UNIT-4

Unconventional Machining Process - Classification, Laser Beam

Machining, Electric Discharge Machining, Electrochemical
Machining, Electrochemical Grinding, Ultrasonic Machining,
Abrasive Jet Machining.
Manufacturing processes can be broadly divided into two groups:
a) Primary manufacturing processes : Provide basic shape and size
b) Secondary manufacturing processes : Provide final shape and size with tighter control
on dimension, surface characteristics

Material removal processes once again can be divided into two groups
1. Conventional Machining Processes
2. Non-Traditional Manufacturing Processes or non-conventional Manufacturing processes
Conventional Machining Processes

➢ 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.

The major characteristics of conventional machining are:

a) Generally macroscopic chip formation by shear deformation
b) Material removal takes place due to application of cutting forces – energy domain
can be classified as mechanical cutting tool is harder than work piece at room
temperature.
Non-conventional manufacturing processes

➢ Non-conventional manufacturing processes is defined as 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 tools as it needs to be used for traditional manufacturing processes.

The major characteristics of Non-conventional machining are:

1. Material removal may occur with chip formation or even no chip formation may
take place. For example in AJM, chips are of microscopic size and in case of
Electrochemical machining material removal occurs due to electrochemical dissolution
at atomic level.
Needs for Non Traditional Machining

❖ Extremely hard and brittle materials or Difficult to machine materials are difficult to

machine by traditional machining processes.

❖ When the workpiece is too flexible or slender to support the cutting or grinding forces.

❖ When the shape of the part is too complex.

❖ Intricate shaped blind hole – e.g. square hole of 15 mm X15 mm with a depth of 30 mm

❖ Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20

❖ Machining of composites.
Classification of NTM processes
classification of NTM processes is carried out depending on the nature of energy used for material
removal.
1. Mechanical Processes
➢ Abrasive Jet Machining (AJM)
➢ Ultrasonic Machining (USM)
➢ Water Jet Machining (WJM)
➢ Abrasive Water Jet Machining (AWJM)
2. Electrochemical Processes
➢ Electrochemical Machining (ECM)
➢ Electro Chemical Grinding (ECG)
➢ Electro Jet Drilling (EJD)
3. Electro-Thermal Processes
➢ Electro-discharge machining (EDM)
➢ Laser Jet Machining (LJM)
➢ Electron Beam Machining (EBM)
4. Chemical Processes
➢ Chemical Milling (CHM)
➢ Photochemical Milling (PCM)
Mechanical: Erosion of the work material by a high velocity stream of abrasives or fluids (or
both)

Thermal: The thermal energy is applied to a very small portion of the work surface, causing that
portion to be removed by fusion and/or vaporization of the material. The thermal energy is
generated by conversion of electrical energy.

Electrochemical: Mechanism is reverse of electroplating.

Chemical: Most materials (metals particularly) are susceptible to chemical attack by certain acids
or other etchants. In chemical machining, chemicals selectively remove material from portions of
the workpart, while other portions of the surface are protected by a mask.
SELECTION OF PROCESS
For selecting a particular process the following common parameters should be taken into
consideration :
1. Shape and size required to be produced.
2. Physical properties of the work material.
3. Process economy.
4. Process capabilities such as expected tolerance, surface finish, rate of metal removal,
power requirement etc.
5. Type of operation required (e.g., cutting, hole making etc.)
Electric Discharge Machining

➢ The Electrical Discharge Machining (EDM) process involves

controlled erosion of electrically conducting materials by the initiation
of rapid and reptitive electrical discharge between the tool (cathode)
and workpiece (anode) separated by a dielectric fluid medium.
 Principle and Working
➢ A suitable gap between the tool and workpiece is maintained to cause the spark discharge. The gap can
be varied to match the machining conditions such as metal removal rate.
➢ As soon as the voltage gradient set up between the tool and the workpiece is sufficient enough to
breakdown the dielectric medium, a conducting electrical path is developed for spark discharge owing
to ionization of the fluid medium and thereby causes the current to flow.
➢ The temperature of the spot hit by the spark may rise upto 10000°C causing the work surface to melt
and vaporize and ultimately to take the form of a sphere as it is quenched by the surrounding fluid.
➢ If the tool is fed downwards, maintaining the predetermined gap, the tool shape/profile will be
reproduced on the workpiece.
➢ The spark gap, generally 0.01 to 0.1 mm, is adjusted so that the gap voltage is around 70 percent of the
supply voltage for charging the capacitor bank.
➢ Higher gap although increases the discharge energy but it decreases the spark frequency due to
increase in charging time of the capacitor.
Important characteristics of EDM :

➢ Tool materials : Copper, brass and graphite.

