17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

MODULE 1
INTRODUCTION

Introduction to Non-traditional machining, Need for Non-traditional

machining process, Comparison between traditional and non-traditional machining,
general classification Nontraditional machining processes, classification based on
nature of energy employed in machining, selection of non-traditional machining
processes, Specific advantages, limitations and applications of non-traditional
machining processes.
08 hours

INTRODUCTION

Since beginning of the human race, people have evolved tools and energy
sources to power these tools to meet the requirements for making the life more
easier and enjoyable.
In the early stage of mankind, tools were made of stone for the item being
made. When iron tools were invented, desirable metals and more sophisticated
articles could be produced.
In twentieth century products were made from the most durable and
consequently, the most unmachinable materials. In an effort to meet the
manufacturing challenges created by these materials, tools have now evolved to
include materials such as alloy steel, carbide, diamond and ceramics.
A similar evolution has taken place with the methods used to power our
tools. Initially, tools were powered by muscles; either human or animal. However
as the powers of water, wind, steam and electricity were harnessed, mankind was
able to further extend manufacturing capabilities with new machines, greater
accuracy and faster machining rates.
The conventional manufacturing processes in use today for material removal
primarily rely on electric motors and hard tool materials to perform tasks such as
sawing, drilling and broaching. Conventional forming operations are performed
with the energy from electric motors, hydraulics and gravity. Likewise, material
joining is conventionally accomplished with thermal energy sources such as
burning gases and electric arcs.
In contrast, non-traditional manufacturing processes harness energy sources
considered unconventional by yesterday’s standards. Material removal can now be
accomplished with electrochemical reaction, high temperature plasmas and high-
velocity jets of liquids and abrasives.
Materials that in the past have been extremely difficult to form, are now
formed with magnetic fields, explosives and the shock waves from powerful
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

electric sparks. Material-joining capabilities have been expanded with the use of
high-frequency sound waves and beams of electrons and coherent light.

During the last 55 years, over 20 different non-traditional manufacturing

processes have been invented and successfully implemented into production.

1. MACHINING
It is the process of removing the material from the work piece to obtain the
desired shape and size. The machining process is classified into two types.
1. Conventional Machining
2. Non-Traditional Machining (or) Non-conventional (or) Unconventional
machining
1.1 Traditional Machining Process
It is the machining in which the metal is removed by making direct contact
between tool and work piece by the use of mechanical energy. Metal removal
process is due to shearing.

Fundamental Work Piece Transfer Energy

Machining energy removal Medium Source

Mechanical Physical Cutting Traditional

energy Shear Contact Tool M/C

Eg: Turnings, milling, grinding, lapping, drilling, shaping, etc.

 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

The difficulties in Traditional Machining’s are

1. In many processes material removal rate mainly depends upon the hardness
of the work piece. The high hardness material such as alloy steel, carbide,
diamond and ceramics are unable to machining by conventional machining
process.
2. Machining of intricate and complicated shapes can’t be obtained in
conventional machining.
3. Machining of thin and fragile components cannot be produced by
conventional machining.
4. The high accuracy cannot be obtained in conventional machining.

The above difficulties are overcome by the development of Non-Traditional

Machining (Eg: USM, PAM, EDM….). As a result of research and development
for the last forty years, several new methods of machining have emerged which are
called in various names such as
Unconventional machining methods or
Non traditional machining methods or
Physical machining processes or
Newer machining process or
Modern machining methods

All these new machining processes have one common characteristic Viz
these processes involve physical phenomena in metal removal where as in
conventional machining methods the metal removal by mechanical means i.e by
using a sharp edged tool harder than work material.

The following are the characteristic features of non traditional machining

processes when compared with traditional machining processes.
1. Material is removed from work piece without mechanical contact (with work
piece).
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

2. In many processes material removal rate is independent of the hardness of

work piece.
3. Cutting forces are independent of the hardness of the work piece.
4. Tool material need not harder that the work material (In many cases softer
material can be used as the tool material.)
5. Generally tool wear is negligible, hence tool wear is not a problem.
6. No burn is left on the work piece.
7. In most cases entire contour (or) design shape can be obtained in one stage
(or) in one setting. This is possible source the material removal takes place
uniformly over the entire surface area in simultaneous.
8. Intricate shaped contours and fine machining of precision holes are possible.
9. For improved productivity modern Machining methods can be easily
integrated with help of CNC.

