Non Traditional Machining Processes by Arshad Habib Khan
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NON TRADITIONAL MACHINING PROCESSES
Presented By-
Arshad Habib Khan
Mechanical EngineeringM H Saboo Siddik College Of Engineering
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Introduction
• Rapid growth in the development of harder materials.
• These materials find application in aerospace, nuclear industries, etc.
• Machining harder materials by traditional method is difficult.
• Non traditional concept was emerged in 1960
• This method uses some form of energy for metal machining.
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TRADITIONAL V/S NON TRADITIONAL
Traditional
• Old method• Tool & work are in contact• Machinability depends on
hardness• Simple shapes• Excessive too wear• Large cutting force• High material removal• Less expensive
Non Tradional
• New method• No contact• Hardness of the workpiece is
immaterial• Complex shapes• Less tool wear• No cutting force• Low material removal• expensive
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CLASSIFICATION
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MATERIAL APPLICATION
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PROCESS SELECTION
• Capital cost• Tooling cost• Consumed power cost• Metal removal rate
(efficiency)• Wear of tooling
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ULTRA SONIC MACHINING (USM)
• The term ULTRASONIC is used to describe a vibratory wave of a frequency(above 16 Hz)
• Ultrasonic Transducer is used.• Electrical energy is converted into
mechanical vibrations• Piezo-electric effect is utilized• Tool is vibrating at 20-30 kHz
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Construction & working
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Pros & Cons
Pros
• Metal removal cost is low
• Stress free
• Good surface finish upto 0.02 to 0.8 microns
• Good accuracy upto +/-0.07mm
• Extremely hard materials can be machined
Cons
• Initial cost is high• Power consumption is high• Soft materials are difficult to
machine• Not suitable for heavy metal
removal
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ABRASIVE JET MACHINING (AJM)
• It is a finishing process• Focus high speed stream of
abrasive particles• Used for machining delicate
or very hard materials• Produces no heat damage to
work piece surface• Produces a taper in deep cut.
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Construction & working
• Consists of a power supply & mixer, ehaust hood a and gas or water supply.
• The nozzle can be held or mounted in a fixture for automatic operation.
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Applications of AJM
• Paint removal• Cleaning• Cutting soft materials• Pocket milling• Drilling• Turning• Textile, leather industry
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WATER JET MACHINING (WJM)
• Uses a high velocity jet of water.
• Mixture of water and abrasives.
• It finds the appliocation in industries from mining to aerospace.
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ELECTRO CHEMICAL MACHINING
• Electro chemical process
• Used for mass production
• For extremely hard materials
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ELECTRO-DISCHARGE MACHINING(EDM)
• Thermo Electric Type• Spark erosion• Material removal due to
thermal energy of the spark
• Electrically conductive materials
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Construction &working of EDM
• Spark machining or Spark erosion
• Material is removed by rapidly recurring current discharges between two electrodes
• Separated by a die electric fluid
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TYPES OF EDM
• Sinker EDM
• Wire EDM
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LASER BEAM MACHINING(LBM)
• LIGHT AMPLIFICATION STIMULATED EMISSION OF RADIATION.
• It is a cutting technology uses laser to cut material