INTRODUCTION

With the development of new materials more and more challenges are
faced by scientists
Conventional Machining processes there is physical contact between
tool and work piece.
In Unconventional no direct physical contact so tool need not be
harder than work.
Unconventional machining processes harness energy sources
considered unconventional by yesterday's standards.
Material removal is accomplished using electrical, chemical,
mechanical and light energies
During the last 55 years over 20 different non-traditional
manufacturing processes have been invented and used successfully

The requirements that lead to the development of

Unconventional machining:
Very high hardness and strength of the material. (above
400 HB.)
The work piece is too flexible or slender to support the
cutting or grinding forces.
The shape of the part is complex, such as internal and
external profiles, or small diameter holes or non-circular
holes.
Surface finish or tolerance better than those obtainable
conventional process.
Temperature rise or residual stress in the work piece are
undesirable.
Economy and High Production rates for advanced materials

Trend Of Increase Of Material Strength

Aerospace alloys are High strength to Weight ratio alloys

HSTR alloys Nimonics, Titanium alloys, Hastalloys
Stainless steels, Maraging steels

ULTRASONIC MACHINING

ABRASIVE JET MACHINING

ELECTRICAL DISCHARGE MACHINING

ELECTROCHEMICAL MACHINING

LASER BEAM MACHINING

ELECTRON BEAM MACHINING

Process

Applications

Abrasive Jet machining

Materials: Hard and Brittle metals,

alloys, non-metallic materials
(Eg.,silicon,glass, ceramics, mica)
Specially suitable for thin sections
Job: Drilling, cutting, deburring,
etching, cleaning

Ultrasonic machining

Materials: Hard and Brittle

materials, non-metals-glass,
ceramics
Job: Round and Irregular holes,
impressions

Electrical discharge machining

Materials: All conducting metals

and alloys
Job: Blind complex cavities, micro
holes for nozzles, through cutting
of non-circular holes, narrow slots

Process

Applications

Electrochemical machining

Materials: All conducting metals

and alloys
Job: Blind complex cavities,
curved surfaces, large through
cavities

Laser beam machining

Materials: All materials

Job: Drilling fine holes, cutting
contours in sheets, cutting narrow
slots

Electron beam machining

Materials: All materials

Job: Drilling fine holes

ULTRASONIC MACHINING(USM)
Frequency: 20 KHz
Amplitude: 15-20m

power
supply ~
Transducer

Up-down vibration of tool

hammers the abrasive particles
against workpiece, causing cutting

Nozzle

Abrasive
slurry

Principle of Working:

An abrasive slurry is pumped between tool and work

In USM the tip of the tool vibrates at low amplitude and high
frequency. This vibration transmits a high velocity to fine abrasive
grains between tool and the surface of the work piece.
Material removal is by brittle fracture caused by impact abrasive
grains due to vibration at high frquency
Tool material being tough and ductile wears out at much slower
rate.
Equipment consists of Transducer, Tool holder and the Tool
Linear oscillatory motion of tool obtained by magnetostrictive
transducer converts electrical energy to mechanical
Transducer consists of stack of nickel laminations that are wound
with a coil high frequency current is passed longitudinal strains
in laminations transmitted to tool thru tool holder
The abrasive grains are usually Al2O3,SiC, B4C, Diamond

ABRASIVE JET MACHINING

Principle of Working:
In AJM a high velocity jet of dry air or some other gas mixed
with abrasive particles is directed at the work piece.
The material removal is due to brittle fracture caused by
impinging abrasive grains at high speed
The abrasive particles are contained in mixing chamber,
compressed air is supplied to the chamber.
The chamber is vibrated and amplitude of vibrations controls
the flow of abrasive particles. From the chamber the stream of
abrasives is directed to the workpiece through a nozzle.
To resist abrasion and wear, nozzles are made up of Tungsten
carbide and synthetic sapphire.
Large size Abrasive grains used for rapid removal rate
Smaller size for good surface finish and precision.
Material removal rate depends on: Dia of nozzle, abrasives
composition, velocity of jet, distance of workpiece from nozzle
tip

ELECTRIC DISCHARGE MACHINING

Principle of Working:
Material removal takes place due to melting and evaporation caused
by high temperature electric spark struck between cathode and anode
Material removal rate and resulting surface finish is controlled by
proper variation in the energy and duration of spark discharge
For improving effectiveness the workpiece and the tool are
submerged in a dielectric fluid (like mineral oil, kersone)
It has been observed that if both the electrodes are made of same
material , the electrode connected to positive terminal generally erodes
at a faster rate. For this reason the workpiece is normally made anode.
The main elements of the setup include, power supply source (DC),
dielectric medium, tool, workpiece, servocontrol unit to maintain
sparkgap
Tool material: brass, copper,graphite
Dielectric uses are two fold: (i) to flush away the chips at machining
zone (ii) to increase the material removal rate

This process is based on principle of electrolysis

This process is considered as reverse of electroplating with some
modifications
A shaped tool or electrode is used which forms the cathode, the
work forms the anode. The shape of the tool is reproduced on the
work.
A small gap is maintained between the tool and work and an
electrode at a high pressure is pumped through it.
Low voltage DC is employed, which in the presence of electrolyte
enables a controlled removal of metal from work by anodic
dissolution
Workpiece is held stationary while tool is fed continuously
The electrolyte so chosen that anode is dissolved but no
deposition takes place on the cathode
Electrolyte used may be sodium nitrate, sodium chloride etc.,
Rate of metal removal is independent of work hardness

Typical parts made by electrochemical machining. (a) Turbine blade made of nickel
alloy of 360 HB. Note the shape of the electrode on the right. (b) Thin slots on a 4340steel roller-bearing cage. (c) Integral airfoils on a compressor disk.

(a) Two total knee replacement systems showing metal implants (top pieces)
with an ultra-high molecular-weight polyethylene insert (bottom pieces). (b)
Cross-section of the ECM process as applies to the metal implant. Source:
Courtesy of Biomet, Inc.

Laser-Beam
Machining
(LBM)

Principle of working:
Light Amplification by Stimulated Emission of Radiation
LASER beam is highly coherent, monochromatic and it can be
focused to a very small diameter and can produce very high power
density
The setup for producing laser consists of a coiled xenon flash tube
placed around the ruby rod and the internal surface of the container
walls is made highly reflecting so that maximum light falls on the ruby
rod for the pumping operation
The emitted laser beam is focused by a lens system and focused
beam meets the working surface removing a small portion of the
material by melting & vaporization
Since the energy released by the flash tube is much more than the
energy transmitted by the laser head, the system must be properly
cooled

Electron-Beam Machining Process

Schematic illustration of the electron-beam machining process.

Unlike LBM, this process requires a vacuum, so workpiece size is
limited to the size of the vacuum chamber.

Principle of working:
Thermal Process
A stream of high speed electrons impinges on the work surface
whereby the kinetic energy transferred to the work material producing
intense heating leading to melting and vaporization of work
The complete EBM setup is enclosed in a vacuum chamber else the
beam of electrons will collide with air molecules and will scatter.
The electrons are emitted from the cathode (a hot tungsten filament) ,
the beam is shaped by the grid cup and the electrons are accelerated due
to a large potential difference between the cathode and anode
The beam is focused with the help of electromagnetic lenses. The
deflecting coils are used to control the beam movement in any
required manner
The process of heating by an electron beam can depending on the
intensity be used for annealing, welding or metal removal.
A suitable viewing device is incorporated to enable the operator to
observe the progress of the machining operation