1.2 NEED FOR NON-TRADITIONAL MACHINING PROCESS

From above introduction, the Non-Traditional Machining processes are needed
for.
1) To Machining the very hard, high strength material which are being
extensively used in aerospace and nuclear industries.
2) To maintain high accuracy and surface finishing.
3) For machining of intricate and complicated shapes.
4) For machining of very thin components and fragile components.
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

5) To improve the productivity by means of automation.

Case I: Square Blind Hole
• Square blind hole in any material with higher
surface finish of about 10 micron (RMS).
• This cannot be obtained in foundry (range of
surface finish 1250-2500 micron) or in forging
(750-1250 micron) practices.
• This has to be finished in a machine shop. If it is a
case of single piece or a mass production-slotting or broaching of blind hole
without a recess cannot be done.

Case II: Small Hole with high Aspect ratio

• Hole with L/D ratio more than 30.
• Hole may be straight or inclined.

Case III: Contoured Die Block

Contoured hole generation in a very hard material like
Tungsten (WC) or stellite (Cobalt-Chromium alloys)
for making a die block.

1.3 Classification & Energy Employed in Non-Traditional Machining Process

The basic principle of machining by these methods is to apply some form of
energy to the work piece directly without almost any physical contact between the
tool and work piece and have the desired shape (or) contour by material removal
from the work piece.
Different forms of energy applied to the work piece are
• Mechanical energy
• Electrical (or) Electro chemical energy
• Thermal energy
• Chemical energy
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Classification of new machining methods is done on the basis of the type of

energy used in the working zone for material removal factor.

1.3.1 Mechanical Energy

Ultrasonic Machining - USM

Ultrasonic Assisted Machining - UAM
Rotary ultrasonic Assisted Machining - RUM
Abrasive Jet Machining - AFM
Abrasive flow Machining - AFM
Orbital Grinding - OG
Water Jet Machining - WJM
1.3.2 Electrical Energy
Electro Chemical Machining - ECM
Electro Chemical Grinding - ECG
Electro Chemical Discharge Grinding - ECDG
Electro Chemical Deburring - ECD
Electro Chemical Honing - ECH
Shaped Tube Electrolytic Machining - STEM
Electro Stream Drilling - ESD
Electro Jet Drilling - EHD

1.3.3 Thermal Energy

Electrical Discharge Machining - EDM
Electron Beam Machining - EBM
Laser Beam Machining - LBM
Electro Discharge Wire Cutting - EDNC
Electro Discharge Grinding - EDG
Plasma Arc Machining - PAM
Plasma Assisted Machining - PAM
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Thermal Deburring - TD
Ion Beam Machining - TBM
1.3.4 Chemical Energy
Chemical Machining - CHM
Chemical Blanking - CHB
Chemical Engraving - CHE
Electro Polishing - ELP
Photo Chemical Machining - PCM
Thermo Chemical Machining - TCM
In the above all the modern machining process, only a few of the NTM have
been accepted by the industries and the manufactures. Those are

(1) EDM (2) USM (3) LBM (4) ECM

1.4 Brief overview of all UCM.
Shear Physical Contact Cutting tool Traditional

AJM
Mechanical High velocity Pneumatic USM
WJM
Erosion Abrasive particles
Hydraulic
ECG

Electrochemical – Ion Displacement – Electrolyte – High Current – ECM

Electrons High Voltage EDM

Vapourizations
Radiation Amplified light LBM

Themro-Electric Ion Stream Ionized material IBM

Fusion Hot Gases PAM

 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Classification of Non-Traditional Machining Processes

Type of energy Mechanism of Transfer media Energy source Processes
metal removal
Erosion High velocity Pneumatic / AJM, USM,
particles Hydraulic WJM
Mechanical pressure
Shear Physical contact Cutting tool Conventional
machining
Electrochemical Ion displacement Electrolyte High current ECM, ECG
Chemical Ablative relation Reactive Corrosive agent CHM
environment
Hot gases Ionized material IBM, PAM
Fusion Electrons High voltage EDM
Thermoelectric Radiation Amplified light LBM
Vaporization Ion stream Ionized material PAM

LIMITATIONS
➢ All modern machining methods are generally costly.
➢ Specific power consumption is quite high.
➢ Work piece and tool must be electrically conductive eg. EDM, ECM.
➢ The depth of cut is limited eg LBM and etc.

Difference between Traditional and Non traditional machining processes.

