten, and Zinc or brass coated
wire. The wire should have high tensile strength and good electrical
conductivity.

26
Cont….
Working:
• During operation wire moves along prescribed path and removes material
from work.
• Same as EDM process material is removed due to series of discrete
discharge between Anode and Cathode in presence of dielectric fluid.
• The place of discharge heated to extremely high temperature and that
surface is melted and material removed.
• Removed particles flushed away by flowing dielectric fluids.

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Cont….
• Advantage:
• Smooth machine surface and polishing not required.
• Forming electrode to product shape is not required.
• Wear of electrode is negligible.
• Production rate is high machine can be easily operated for long time.

Application:
• Intricate components for electrical and aerospace industries.
• Machining of sheet metal die, extrusion dies and prototype parts.
• Cylindrical objects are cut with high precision.

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Chemical Machining
• In Chemical Machining process material is removed by chemical dissolution
using chemical reagents or etchants (Acids or Alkaline solutions).
• Chemical reaction takes place between work surface and etchants resulting
into removal of material from surface.
• The surface which etched away, exposing the lower layers and process is
continued till the desired amount of material removed.
• Classification of Chemical Machining:
a) Chemical blanking
b) Chemical Milling
c) Chemical engraving

Steps for Chemical Machining:

• Residual stress relieving

• Cleaning the work piece
• Masking
• Etching
• De-masking 29
Cont….

30
Cont….
Application of CM:
• CM is used as chemical blanking for burr free etching of printed chemical
printed circuit boards, decorative panels.
• Chemical milling is commonly used in aerospace industry to remove shallow
layers of material from large aircraft components like missile skin panels and
airframe parts.

Advantage:
• It doesn’t distort the work and all the faces of work machined simultaneously.
• Low setup, maintenance and tooling cost.
• It can be used to machine complex profiles of delicate and intricate design
parts.
• Improves productivity.

Disadvantage:
• Large tank and large floor area required.
• High operation cost.
• Chemicals used in process may be dangerous to health.
31
Electro Chemical Machining
• ECM is metal removal process based on principle of reverse electroplating.

Construction:
• It consist cathode (tool), Anode (work), Servomotor to control tool feed,
Electrolyte tank and it’s circulation arrangement, DC power supply.
• Servomotor controlled the feed of tool.
• Pump is placed for providing strong stream of electrolyte.

Working:
• DC power supply provides current 50 to 40000 A at 5 to 30 V for across the
gap of 0.05 to 0.07 mm between tool and work. Electrolyte flows through
this gap at velocity 30 to 60 m/s.
• Current started flowing through electrolyte having positively charged ions
attracted towards the tool and negatively charged ions attracted towards
work.
• Due to this flow electrochemical reaction takes place and metal removes in
form sludge.
• This sludge is taken away from gap by strong stream of electrolyte.

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Cont….
• Following reactions takes place while machining of pure iron through ECM
using NaCl+H2O as electrolyte.

33
Cont….
Process Parameter:
• Voltage: 4 to 30 V
• Current: 50 to 40000 A
• MRR: 1600 mm3/min
• Surface Finish: 0.1-2.5 mm (CLA)
• Gap: 0.025 to 0.75 mm

Properties of Electrolyte:
• Electrolyte provides several functions like complete the circuit, Remove
material from cutting region by pressure, Carry away heat to be generated.
• High thermal and Electrical Conductivity
• Low viscosity
• Cheaper and Available
• Non corrosive and Non toxic
• Chemically Stable at process temperature
34
Electrochemical Grinding
• It is combination of conventional mechanical grinding and electrochemical
machining in which material removed by electrolytic activity. In this process
mostly material removed by electrochemical decomposition and remaining
material is removed by abrasion of metal.
• ECG is widely used because it gives burrs free surface without producing
heat and after ECG, any secondary machining operation not required.

35
Cont….
Construction:
• It consist of metallic grinding wheel as cathode, Work-piece as anode,
Electrolyte tank and circulation system.
• Grinding wheel is maid such that diamond or aluminum oxide particles
embedded in it and it slightly projecting out from the surface so that they
touch work surface with a very little pressure. This abrasive particles
preventing direct contact between wheel and work piece.
• As Electrolyte, non corrosive salt solution is used with water. It works as
both Electrolyte and coolant.

Working:
• DC power is supplied between electrodes and Grinding wheel start rotating
by means of motor.
• Pump circulating electrolyte From reservoir tank to machining place. When
electrolyte entrapped in small cavities between work and abrasive particles
it forms electrolyte cell.
• Current started flowing grinding wheel (Cathode) to work (Anode).
• Oxide film forms on surface of work due to electro chemical oxidation and
this film is removed by projecting abrasive particles, which results in
accurate surface finish.
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Cont….
Application:
• For grinding Carbide tools, refractory metals and Cobalt based alloy
ECG is used.

Advantage:
• Process is independent of material hardness and strength.
• Not completely depends on abrasive process.
• Work is not subjected to any mechanical distortion and no heat
generation.
• High surface finish and tool wear is negligible.
• Rapid MRR.

