Introduction

Manufacturing Technology I
Metal casting (Sand casting and other
casting processes)
Materials Joining (Arc welding, TIG, EBW,
PAW, etc.)
Bulk deformation (Metal Forming Forging,
Rolling, Extrusion)
Sheet metal processes (Shearing, bending,
drawing, etc.)
Manufacturing of plastic materials (Injection
molding, etc).
Manufacturing Technology II (Material removal
process)
Metal Cutting or Mechanical Abrasion
Centre lathe and special purpose lathes

Introduction Contd.
Machining produces finished products with
high degree of accuracy.
Conventional machining
Utilizes cutting tools (harder than work
piece material).
Needs a contact between the tool and work
piece.
Needs a relative motion between the tool
and work piece.
Absence of any of these elements makes the
process a unconventional or nontraditional one.
The need for higher productivity, accuracy and
surface quality led to combination of two or
more machining actions, called hybrid

History of Machining
In ancient days hand tools (stones, bones or
stick).
Later hand tools of elementary metals (bronze
or iron)
Till 17th Century tools were either hand
operated or driven mechanically by very
elementary methods.
Wagons, ships, furniture, etc. were produced.
Introduction of water, steam and electricity
power driven machine tools
Caused a big revolution in 18th and 19th
centuries.
1953 Numerical control machine tools
enhanced the product productivity and

Traditional or Conventional Machining

Metal Cutting Processes

Abrasive Machining
Cylindrical grinding

Flat surface grinding

Abrasive Machining

Centreless grinding

Need for Unconventional Machining

Greatly improved thermal, mechanical and
chemical properties of modern materials Not
able to machine thru conventional methods.
(Why???)
Ceramics & Composites high cost of
machining and damage caused during
machining big hurdles to use these materials.
In addition to advanced materials, more
complex shapes, low rigidity structures and
micro-machined components with tight
tolerances and fine surface finish are often
needed.
To meet these demands, new processes are

Need for 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.
Surface finish or tolerance better than those
obtainable conventional process.
Temperature rise or residual stress in the work
piece are undesirable.

Unconventional Machining Processes Classification

Electrical

11

Mechanical Based Processes

1. Working principles
2. Equipment used
AJM

3. Process parameters

WJM

4. MRR

AWJM

5. Variation in techniques
used

USM

6. Applications

Electrical Based Processes

1.

Working principle

2.

Equipment used

3.

Process parameters

4.

Surface finish & MRR

5.

Electrode/Tool

EDM

6.

Power & Control circuits

WEDM

7.

Tool wear

8.

Dielectric

9.

Flushing

Electrical

10. Applications

13

Chemical & Electrochemical Based Processes

CHM
ECM
ECG
ECH

1.

Working principles

2.

Etchants & Maskants

3.

Techniques of applying
maskants

4.

Process parameters

5.

Surface finish & MRR

6.

Electrical circuits in case of

ECM

7.

Applications

14

Thermal Based Processes

LBM

1.

Working principles

2.

Equipment used

3.

Types

4.

Beam control
techniques

5.

Applications

PAM
EBM

15

Mechanical based
Unconventional Processes
USM thru mechanical
abrasion in a medium
(solid abrasive particles
suspended in the fluid)
WJM Cutting by a jet of
fluid
AWJM Abrasives in fluid
jet.
IJM Ice particles in fluid
jet.
Abrasives or ice
Enhances cutting action.

Thermal based Unconventional Processes

Thru melting &
vaporizing
Many secondary
phenomena surface
cracking, heat affected
zone and striations.
Heat Source:
Plasma EDM and PBM.
Photons LBM
Electrons EBM
Ions IBM
Machining medium:
different for different
processes.

Chemical & Electrochemical

based Unconventional Processes

CHM uses Chemical dissolution

action in an etchant.
ECM uses Electrochemical
dissolution action in an
electrolytic cell.