➢ Workpiece materials : Conducting metals and alloys.
➢ Process parameters : Voltage, capacitance, spark gap and melting temperature
of workpiece.
➢ Material removal : Melting and vaporisation.

Dielectric Fluid
➢ Fluid medium which doesn’t conduct electricity
➢ Dielectric fluids generally used are paraffin, white spirit, kerosene, mineral oil
➢ Must freely circulate between the work piece and tool which are submerged in it
➢ Eroded particles must be flushed out easily
➢ Dielectric fluid must be filtered before reuse so that chip contamination of fluid
will not affect machining accuracy
Advantages of EDM
➢ Any materials that are electrically conductive can be machined by EDM.
➢ Materials, regardless of their hardness, strength, toughness and microstructure can be
easily machined/cut by EDM process.
➢ The tool (electrode) and workpiece are free from cutting forces.
➢ Edge machining and sharp corners are possible in EDM process.
➢ The tool making is easier as it can be made from softer and easily formable materials
like copper, brass and graphite.
➢ The process produces good surface finish, accuracy and repeatability.
➢ Hardened workpieces can also be machined since the deformation caused by it does
not affect the final dimensions.
➢ EDM is a burr free process.
 Limitations of EDM

➢ This process can only be employed in electrically conductive materials;

➢ Material removal rate is low and the process overall is slow compared to

conventional machining processes;

➢ Unwanted erosion and over cutting of material can occur;

➢ Rough surface finish when at high rates of material removal.

Applications :

1. Very useful in tool manufacturing due to ease with which hard metals and alloyed can

be machined.

2. Resharpening of cutting tools and broaches, trepanning of holes with straight or

curved axes.

3. Machining of cavities for dies and re-machining of die cavities without annealing.

This process can be used to preform almost all conventional machining operations.
Laser Beam Machining

➢ Laser-beam machining is a thermal material-

removal process that utilizes a high-energy,
coherent light beam to melt and vaporize
particles on the surface of metallic and non-
metallic workpieces.
➢ Lasers can be used to cut, drill, weld and
mark. LBM is particularly suitable for
making accurately placed holes.
Working of laser beam machining:-
➢ At first laser material CO2 or other laser material is filled into discharge tube.
➢ After that the power supply is switched on which is used to light up the flash lamp. The light
from flash lamp is used to excite the electrons of atom.
➢ Then the atoms of laser material absorbs energy from the light energy produced by flash lamp.
Due to absorption of energy, the electron of atom jump from lower energy level to higher
energy level. But this is unstable condition of atom.
➢ When the atom reaches its absorption limit, it starts emitting energy continuously. This energy
is emitted in the form of highly amplified same frequency and same wavelength coherent light.
➢ This laser light released by atom is collected in the convex lens and is directed towards the
workpiece.
➢ As the laser falls on workpiece, it starts the machining process by melting or vapourising
material from contact surface of workpiece.
Characteristics of LBM :

➢ Tool : High powered focused laser beam.

➢ Workpiece materials : Any material.

➢ Process parameters : Power intensity of laser beam, focused diameter of

laser beam and melting temperature of workpiece material.

➢ Material removal : Melting and vaporisation.

➢ Medium : Air.
Advantages of Laser Beam Machining
1.It can drill and cut all materials.
2.High surfaces are obtained in this machining process.
3.The tool is not used in this machining process.
4.Micro holes can be drilled accurately.
5.Very hard materials can be cut through laser beam machining.
6.High accuracy can be achieved.

