Non Traditional Machining-21ME751

Module 1
Introduction to Non Traditional machining
SYLLABUS
Introduction to Non-traditional machining, Need for Non-traditional machining process, Comparison
between traditional and non-traditional machining, general classification, Non-traditional
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.

1.1 Introduction to Non-traditional machining

Non-traditional manufacturing processes is defined as a group of processes that remove excess
material by various techniques involving mechanical, thermal, electrical or chemical energy or
combinations of these energies but do not use a sharp cutting tool as it needs to be used for
traditional manufacturing processes.
Extremely hard and brittle materials are difficult to machine by traditional machining processes
such as turning, drilling, shaping and milling. Non-traditional machining processes, also called
advanced manufacturing processes, are employed where traditional machining processes are not
feasible, satisfactory or economical due to special reasons as outlined below.
 Very hard fragile materials difficult to clamp for traditional machining
 When the work piece is too flexible or slender
 When the shape of the part is too complex.

Several types of non-traditional machining processes have been developed to meet extra required
machining conditions. When these processes are employed properly, they offer many advantages
over non-traditional machining processes. The common non-traditional machining processes are
described in this section.

Definition: A machining process is called Non-traditional machining if its material removal

mechanism is basically different than those in the traditional processes, i.e. a different form of energy
(other than the excessive forces exercised by a tool, which is in physical contact with the work piece)
is applied to remove the excess material from the work surface, or to separate the workpiece into
smaller parts.

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1.2 Need for development of Non-Conventional Processes

The strength of steel alloys has increased five folds due to continuous R&D effort. In aero-space
requirement of high strength at elevated temperature with light weight led to development and use of
hard titanium alloys, nimonic (Nickel based) alloys, and other HSTR alloys. The ultimate tensile
strength has been improved by as much as 20 times. Development of cutting tools which has
hardness of 80 to 85 HRC which cannot be machined economically in conventional methods led
to development of non –traditional machining methods.
1. Technologically advanced industries like aerospace, nuclear power, wafer fabrication, automobiles
has ever increasing use of high-strength temperature resistant (HSTR) alloys (having high strength
to weight ratio) and other difficult to machine materials like titanium, SST, nimonics, ceramics
and semiconductors. It is no longer possible to use conventional process to machine these alloys.
2. Production and processing parts of complicated shapes (in HSTR and other hard to machine alloys)
is difficult, time consuming an uneconomical by conventional methods of machining.
3. Innovative geometric design of products and components made of new exotic materials with
desired tolerance, surface finish cannot be produced economically by conventional machining.
4. The following examples are provided where NTM processes are preferred over the conventional
machining process:
♦ Intricate shaped blind hole – e.g. square hole of 15 mmx15 mm with a depth of 30 mm with
a tolerance of 100 microns
♦ Difficult to machine material – e.g. Inconel, Ti-alloys or carbides, Ceramics, composites, HSTR
alloys, satellites etc.,
♦ Low Stress Grinding – Electrochemical Grinding is preferred as compared to conventional
grinding
♦ Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20
♦ Machining of composites.
Non-Traditional Machining (NTM) Processes are characterized as follows:

 Material removal may occur with chip formation or even no chip formation may take place. For
example in AJM, chips are of microscopic size and in case of Electrochemical machining material
removal occurs due to electrochemical dissolution at atomic level

 In NTM, there may not be a physical tool present. For example in laser jet machining, machining
is carried out by laser beam. However in Electrochemical Machining there is a physical tool that
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is very much required for machining

 In NTM, the tool need not be harder than the work piece material. For example, in EDM, copper
is used as the tool material to machine hardened steels.
 Mostly NTM processes do not necessarily use mechanical energy to provide material removal.
They use different energy domains to provide machining. For example, in USM,AJM, WJM
mechanical energy is used to machine material.

1.3 Differences between Conventional and Non-Conventional machining processes

Sl No. Conventional Process Non-Conventional Process

The cutting tool and work piece are always
There is no physical contact between the tool
in physical contact with relative motion
1. and work piece, In some non-traditional
with each other, which results in friction
process tool wear exists
and tool wear
Material removal rate is limited by NTM can machine difficult to cut and hard
mechanical properties of work material to cut materials like titanium, ceramics,
2.
nimonics, SST, composites, semiconducting
materials
Relative motion between the tool and work Many NTM are capable of producing
is typically rotary or reciprocating. Thus complex 3D shapes and cavities
the shape of work is limited to circular or
3.
flat shapes. In spite of CNC systems,
production of 3D surfaces
is still a difficult task
Machining of small cavities, slits, blind Machining of small cavities, slits and
holes or through holes are difficult Production of non-circular, micro sized,
4.
large aspect ratio, shall entry angle holes are
easy using NTM

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Use relative simple and inexpensive Non-traditional processes requires expensive

5.
machinery and readily available cutting tools and equipment as well as skilled
tools labour, which increase the production cost
significantly

Capital cost and maintenance cost is low Capital cost and maintenance cost is high
6.