Sl No. Conventional Process Non Conventional Process
1 The cutting tool and work piece are There is no physical contact between the tool
always in physical contact with and work piece, In some non traditional
relative motion with each other, process tool wear exists.
which results in friction and tool
wear.
2 Material removal rate is limited by NTM can machine difficult to cut and hard to
mechanical properties of work cut materials like titanium,ceramics,nimonics,
material. SST,composites,semiconducting materials
3 Relative motion between the tool Many NTM are capable of producing
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

and work is typically rotary or complex 3D shapes and cavities

reciprocating. Thus the shape of
work is limited to circular or flat
shapes. In spite of CNC systems,
production of 3D surfaces is still a
difficult task.
4 Machining of small cavities , slits , Machining of small cavities, slits and
blind holes or through holes are Production of non-circular, micro sized, large
difficult aspect ratio, shall entry angle holes are easy
using NTM
5 Use relative simple and inexpensive Non traditional processes requires expensive
machinery and readily available tools and equipment as well as skilled labour,
cutting tools which increase the production cost
significantly
6 Capital cost and maintenance cost Capital cost and maintenance cost is high
is low
7 Traditional processes are well Mechanics of Material removal of Some of
established and physics of process NTM process are still under research
is well understood
8 Conventional process mostly uses Most NTM uses energy in direct form For
mechanical energy example : laser, Electron beam in its direct
forms are used in LBM and EBM respectively
9 Surface finish and tolerances are High surface finish(up to 0.1 micron) and
limited by machining inaccuracies. tolerances (25 Microns)can be achieved.
10 High metal removal rate. Low material removal rate.
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Selection of non-traditional machining processes

The correct selection of the non-traditional machining methods must be
based on the following aspects.
i) Physical parameters of the process.
ii) Shape to be machined
iii) Process capability
iv) Economics of the processes
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Physical parameter of the process:

The physical parameters of the different NTM are given in the Table 1.0 which
indicates that PAM and ECM require high power for fast machining. EBM and
LBM require high voltages and require careful handling of equipment. EDM and
USM require medium power . EBM can be used in vacuum and PAM uses oxygen
and hydrogen gas.
Process Parameters
Holes (Micro, Small, deep, Shallow) LBM, EBM,ECM, USM & EDM
Precision Work USM & EDM
Horning ECM
Etching ECM & EDM
Grinding AJM & EDM
Deburring USM & AJM
Threading EDM
Profile Cut PAM

Physical parameters of the Non Traditional Machining Processes

 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

• EDM and USM require approximately same power

• ECM consumes roughly 40% more
• ECM is an excellent method for drilling long slender holes (Length
/diameter >20)

Shape to be machined
Shapes cutting capability the different shapes can be machined by NTM.
EBM and LBM are used for micro drilling and cutting. USM and EDM are useful
for cavity sinking and standard hole drilling. ECM is useful for fine hole drilling
and contour machining. PAM can be used for cutting and AJM is useful for
shallow pocketing
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Process capability & Machining Characteristics

The process capability of NTM is given in Table. EDM which achieves
higher accuracy has the lowest specific power requirement. ECM can machine
faster and has a low thermal surface damage depth. USM and AJM have very
material removal rates combined with high tool wear and are used non metal
cutting. LBM and EBM are, due to their high penetration depth can be used for
micro drilling, sheet cutting and welding. CHM is used for manufacture of PCM
and other shallow components.
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Process MRR Surface Accuracy Power (kW/

( mm3/s ) Finish (μm) (μm) cm3

LBM 0.10 0.4 – 6.0 25 2700

EBM 0.15 - 40 0.4 – 6.0 25 450

EDM 15 - 80 0.25 10 1.8

ECM 27 0.2 -0.8 50 7.5
PAM 2500 Rough 250 0.90
USM 14 0.2 – 0.7 7.5 9.0
AJM 0.014 0.5- 1.2 50 312.5
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Economics of the processes

Capital Cost Tool & Power Efficiency

Fixtures Requirement
EDM Medium High Low High
CHM Medium Low High Medium
ECM V. High Medium Medium V. Low
AJM V. Low Low Low Low
USM High High Low Medium
EBM High Low Low V. High
LBM Medium Low V. Low V. High
PAM V. Low Low V. Low V. Low
Conventional V. Low Low Low V. Low
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Advantages of Non Traditional machining processes

1) High accuracy and surface finish
2) Less / no wear
3) Tool life is more
4) Quieter operation
5) Increase productivity
6) It reduces number of rejected components
7) The tool material need not be harder than work piece material as in conventional
machining.
8) Harder and difficult to machine materials can be machined by this process.

Disadvantages of Non Traditional machining processes

1) High cost.
2) Complex set up.
3) Skilled operator required.
4) Material removal rate is less.
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

Applications of non-traditional machining processes.