Disadvantages of Laser Beam Machining

1. Initial cost and operating cost is high.
2. Recommended for some specific operations only, as production rate is very slow.
3. Cannot be used for high light reflecting materials.
4. A highly skilled operator is required.
5. The efficiency is low.
6. Used for thin materials only.
7. The materials removal rate is slow.
Application of Laser Beam Machining

➢ It is used to drill small holes of diameter approximately 0.005 mm in refractory and

ceramic materials.

➢ It is used for drilling holes and cutting both metals and non-metals.

➢ It is mostly used in aerospace industries.

➢ Used for complex profiles where machining by the tool is not possible.
 Electrochemical Machining

➢ Electrochemical machining is one of the most unconventional machining processes.

➢ The process is actually the reverse of electroplating with some modifications.

➢ It is based on the principle of electrolysis.

➢ In a metal, electricity is conducted by free electrons but in a solution the conduction

of electricity is achieved through the movement of ions.

➢ Thus the flow of current through an electrolyte is always accompanied by the

movement of matter.
Working Procedure of Electrochemical Machining
➢ The tool is connected with the negative terminal (as the cathode) of the battery, and the workpiece is
connected with the positive terminal (as the anode) of the battery.
➢ Both are kept at a distance in an electrolyte solution.
➢ When DC current (3 to 30V) is supplied to the electrode, the metal begins to move away from the
workpiece.
➢ In ECM, NaCl is usually in water as an electrolyte.
➢ When current passes through the electrodes, the anode or workpiece and the cathode or tool reaction
occurred >
➢ NaCl = (Na+) + (Cl-)
➢ H2O = ( H +) + ( OH-)
➢ Positive ions move towards the tool and negative ions towards the workpiece.
➢ Thus the hydrogen ion moves towards the tool.
➢ As hydrogen reaches the tool, it takes some electrons from it and turns into a gas. This gas goes into the
environment.
➢ Now, if the tool is given a downward motion, the work surface tends to take the same shape as that of
the tool, and at a steady state the gap is uniform.
Characteristics of ECM :

Tool materials : Copper and brass.

Workpiece materials : Conducting metals and alloys.

Process parameters : Current, voltage, feed rate and electrolyte.

Material removal : Electrolysis.

Advantages of Electro-Chemical Machining
➢ Machining of hard and brittle material is possible with good quality of surface finish
and accuracy.
➢ Complex shapes can be easily machined.
➢ There is almost negligible tool wear, so the cost of tool making is an only one-time
investment for mass production.
➢ There is no use of force, no direct contact between tool and workpiece.
➢ No use of heat, so mechanical and thermal remaining stresses are absent in the
workpiece.
➢ Very close tolerances can be obtained.
Disadvantages of Electro-Chemical Machining
➢ All non-conducting materials cannot be machined.
➢ The tool and workpiece should be chemically still with the electrolyte solution.
➢ Designing and making tool is difficult but its life is long recommended only for
mass production.
➢ The accurate feed rate of the tool is required.
➢ High initial cost of the machine.
➢ The process cannot be used to machine sharp interior edges and corners less than
0.2 mm radius because of very high current densities at those points.
Application of Electrochemical Machining

➢ ECM is used in the machining of disc or turbine rotor blades.

➢ It can be used to slot very thin walled collets.

➢ The ECM is used to generate the internal profile of the internal cam.

➢ ECM is also used in the Production of satellite rings and connecting rods, machining of

gears and long profiles, etc.

Electrochemical Grinding
 ➢ In this electrochemical grinding process, the metal is removed by both electrochemical
and grinding processes.
➢ In the grinding process, only 10% of the metal is removed while 90% of the metal is
removed by an electrochemical process.

Working Principle:
➢ The workpiece to be machined is first kept on the worktable and then clamped using fixtures.

➢ The grinding wheel is placed at the required position. A gap is maintained between the workpiece
and the grinding wheel. This gap is generally 0.02mm.

➢ Now the power supply is switched on. The pump is then driven to supply the electrolyte to the
required position.
➢ At first, the electrolyte passes through a filter where all the impurities are filtered. Then the
electrolyte is passed through a pressure gauge where the operator checks for the correct
pressure.

