An unconventional machining process (or non-traditional

machining process) is a special type of machining process in

which there is no direct contact between the tool and the work
piece. In this process, a form of energy is used to remove
unwanted material from a given work piece.
 Extremely hard and brittle materials are difficult to
machine by traditional machining processes such as
turning, drilling, shaping and milling.
 Nontraditional machining processes, also called
advanced manufacturing processes.
 Manufacturing processes can be broadly divided
into two groups.
1) Primary manufacturing processes: Provide basic
shape and size.
2)Secondary manufacturing processes: Provide final
shape and size with tighter control on dimension, surface
characteristics.
Material Removal Processes divided Into 2 Groups

1)Conventional Machining Processes

2)(Non-Traditional Manufacturing Processes or ucmp)
Conventional Machining Processes mostly
remove material in the form of chips by applying forces on the
work material with a wedge shaped cutting tool that is harder
than the work material under machining condition.
LIMITATIONS OF UCMP:
1)More expensive
2)Metal removal rate is slow

DISADVANTAGES:
1)Tool need not be harder than work piece.
2)Harder and difficult to machine materials can be machined.
3)The machined surface do not have any residual stresses
CLASSIFICATION OF UCM PROCESSES:
1. Mechanical Processes:
Material is removed by mechanical erosion of the work
piece material.
(AJM),(AWJM),(WJM),(USM)

2. Electrochemical Processes:
Material is removed by ion displacement of w.p
material in contact with chemical solution.
(ECM),(ECG),(EJD)

3. Electro-Thermal Processes:
Heat is concentrated on small area of workpiece,to
melt and vaporise the tiny bits of material, final
shape is required(EDM),(LJM),(EBM)
 ECM:-ELECTRO –CHEMICAL MACHINING PROCESS
INTRODUCTION

•A shaped tool(electrode is used in this process,

which is used connected to negative
terminal(cathode) and w.p to positive terminal
(anode).
•The tool material used for this process are
stainless steel, titanium, brass and copper.
•The electrolyte solution used for this process is
sodium nitrate some other chemicals are sodium
hydroxide, sodium flouride, potassium nitrate and
potassium chloride.
 WORKING

•The tool and w.p are held close to each other with avery
small gap(0.005 to 0.5 mm)
•The electrolyte from reservoir is pumped at high
pressure and flow through the gap between the w.p and
tool at high velocity of 30 to 60 m/s.
•A mild D.c voltage about 5 to 30 volts is applied
between tool and w.p
•Due to applied voltage ,the current flows through the
electrolyte +ve charged ions and –ve charged ions.The
+ve ions move towards tool(cathode) while negative
ions move towards the w.p(anode).
•The electrochemical reaction takes place due to this
flow of ions and causes the removal of metal from w.p
in the form of sledge.
ADVANTAGES:

1)Material removal rate is high

2)Machining is done at low voltage

3)Wear and tear of tool is negligible

4)Intricate and contour shapes can be

machined.

5)The machined surface is free of stresses.

.
DISADVANTAGES:

1)Non-conductive materials cannot be machined.

2)Machining process is slow.

3)Equipment requires more space

APPLICATIONS:

1)Drilling small deep holes, such as in nozzles.

2)Machining of cavities and holes of irregular shapes

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