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Tuesday, February 12, 2013

Conventional Machining VS. Non-Conventional

Machining

INTRODUCTION:
Manufacturing processes can be broadly divided into two groups and they are
primary manufacturing processes and secondary manufacturing processes. The
former ones provide basic shape and size to the material as per designers
requirement. Casting, forming, powder metallurgy are such processes to name a
few. Secondary manufacturing processes provide the final shape and size with
tighter control on dimension, surface characteristics etc. Material removal
processes are mainly the secondary manufacturing processes.
Material removal processes once again can be divided into mainly two groups and
they are Conventional Machining Processes and Non-Traditional
Manufacturing Processes.
Examples of conventional machining processes are turning, boring, milling,
shaping, broaching, slotting, grinding etc. Similarly, Abrasive Jet Machining
(AJM), Ultrasonic Machining (USM), Water Jet and Abrasive Water Jet
Machining (WJM and AWJM), Electro-discharge Machining (EDM) are some of
the Non Traditional Machining (NTM) Processes.

Conventional Machining VS. Non-Conventional

Machining:

Conventional machining usually involves changing the shape of a work piece using
an implement made of a harder material. Using conventional methods to machine
hard metals and alloys means increased demand of time and energy and therefore
increases in costs; in some cases conventional machining may not be feasible.
Conventional machining also costs in terms of tool wear and in loss of quality in
the product owing to induced residual stresses during manufacture. With ever
increasing demand for manufactured goods of hard alloys and metals, such as
Inconel 718 or titanium, more interest has gravitated to non-conventional
machining methods.
Conventional machining can be defined as a process using mechanical (motion)
energy.
Non-conventional machining utilizes other forms of energy.
The three main forms of energy used in non-conventional machining
processes are as follows:
Thermal energy
Chemical energy
Electrical energy

Comparison

Conventional Manufacturing
Processes

Non-Conventional
Manufacturing Processes

1. Generally macroscopic chip formation

1. Material removal may occur with chip
by shear deformation.
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

2. There may not be a physical tool present.

2. There may be a physical tool present.
For example in laser jet machining,
for example a cutting tool in a Lathe
machining is carried out by laser beam.
Machine,
However in Electrochemical Machining
there is a physical tool that is very much
required for machining.
3.
3. Cutting tool is harder than work piece
at room temperature as well as under
machining conditions

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 is very much
required for machining.

4. Mostly NTM processes do not necessarily

use mechanical energy to provide material
4. Material removal takes place due to removal. They use different energy domains
application of cutting forces energy to provide machining. For example, in USM,
domain can be classified as mechanical
AJM, WJM mechanical energy is used to
machine material, whereas in ECM
electrochemical
dissolution
constitutes
material removal.
5. Whereas unconventional machining does

not require the direct contact of tool and

5. Conventional machining involves the work piece.
direct contact of tool and work piece
6. Higher accuracy and surface finish.
6. Lower accuracy and surface finish.
7. Suitable for every type of material
7. Not Suitable for every type of material
economically
economically
8. Tool life is less due to high surface
8. Tool life is more
contact and wear.
9. Lower waste of material due to low or no
9. Higher waste of material due to high
wear.
wear.
10. Quieter
operation
mostly
10. Noisy operation mostly cause sound
sound pollutions are produced.
pollutions

11. Lower capital cost

11. Higher capital cost

12. Easy set-up of equipment.

12. Complex set-up equipment.

no

13. Skilled operator required.

13. Skilled or un-skilled operator may
required
14. Generally they are manual to operate. 14. Generally they are fully automated process.
15. Can be used to produce prototype parts very
15. They cannot be used to produce
prototype parts very efficiently and efficiently And economically.
economically.
Posted by Muhammad Umair Bukhari at 11:54 PM
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