1. Machining.
2. Cutting.

Ultrasonic machining (USM)

3. Casting and welding of metals.

4. Forming of plastics
5. Measurement of velocity of moving fluids.
6. Measurement of density, viscosity and elastic constants.
7. Measurement of hardness and grain size determination of metals.
8. Nondestructive residual stress determination.
9. Flaw detection.
10.Leak detection.
11.Machining of Tungsten, hard carbides, gem stones.

Abrasive Jet Machining (AJM)

12.Removing flash and parting lines from injection moulded parts.

13.Deburring and polishing plastic, nylon and Teflon components.
14.Cleaning metallic mould cavities which otherwise may be inaccessible.
15.Cutting thin sectioned fragile components made of glass, refractories,
ceramics, mica etc.
16.Producing high quality surface.
17.Removing glue and paint from paintings and leather objects.
18.Reproducing designs on a glass surface with the help of masks made of
rubber, copper etc.
19.Frosting interior surfaces of glass tubes.
20.Etching markings on glass cylinders.

Water Jet Machining (WJM)

21.Mining industries- to cut coal from the face.

22.Cutting of coal and rock like granite, glass etc.
23.Drilling.
24.Cleaning and descaling.
25.Cut ferrous and non-ferrous metals.

Electrochemical Machining (ECM)

26.Machining of fragile materials.

 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

27.Facing and turning three dimensional surfaces.

28.Die sinking, particularly deep narrow slots and holes.
29.Profiling and any old shape contouring.
30.Multiple hole drilling.
31.Trepanning
32.Broaching.
33.Deburring.
34.Grinding.
35.Honing.
36.Cutting off.

Electrochemical Grinding

37.Machining of few microns level.

38.Machining of taper sheets and pre-formed shapes.
39.Engraving on any metal piece.
40.Produce stepped webs.

Electric Discharge Machining (EDM)

41.Making stamping tools.

42.Wire drawing and extrusion dies.
43.Header dies.
44.Forging dies.
45.Intricate mould cavities.
46.Machining of exotic materials used in aero-space industries
47.Machining of refractory metals, hard carbides and hardenable steels.
48.Copper tubes fitting into vacuumtubes.

Plasma Arc Machining (PAM)

49.Welding of materials like titanium, stainless steel etc.

50.Plasma arc surfacing.
51.Plasma arc spraying.
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

BRIEF OVERVIEW OF NON TRADITIONAL MACHINING

1 ULTRA SONIC MACHINING (USM)

USM is a mechanical material removal process in which the material is removed by repetitive
impact of abrasive particles carried in liquid medium on to the work surface, by a shaped tool,
vibrating at ultrasonic frequency.

2 ABRASIVE JET MACHINING (AJM)

It is the material removal process where the material is removed or machined by the impact
erosion of the high velocity stream of air or gas and abrasive mixture, which is focused on to the
workpiece.

3.WATER JET MACHINING (WJM)

Water jet cutting can reduce the costs and speed up the processes by eliminating or reducing
expensive secondary machining process. Since no heat is applied on the materials, cut edges are
clean with minimal burr. Problems such as cracked edge defects, crystallization, hardening,
reduced wealdability and machinability are reduced in this process.

4.ELECTROCHEMICAL MACHINING (ECM)

It is the controlled removal of metals by the anodic dissolution in an electrolytic medium, where
the work piece (anode) and the tool (cathode) are connected to the electrolytic circuit, which is
kept, immersed in the electrolytic medium.

5.ELECTOCHEMICAL GRINDING (ECG)

ECG is the material removal process in which the material is removed by the combination of
Electro- Chemical decomposition as in ECM process and abrasive due to grinding.

6.ELECTRICAL DISCHARGE MACHINING (EDM)

EDM is the controlled erosion of electrically conductive materials by the Initiation of rapid and
repetitive spark discharge between the electrode tool to the cathode and work to anode separated
by a small gap kept in the path of dielectric medium. This Process also called spark erosion

7.PLASMA ARC MACHINING

Plasma is defined as the gas, which has been heated to a sufficiently high temperature to become
ionized.

8.LASER BEAM MACHINING

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.

9.ELECTRON BEAM MACHINING (EBM)

It is the thermo-electrical material removal process on which the material is removed by the high
velocity electron beam emitted from the tungsten filament made to impinge on the work surface,
 17ME554 Non-Traditional Machining (Professional Elective – I) Module 1

where kinetic energy of the beam is transferred to the work piece material, producing intense
heat, which makes the material to melt or vaporize it locally.