Non Traditional

Machining
Processes
Presented By :

Yashpal Maru (111133)

Sitesh (111209)
Karan Sharma (111616)
Abhilash(111671)
Ankit lal (111672)
Anshu(111753)
Sonu Meena(111865)
The Need for Advanced Machining
Processes
Traditional machining processes
Material removal by mechanical means, such as chip
forming, abrasion, or micro-chipping
Advanced machining processes
Utilize chemical, electrical, and high-energy beams
The following cannot be done by traditional
processes:
Work piece strength and hardness very high,
>400HB
Work piece material too brittle, glass, ceramics,
heat-treated alloys
Work piece too slender and flexible, hard to clamp
Part shape complex, long and small hole
Special surface and dimensional tolerance
requirements
www.mindsover.com 2
Development
Development of harder and difficult to
machine materials such as hast alloy, nitra
alloy, waspalloy, nimonics, carbides, stainless
steel, heat resisting steels and many other
HSTR alloys
Used in aerospace industry, nuclear
engineering and other industries owing to
their high strength to weight ratio, hardness
and heat resisting quality.
CHIPS FORMATION IN
CONVENTIONAL MACHINING
PROCESS

CHIP

TOO
L

WORKPIE
CE

Thus the major characteristics of conventional machining are:

Generally macroscopic chip formation by shear deformation
Material removal takes place due to application of cutting
forces energy domain can be classified as mechanical
Cutting tool is harder than work piece at room temperature
as well as under machining conditions TOOL WORKPIECE CHIP
Schematic representation of various metal cutting operations .
The broad classification is given as
follows:

Thus classification of NTM processes is carried out

depending on the nature of energy used for material
removal.
Mechanical Processes
Abrasive Jet Machining (AJM)
Ultrasonic Machining (USM)
Abrasive Water Jet Machining (AWJM)
Electrochemical Processes
Electrochemical Machining (ECM)
Electro Chemical Grinding (ECG)
Electro Jet Drilling (EJD)
 Electro-Thermal Processes
Electro-discharge machining (EDM)
Laser Beam Machining (LBM)
Electron Beam Machining (EBM)
Chemical Processes
Chemical Milling (CHM)
Photochemical Milling (PCM) etc.
Abrasive Jet Machining
(AJM)
Abrasiv
e feeder
filter

Pressure control
exhaus
valve
t
Mixing
Drier chambe
r
Nozzle
turn valve
Air Electro-magnetic
compressor shaker work
piece
LASER Beam Machining
(LBM)
Electron Beam Machining (EBM)
Chemical Machining
(CHM)
PAM
ELECTROCHEMICAL MACHINING
(ECM)
 Combines chemical attack and electrical attack
High material removal rate
Masking is used to control attack
Conforming electrodes are to control shape
Commonly used for aircraft parts such as airfoil shapes
Normally followed by abrasive finishing or laser peening to
remove partially adhering particles
Works with a wide variety of metals

14
Electrolyte
Anelectrolyteis any substance containing freeionsthat make the
substanceelectrically conductive. The most typical electrolyte is
anionic solution, but molten electrolytes andsolid electrolytesare
also possible.

Function of electrolyte-
Carrying current between tool and work peice
Remove products of machining and other insoluble products from
cutting region
Dissipate heat produced in the operation.
Maintain a constant temperature in the machining region

Electrolyte used- Sodium chloride, Sodium Nitrate, Sodium Hydroxide

Characteristics of
Electrolyte
Good electrical conductivity
Non toxicity and chemical stability
Non corrosive property
Low viscosity and high specific heat
inexpensive and easily available
Avoid the formation of a passive film on the anodic surface.
Not deposit on the cathode surface, so that the cathode
shape remains unchanged
Maintain its stable ingredients and pH value, during the
machining period
Advantages of ECM
There is no wear in the tool because there is no contact
between the tool and the workpiece.
Machining is done at low voltages, compared to other
processes, with high metal removal rates.
Very small dimensions up to 0.05 mm can be controlled.
Complicated profiles can be machined easily in a single
operation
Because of the low temperature developed, no thermal
damage occurs to the workpiece structure.
Hard conductive materials can be machined
The surface finish can be maintained at 0.1 to 1.25 m Ra.
Because of its high capital cost, ECM is only suitable for
mass production work.
Disadvantages
A huge amount of energy is consumed (about 100 times that
required
for turning or drilling steel).
Metal removal rates are slow compared with conventional
methods.
ECM can only be applied to electrically conductive workpiece
materials.
There are difficulties in safely removing and disposing of the
explosive
hydrogen gas generated during machining.
The workpiece needs to be cleaned and oiled immediately
after
machining.
 There are difficulties with handling and containing the
electrolyte, which may attack the equipment.
It is not easy to duplicate the shape of the tool electrode in
the workpiece with a high degree of accuracy because of
the side machining effect.
The process cant produce sharp internal or external edges.
The pumping of high-pressure electrolyte into the narrow
machining
gap gives rise to large forces acting on the tool and the
workpiece.
Ultrasonic Machining
(USM)
Electric Discharge
Machining (EDM)
Successive electric arcs melt tiny
droplets from surface of workpiece
Frozen droplets must be flushed
away
Electrodes are made from graphite,
copper or copper-tungsten alloy
Material removed from electrode by
arc
Recast layer of approximately 0.001
in depth left on surface
Secondary process such as chemical
machining used to remove recast
layer www.mindsover.com 21
Dielectric Fluid
Adielectricis an electricalinsulatorthat can be
ionizedby an appliedelectric field. When a dielectric
is placed in an electric field, electric charges do not
flow through the material as they do in aconductor,
but only slightly shift from their average equilibrium
positions causingdielectric polarization.
Characteristic-
Low viscosity
High fluidity
Controlled level of toxicity
Cheap and easily available
Function of Dielectric
Fluid
Insulation Until required breakdown voltage attained.
Should act as conductor after required breakdown
voltage attained.
Should demonize rapidly after the discharge has
been occurred.
Clean spark gap by carrying away the molten metal.
Should cool the tool work piece and spark region.