Traditional processes are well established Mechanics of Material removal of some of

7. and physics of process is well understood NTM process are still under research

Conventional process mostly uses Most NTM uses energy in direct form. For
8. mechanical energy example: laser, Electron beam in its direct
forms are used in LBM and EBM
respectively
Surface finish and tolerances are limited by High surface finish (up to 0.1 µm) and
9. machining inaccuracies tolerances (25 µm) can be achieved

High metal removal rate Low material removal rate

10.

1.4 Classification of NTM process

 Mechanical Processes - Erosion of work material by a high velocity stream of abrasives or fluid
(or both) is the typical form of mechanical action. It is characterized by the fact that the material
removal is due to the application of mechanical energy in the form of high frequency vibrations
or kinetic energy of an abrasive jet.

 Abrasive Jet Machining (AJM)

 Ultrasonic Machining (USM)

 Water Jet Machining (WJM)

 Electrochemical Processes – Electro chemical energy to remove material (reverse of

electroplating). Electrical energy used in combination with chemical reactions to remove material.

 Electro Chemical Machining (ECM)

 Electro Chemical Grinding (ECG)

 Electro Jet Drilling (EJD)

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 Electro-Thermal Processes - Thermal energy usually applied to small portion of work surface,
causing that portion to be removed by fusion and/or vaporization

 Electro-discharge machining (EDM)

 Laser Jet Machining (LJM)

 Electron Beam Machining (EBM)

 Chemical Processes - Chemical etchants selectively remove material from portions of work part,
while other portions are protected by a mask.

 Chemical Milling (CHM)

 Photochemical Milling (PCM)

Fig.1 Classification non-traditional machining processes

1.5 Selection of Non Traditional machining Process

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
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i) Physical parameter of the process

The physical parameters of the different NTM are given in the Table (refer ppt.) 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.
ii) Shapes cutting capability

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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.

iii) Process capability

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The process capability of NTM is given in Table 2.0 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.
iv) Economic consideration

1.6 Applications of NTM

 NTM are used to machine hard and difficult-to-cut materials like superalloys,
nimonics, carbides, heat resisting steel, etc, which are widely used in various
engineering applications.
 NTM is used for machining very thin and fragile parts, complex geometrical
profiles with superior finish, accuracy and tolerance, which are mostly preferred in
aerospace, automotive, nuclear, mining and other sectors.
 NTM are used for shaping hard cutting tools having complex geometrical profiles
with much precise accuracy.
 Apart from engineering applications, NTM processes are also used for preparation
of jewels for watch and timer movements; removing glue and paint from leather
objects and paintings; engraving of products with alphanumeric or bar codes,

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logos, symbols, graphics and other applications.
 In addition, NTM are also used in machining of cavities in forging dies, drilling
deeper holes and irregular shaped holes which cannot be obtained by conventional
machining methods.

1.7 Advantages
 Difficult to machine materials can be machined with non-conventional process
 Machining materials in the complex shapes is possible with non-conventional process
 Economical for mass production for long duration
 High strength to weight ratio, hardness and heat resisting materials can be
machined with non- conventional process
 High accuracy and surface finish
 Burr-free machining(ECM,EDM,CHM)
 Material removed without mechanical contact with the workpiece
(ECM,EDM,LBM,CHM).
 Material removal rate is independent of workpiece hardnesss (ECM,LBM,EDM)
 Cutting forces are independent of workpiece hardness (ECM,LBM,EDM,CHM)
 Tool material need not be harder than the workpiece material
(ECM,LBM,EDM,CHM,USM)
 Tool wear is not a problem (ECM,LBM,CHM)
 Ability to machine any material.(LBM)
 Stress- free machining (ECM,ECG,CHM)
 Uniform material removal over the entire area simultaneously (ECM,CHM)
 Superior surface integrity possible (ECM,CHM,ECG)
 Intricately shaped, very hard and fragile materials can be machined.(USM)
 Finely focused micro machining
 Micro- hole drilling at shallow entrance angles possible (EDM,ECM,LBM,EBM)
 Easy compatibility with numerical control and mini- computer controls
(ECM,EDM,LBM,EBM)

1.8 Limitations
 Work piece and tool must be electrically conductive (EDM,ECM)
 Depth of cut is limited (LBM)

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 Recast or heat affected zones (HAZ) of surfaces produced may be troublesome
(EDM,LBM,EBM)
 For this purpose the compatibility of the process with the metallurgical state of the
work piece materials can be studied before using a particular non-traditional
machining process for production work.
 There may be taper in the sidewalls of holes or cavities (EDM,LBM)
 Most of these limitations can be overcome and controlled, so that the advantages
can be obtained with good product quality assurance.

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