Unconventional machining process

UNCONVENTIONAL
MACHINING
PROCESS

INTRODUCTION
We all know that the term machinability refers to the
case with which a metal can be machined to an
acceptable surface finish.
 Nontraditional machining processes are widely used to
manufacture geometrically complex and precision parts
for aerospace, electronics and automotive industries.

In ordinary machining we use harder tool to work on work
piece, this limitations is overcome by unconventional
machining, unconventional machining is directly using
some sort of indirect energy For machining.
Ex: sparks , laser, heat, chemical etc.
applied in EDM , laser cutting machines etc.
Non conventional Machining is a recent development in
machining techniques.

The requirements that lead to the
development of nontraditional machining.
 Very high hardness and strength of the material.
 The work piece: 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.

 Conventional machining involves the direct contact of
tool and work -piece, whereas unconventional machining
does not require the direct contact of tool and work piece.
Conventional machining has many disadvantages like tool
wear which are not present in Non-conventional
machining.

Advantages of Non-conventional
machining:
1) High accuracy and surface finish
2) Less/no wear
3) Tool life is more
4 ) Quieter operation

Disadvantages of non-conventional
machining:
1) High cost
2) Complex set-up
3) Skilled operator required

MACHINING
CHARACTERISTICS
The machining characteristics of different non-
conventional processes can be analysed withrespect
to :
 Metal removal rate
 Tolerance maintained
 Surface finish obtained
 Depth of surface damage
 Power required for machining

Unconventional machining processes
o Chemical machining(CM)
o Electrochemical machining(ECM)
o Electrochemical Grinding (ECG)
o Electrical Discharge Machining (EDM)
o Wire EDM
o Laser Beam Machining (LBM)
o Electron Beam Machining(EBM)
o Water Jet Machining (WJT)
o Abrasive Jet Machining (AJM)
o Ultrasonic Machining (USM)

CLASSIFICATION OF
UNCONVENTIONAL MACHINING PROCESS
Mechanical processes
electro-thermal
processes
Chemical/electrochemical
processes
Unconventional
machining process

Unconventional machining process

 Oldest nontraditional machining process.
 Material is removed from a surface by chemical
dissolution using chemical reagents or etchants like
acids and alkaline solutions.
CHEMICAL
MACHINING (CM)

Types of chemical machining
1. Chemical Milling
By selectively attacking different areas of work
piece with chemical reagents shallow cavities can
be produced on plates, sheets, forging and
extrusion.
2. Chemical blanking
It is similar to blanking in sheet metals except
material is removed by chemical dissolution rather
than by shearing. Used in bur free etching of
printed circuit boards, decorative panels etc.
3. Photochemical blanking
This process is effective in blanking fragile work
pieces and materials. Material is removed using
photographic techniques. Applications are electric
motor lamination, flat springs, masks for color
television, printed circuit cards etc.

 Reverse of electroplating
 An electrolyte acts as a current carrier and high
electrolyte movement in the tool-work-piece gap
washes metal ions away from the work piece (anode)
before they have a chance to plate on to the tool
(cathode).
 Tool – generally made of bronze, copper, brass or
stainless steel.
 Electrolyte – salt solutions like sodium chloride or
sodium nitrate mixed in water.
 Power – DC supply of 5-25 V.
ELECTROCHEMICAL
MACHINING

 Process leaves a burr free surface.
 Does not cause any thermal damage to the parts.
 Lack of tool force prevents distortion of parts.
 Capable of machining complex parts and hard
materials
 ECM systems are now available as Numerically
Controlled machining centers with capability for
high production, high flexibility and high
tolerances.
ADVANTAGES OF ECM

 Combines electrochemical machining with
conventional grinding.
 The equipment used is similar to conventional
grinder except that the wheel (bonded with
diamond or Al oxide abrasives) is a rotating
cathode with abrasive particles where
abrasives serve as insulator between wheel
and work piecee.
 A flow of electrolyte (sodium nitrate) is
provided for electrochemical machining.
ELECTROCHEMICAL GRINDING (ECG)

 Suitable for grinding very hard materials where wheel
wear is very high in traditional grinding process .

 Based on erosion of metals by spark discharges.
 EDM system consist of a tool (electrode) and work
piece, connected to a dc power supply and placed in a
dielectric fluid.
 When potential difference between tool and work piece
is high, a transient spark discharges through the
fluid, removing a small amount of metal from the work
piece surface.
 This process is repeated with capacitor discharge rates
of 50-500 kHz.
ELECTRICAL DISCHARGE MACHINING

 dielectric fluid – mineral oils, kerosene, distilled and
deionized water etc.
role of the dielectric fluid
1. acts as a insulator until the
potential is sufficiently high.
2. acts as a flushing medium and
carries away the debris.
3. also acts as a cooling medium.
 Electrodes – usually made of graphite.
 EDM can be used for die cavities, small diameter deep
holes,turbine blades and various intricate shapes.

ELECTRICAL
DISCHARGE
MACHINING

 This process is similar to contour cutting with a band
saw.
 a slow moving wire travels along a prescribed
path, cutting the work piece with discharge sparks.
 wire should have sufficient tensile strength and fracture
toughness.
 wire is made of brass, copper or tungsten. (about
0.25mm in diameter).
Wire EDM

 In LBM laser is focused and the work piece which melts
and evaporates portions of the work piece.
 Low reflectivity and thermal conductivity of the work
piece surface, and low specific heat and latent heat of
melting and evaporation – increases process efficiency.
 Application - holes with depth-to-diameter ratios of 50 to
1 can be drilled. e.g. bleeder holes for fuel-pump
covers, lubrication holes in transmission hubs.
Laser beam
machining (LBM)

 Similar to LBM except laser beam is replaced by high
velocity electrons.
 When electron beam strikes the work piece surface, heat
is produced and metal is vaporized.
 Surface finish achieved is better than LBM.
 Used for very accurate cutting of a wide variety of
metals.
Electron beam
machining (EBM)

 Water jet acts like a saw and cuts a narrow groove in
the material.
 Pressure level of the jet is about 400MPa.
 Advantages
- no heat produced
- cut can be started anywhere
without the need for predrilled holes
- burr produced is minimum
- environmentally safe and friendly
manufacturing
 Application – used for cutting
composites, plastics, fabrics, rubber, wood products
etc. Also used in food processing industry.
WATER JET MACHINING (WJT)

 In AJM a high velocity jet of dry air, nitrogen or CO2
containing abrasive particles is aimed at the work piece.
 The impact of the particles produce sufficient force to cut
small hole or slots, deburring, trimming and removing
oxides and other surface films.
Abrasive Jet
Machining (AJM)

 In UM the tip of the tool vibrates at low amplitude and
at high frequency. This vibration transmits a high
velocity to fine abrasive grains between tool and the
surface of the work piece.
 Material removed by erosion with abrasive particles.
 The abrasive grains are usually boron carbides.
 This technique is used to cut hard and brittle materials
like ceramics, carbides, glass, precious stones and
hardened steel.
ULTRASONIC MACHINING (UM)

Made by:
Vatsal Vaghela (111)
THANK YOU

Unconventional machining process

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Unconventional machining process