Dielectric Used:-
light hydro carbon oil, kerosene, paraffin,
transformer oil, try ethylene glycol.
Difference between EDM & ECM
1. Uses dielectric fluid as a
conducting medium between
tool and work piece.
2. Wear of tool takes place during
the process.
3. Heat is generated during the
process.
4. Low metal removal rate.
5. It works on the principle of
spark erosion.
6. Metal is removed by melting
and vaporization.
7. Tools used are oversize for
machining inside surfaces and
undersize for machining outside
surfaces.
1. Using electrolyte as a
conducting medium between
tool and work piece.
2. No wear of tool during
process so tool life is high.
3. No heat is generated during
the process.
4. Metal removal rate is high.
5. It works on principle of
Faradays law of electrolysis.
6. Metal is removed by
electrochemical reaction.
7. Tool used are of required size
of the work piece.
Dielectric
Electrolyte
1. It is used as
conducting medium 1. It used as conducting
medium in ECM
in EDM process.
process.
2. It act as conductor
2. It always provide
and insulator both. passage for supply of
3. Tool wear takes electricity.
place in the 3. The electrolyte
dielectric fluid. selected is such that
4. It may or may not be there is no wear of tool.
corrosive in nature. 4. It should be non
corrosive in nature.
Economics of Advanced Machining
Processes
High cost of equipment, which typically
includes computer control
May use hard tooling, soft tooling, or
both
Low production rates
Can be used with difficult-to-machine
materials
Highly repeatable
Typically requires highly skilled
operators
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HYBRID MACHINING
Process
HYBRID MACHINING
PROCESS
Hybrid machining is a manufacturer of
fastener machinery to make a single
product out of two operations or two
different raw materials.

Reasons for developing this process are

to make use of the combined or mutually
enhanced advantages, and to avoid or
reduce adverse effects.

Example: Biometals rivets.

METHODOLOGY FOR HYBRID
MACHINING
Processes in which all constituents processes
are directly involved in material removal.

Processes in which only one of the

participating processes directly removes the
material while the other only assist in removal
by changing the conditions of machining in a
positive direction from the point of view of
improving capabilities of machining.
PROCESSES AND THEIR
INTERACTIONS
Different kind of machining process based on
different kind of interaction for improving
manufacturing characterstics of shaping and
finishining process.

Thermal interaction
Mechanical interaction
Chemical interaction and
Electro-chemical interaction
TYPES OF HMP

Abrassive electro-chemical grinding,

Abrassive electro-chemical honing,
Electro-chemical discharge machining,
Electro-chemical arc machining,
Laser electro-chemical machining,
Abrassive electrical discharge machining,
Ultrasonic machining
Magnetic abrassive machining
 ELECTROCHEMICAL
DISCHARGE MACHINING
PRINCIPLE OF WORKING
ECM-Anodic dissolution of work
EDM-Spark erosion
ECDM-Anodic dissolution & Spark erosion
Electro chemical reaction
Passivating film
Spark erosion
EQUIPMENT
Voltage-40-200V,DC

Current-3-4A

Electrolyte-semi dielectric fluids

Electrode gap-.01-1micro meters

3D tool feeder
WORKING
Anodic dissolution

Passivating film formation

Spark errosion
TOOL PROPERTIES
High electrical conductivity

High themal conductivity

High melting point

Cheapness

High machinability
Eg:cu,chisel steel,graphite,etc.
 FUNCTIONS OF
ELECTROLYTE
Maintain constant resistance accross the gap

Cools the spark region

Removes erroded particles

Aviod welding of tool and work

Eg:aqu solution of KOH,sodium silicate,sodium

nitrate,etc
TOOL WEAR
FACTORS AFFECTING TW
1.Diameter of tool
2.Voltage
3.Capacity
4.Liquid density

w = 1.329 10^ 11 D ^1.27 U^ 5.739

C^ 0.36 ^ 9.655
COMPARISON
ASPECTS ECM EDM ECDM
PRINCIPLE Anodic Spark errossion Both
dissolution
POWER 10,000A,2- 200A,50- 3-4A,40V,DC
3V,DC 200V,DC
WORK PIECE conductive conductive Conductive&no
n conductive
MRR less less 5times faster
than EDM
TOOL WEAR Lessthan both Higher than Lessthan EDM
ECDM
ACCURACY Higherthan EDM Dimensional +-.01mm
acc:+-.03mm
SURFACE FINISH Higher than less Higher than
both EDM
ADVANTAGES
High accuracy
Method does not leave any chips or burrs
High surface finish
Less power consumption
Does not need skilled operators
Machine conducting and non concucting
DISADVANTAGES
Low mrr
Electrode wear
High initial cost
Thickness of ceramic material can be
machined is limited to 1.5mm
Radial over cut
applications
ECDG

ECDD
CONCLUSION
It utilizes both the advantages of ECM &EDM

The applied voltage,electrotyte

cocetration,elecrode gap are affect the MRR

The applied voltage,dia of

tool,density,capacity are affect the tool wear
THANK YOU