Nontraditional Machining

Nontraditional machining refers to a

group a processes which removes
excess material by various
techniques involving mechanical,
thermal, electrical or chemical energy
These processes do not use a sharp
cutting tool in the conventional sense

 Nontraditional processes have

been developed in response to
new and unusual machining
requirements, including
The need to machine newly
developed materials with special
properties (high strength, high
hardness, high toughness)
The need for unusual and/or
complex geometries
The need to avoid surface damage

 Classification of nontraditional
manufacturing processes by
principle form of energy
Mechanical - mechanical energy
in some form different from the
action of a conventional cutting
tool; erosion of the workpiece
material is typical
Electrical - electrochemical
energy to remove material

 Thermal - thermal energy generally

applied to a small portion of the work
surface, causing removal by fusion
and/or vaporization; thermal energy is
generated by conversion of electrical
energy
Chemical - most materials are
susceptible to chemical attack by
certain acids or other etchants;
chemicals selectively remove material
from portions of the workpiece, while
other portions of the surface are
protected

Non-Traditional Manufacturing Processes

Chemical Machining (CM)

Electrochemical Machining (ECM)
Electro-Discharge Machining (EDM)
Laser cutting
Ultrasonic Machining (USM)
Water-Jet and Abrasive Water-Jet Machining

ELECTROCHEMICAL
MACHINING
Elecrochemical machining (ECM) is
a non-conventional
machining
process that is used for machining
complicated
shapes
and
high
strength, high temperature resistant
materials.
This process works on the principle
of electrolysis.

ECM reaction

02/01/17

Electrochemical Machining (ECM)

Schematic diagram of
Electrochemical
Machining

Controlled anodic
dissolution of work piece in
ECM

Schematic representation of electro-chemical

machining
02/01/17

Reactions at Anode
cathode

02/01/17

Reactions at

The most common electrolytes used are

sodium chloride (NaCl), sodium nitrate
(NaNO3), and sodium hydroxide.

02/01/17

PARAMETERS IN ECM
Input parameters:
Electrolyte concentration
Voltage
Feed rate
Inter electrode gap
Out put parameters:
Material removal rate
Radial over cut
Surface roughness
Cylindricity error

Tool Feed
Mechanism

Machining
Chamber

Pump

Electrolyte
Circulation

Electrochemical Machining setup

Control
Panel

Tool without
insulation

Tool with
insulation

Electrochemical hole drilling.

02/01/17

Advantages:
No mechanical stress impact into the processed work piece.
No thermal impact on the work piece.
The removal rate is not determined by the hardness or toughness of
the material.
No process related tool wear.
Great versatility for machining of geometrical complex shapes.
No burr formation.

Disadvantages:
High specific energy consumption.
Not suited for non-conducting pieces.
High initial and working cost.

Various machining operations based on electrochemical

dissolution of anode:
Electrochemical Boaring
Electrochemical Broaching
Electrochemial Drilling
Electrochemical Honing
Electrochemial Turning
Electrochemial Micromachining