Disadvantage:
• Power consumption is more and High Capital cost.
• Not applicable for non-conductive work-piece.
• It is not suitable for soft materials.
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Laser Beam Machining
• It is thermal metal removal process which uses LASER beam to melt
and vaporize particles on the surface of metallic and non-metallic
work-pieces.

38
Cont….
Construction:
• It consist cylindrical crystal ruby tube, flash tube, focusing lens, power supply
source, total and partial reflecting mirror and cooling system.
• Ruby is Aluminum oxide with 0.05% Cr dispersed and it’s one end is blocked
with total reflective mirror while other end having partially reflected mirror.
• Flash tube is placed outside ruby crystal.

Working:
• Capacitor bank is charged by high voltage energy supplied which energize flash
tube by trigging system.
• Flash tube flashes white light and Cr atoms in ruby crystal absorb this energy
and get excited.
• These atoms pumped to high energy level and drop back to original state. When
atoms jump from one to another level it emits photons (Red fluorescent light).
This phenomenon is known as lasing action or stimulation effect.
• Due to reflection this effect is enhanced and finally photons will come out from
partially reflected mirror with great intensity called LASER.
• Laser beam is focused with the help of lens and work is placed near focal point
of lens. Due to high temperature work material will melt and vaporize.
• Ruby rod becomes high efficient at low temperature. Thus it is continuous
cooled with water or liquid Nitrogen.
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Cont….
Process parameters:
• Voltage: 4500 V
• Pulse duration: 100 microsecond
• MRR: 0.1 mm3/min
• Surface Finish: 0.5-1.2 μm (CLA)

Application:
• LASER drilling
• LASER metal cutting
• LASER welding

Advantage:
• Small, complex and micro sized holes.
• No direct contact between tool and work.
• Accuracy is high and doesn’t require filler material.
• Dissimilar material can be easily welded.
• Automated easily.

Disadvantage:
• It can’t be used to drill deep holes.
• Highly reflective material can’t be effectively machined.
• Initial investment is high.
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Plasma Arc Machining
• It is method of metal cutting with arc of plasma (jet of high velocity
ionized gas) that removes material from work-piece.
• At very higher temperature atoms of gas become ionized and this stage
of gas is known as Plasma.

Construction:
• Plasma torch makes plasma and direct it for cutting.
• Plasma torch consist gas chamber, Nozzle as Anode and Tungsten
electrode as Cathode and power supply.
• Argon, nitrogen, hydrogen, or compressed air introduced around
cathode.

41
Cont….
Working Principle:
• In gas chamber high velocity arc is generated between Anode and Cathode.
Gas molecules are collide with high velocity electrons of arc and due to this
gas gets ionized and large amount of heat energy librated.
• This high velocity stream of hot ionized gas (Plasma) is directed on the
work-piece to melt the material.

42
Cont….
Process Parameter:
• Voltage: 30-250 V
• Current: Up to 600 A
• Power: 2-200 KW
• Velocity of plasma jet: 500 m/s
• MRR: 1,50,000 mm3/min

Advantages:
• Any electrically conductive material machined regardless it’s
hardness.
• Doesn’t require any surface preparation.
• It has high cutting rate.

Disadvantage:
• Power consumption is very high.
• High equipment cost.
• It produced tapered surface.
• Noise protection is required.
43
Electro Beam Machining
• EBM is thermo Electrical process in which material is removed by high
velocity electron beam emitted from tungsten filament. Kinetic energy of
beam transferred to work, producing heat and melts or vaporize material
locally.

Construction:
• It consist vacuum chamber, electron gun, magnetic lens to focus beam,
deflecting coil, and work table for holding.
• Electron gun consist grid cup, tungsten filament (cathode), Anode. The
filament and anode are connected with DC power supply.

Working:
• The tungsten filament is heated about 2500-3000 °C by high voltage DC
supply in order to emit electrons. Grid cup direct electrons to travel towards
the work.
• Electrons are attracted by the Anode, and passed through already placed
hole without colliding with it. 44
Cont….
• Due to high potential
difference electrons
accelerated and it’s velocity
reaches near 2/3 of light
velocity.
• Electron beam is refocused by
electromagnetic lens system
so that beam is directed with
control (typically 0.25 mm
diameter) towards work.
• For controlling path of cut
deflector coil is used to
deflect electron beam.
• Kinetic energy of high
velocity beam is transmitted
into heat and temperature of
work increased above boiling
point. 45
Cont….
Process parameter:
• Voltage: 1,50,000 V
• Vacuum requirement: 133 x 10-6 N/m2
• MRR: 1.6 mm3/min
• Surface Finish: 0.4-2.5 mm (CLA)

Application:
• To drill holes in pressure differential device and to machine low
thermal conductive and high melting point materials.
• Advantage:
• Drill very small hole with high accuracy.
• Brittle material can be easily machined.
• Set up can be automated easily.

Disadvantage:
• Vacuum chamber is essential
• Equipment cost is high.
• Low MRR and skilled operator required.
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