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I Unit - Introduction To Unconventional Machining Processes

This document provides an introduction to unconventional machining processes. It discusses how conventional machining utilizes cutting tools and contact between the tool and workpiece, while unconventional processes lack one or more of these elements. The need for unconventional processes is due to materials with improved properties that cannot be machined conventionally, as well as demands for complex shapes, tight tolerances, and fine surfaces. Unconventional processes are then classified as mechanical, electrical, thermal, or chemical/electrochemical based and examples from each category are outlined, along with their basic working principles.

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Ravichandran G
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618 views19 pages

I Unit - Introduction To Unconventional Machining Processes

This document provides an introduction to unconventional machining processes. It discusses how conventional machining utilizes cutting tools and contact between the tool and workpiece, while unconventional processes lack one or more of these elements. The need for unconventional processes is due to materials with improved properties that cannot be machined conventionally, as well as demands for complex shapes, tight tolerances, and fine surfaces. Unconventional processes are then classified as mechanical, electrical, thermal, or chemical/electrochemical based and examples from each category are outlined, along with their basic working principles.

Uploaded by

Ravichandran G
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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ME2026

Unconventional Machining Processes

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
Shaper, Planer, Slotter, Milling, Drilling, Broaching, Gear cutting, etc.
Grinding, Honing, Lapping, etc.
CNC and DNC
2

Introduction Contd.
Machining produces finished products with high degree of
accuracy.
Conventional machining
Utilizes cutting tools (harder than workpiece material).
Needs a contact between the tool and workpiece.
Needs a relative motion between the tool and workpiece.

Absence of any of these elements makes the process a


unconventional or nontraditional one.
Big boon to modern manufacturing industries.
The need for higher productivity, accuracy and surface
quality led to combination of two or more machining
actions, called hybrid machining processes.

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 accuracy.

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 developed.
Play a considerable role in aircraft, automobile, tool, die and
mold making industries.

10

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.

11

Unconventional Machining Processes Classification

Electrical

12

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

13

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

14

Chemical & Electrochemical Based


Processes
1.

Working principles

2.

Etchants & Maskants

3.

Techniques of applying maskants

CHM

4.

Process parameters

ECM

5.

Surface finish & MRR

ECG

6.

Electrical circuits in case of ECM

ECH

7.

Applications

15

Thermal Based Processes

LBM
PAM
EBM

1.

Working principles

2.

Equipment used

3.

Types

4.

Beam control techniques

5.

Applications

16

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.

17

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.
18

Chemical & Electrochemical based


Unconventional Processes

CHM uses Chemical dissolution


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

19

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