Non-Traditional

Machining (NTM)
DE/PE-2.0

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 Nontraditional Processes Defined

A group of processes that remove excess material by

various techniques involving mechanical, thermal,
electrical, or chemical energy (or combinations of
these energies) but do not use a sharp cutting tool
in the conventional sense

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 1. Introduction:
Latest trends in Manufacturing, Introduction to Flexible
manufacturing system, Introduction to computer integrated
manufacturing, Limitations of conventional machining processes,
Development of Non conventional machining processes, their
classification, advantages and
major applications
2. Advanced Mechanical Processes:
Ultrasonic machining, Water Jet Machining and Abrasive Flow
Machining-elements of process,
Applications and limitations
3. Electrochemical & Chemical Removal Processes:
Principle of operation, elements and applications of Electrochemical
Machining, Electrochemical
grinding, Electrochemical deburring, Electrochemical honing,
Chemical Machining,
Photochemical machining

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 5. Thermal Metal Removal Processes:
Electric Discharge Machining- Mechanism of metal removal,
electrode feed control, die electric fluids flushing, selection
of electrode material, applications. Plasma Arc Machining-
Mechanism of metal removal, PAM parameters, Equipment's
for unit, safety precautions and applications.
Laser Beam machining- Material removal, limitations and
advantages. Hot machining- method of heat, Applications
and limitations. Electon-Beam Machining-, Generation and
control of
electron beam, process capabilities and limitations
6. Hybrid Machining Processes:
Concept, classification, application, Advantages

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 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.

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Conventional Machining VS
Non-Conventional Machining
The cutting tool and workpiece are always in physical contact, with a
relative motion against each other, which results in friction and a
significant tool wear.

In non-traditional processes, there is no physical contact between the

tool and workpiece. Although in some non-traditional processes tool
wear exists, it rarely is a significant problem.

Material removal rate of the traditional processes is limited by the

mechanical properties of the work material. Non-traditional processes
easily deal with such difficult-to-cut materials like ceramics and
ceramic based tool materials, fiber reinforced materials, carbides,
titanium-based alloys.

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 Continue

In traditional processes, the relative motion between the tool and work
piece is typically rotary or reciprocating. Thus, the shape of the work
surfaces is limited to circular or flat shapes. In spite of widely used CNC
systems, machining of three-dimensional surfaces is still a difficult task.
Most non-traditional processes were develop just to solve this problem.

Machining of small cavities, slits, blind or through holes is difficult with

traditional processes, whereas it is a simple work for some non-
traditional processes.

Traditional processes are well established, use relatively simple and

inexpensive machinery and readily available cutting tools. Non-
traditional processes require expensive equipment and tooling as well as
skilled labor, which increases significantly the production cost.

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 Unconventional Machining Processes -
Classification

Electrical

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 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

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 Electrical Based Processes

1. Working principle
2. Equipment used
3. Process parameters
Electrical
4. Surface finish & MRR
5. Electrode/Tool
EDM 6. Power & Control circuits
WEDM 7. Tool wear
8. Dielectric
9. Flushing
10. Applications

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 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

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 Thermal Based Processes

1. Working principles
2. Equipment used
3. Types
LBM
4. Beam control techniques
PAM
5. Applications
EBM

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 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.

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 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.

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 Chemical & Electrochemical based
Unconventional Processes

CHM uses Chemical dissolution

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

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