➢ Then electrolyte is passed through a flow meter where flow is checked by the operator.

➢ After passing through all the stages the electrolyte reaches the nozzle. Nozzle increases the
velocity of the electrolyte and sprays it over the workpiece.

➢ As soon as the electrolyte comes in contact with the workpiece and the grinding wheel, the
circuit is completed which results in Oxidation of the metal surface.

➢ This forms a layer of oxide which is removed by the flow of electrolyte and the Abrasive
particles in the grinding wheel. After the grinding is done, the flow is stopped and the
power supply is switched off.

➢ The workpiece is then unclamped and the remaining electrolyte is wiped out from the
surface.
Advantages :
1. Fairly good surface finish obtained (surface finish of 0.05 to 1 μm is possible.
2. Accuracy of the order of 0.01 mm can be achieved by proper selection of wheel grit size
and abrasive particles.
3. Negligible wear of the tool (grinding wheel).
4. Increased wheel life.
5. Considerable saving in wheel dressing time, as it is not required to be dressed very
frequently.
6. As compared to conventional grinding, a very little cutting force is applied to the
workpiece.
7. Since the heat is not generated in the process therefore work is free of surface cracks.
8. Work material is not subjected to any structural changes.
Disadvantages :
1. Metal removal rate is very low (of the order of 15 mm3/s).
2. Power consumption is high.
3. Only electrically conductive materials can be machined.
4. Preventive measures are always required against corrosion by the electrolyte.
5. High initial cost.
Applications :
1. This process is best suited for very precision grinding of hard metals like tungsten carbide tool
tips as the grinding pressure is very less and the temperature is very low due to which the defects
like grinding cracks, tempering of work transformation of layers and dimensional control
difficulties are eliminated.
2. Cutting thin sections of hard materials without danger of any damage or distortion.
Ultrasonic Machining
➢ Ultrasonic machining is also a mechanical energy based non-conventional machining process that is
used to machine brittle and hard materials.
➢ Ultrasonic machining is a process in which material is removed due to the action of abrasive grains.
Working Procedure of Ultrasonic Machining
➢ First of all the low-frequency electric current is sent from the power supply (electric supply).
➢ This low frequency current is converted into high frequency current through some electrical equipment.
➢ This high frequency current passes through the transducer. The transducer converts this high frequency electric
signal to high frequency mechanical vibration. This mechanical vibration passes through the booster.
➢ The booster amplifies this high-frequency vibration and sends it to the horn.
➢ Horn, also known as a tool holder, transferred this amplified vibration to the tool. Where the tool vibrates at an
ultrasonic frequency.
➢ An abrasive gun is used to supply an abrasive slurry (eg, aluminum oxide, silicon carbide, boron carbide,
diamond dust, etc.) and the mixture of abrasive slurry and water is sent between the tool and the workpiece.
➢ As the instrument vibrates, the abrasive slurry also starts vibrating at this high frequency.
➢ The impact of the hard abrasive grains fractures the hard and brittle work surface, resulting in the removal of the
work material in the form of small wear particles.
➢ This abrasive slurry attacks the workpiece and gives it a metallic appearance.
Characteristics of USM :
➢ Tool materials : Brass and mild steel.
➢ Work materials : Hard and brittle materials like semiconductors, glass and ceramics.
➢ Process parameters : Frequency, amplitude, grain size, slurry concentration and feed
force.
➢ Material removal : Fracture of work material due to impact of grains.
➢ Abrasive : Aluminium oxide, silicon carbide and boron carbide.
➢ Grain size : Mesh-size 100-800.
➢ Gap : 0.2 to 0.5 mm.
Advantages :
1. Noiseless operation.
2. Low metal removal cost.
3. Extremely hard and brittle materials can be easily machined.
4. Operation of the equipment is quite safe.
5. Highly accurate profiles and good surface finish can be easily obtained.
6. Because of no heat generation in the process, the physical properties of the work materials
remain unchanged.
7. The machined workpieces are free of stresses.
Disadvantages :
1. High tooling cost.
2. Low metal removal rate.
3. The size of the cavity that can be machined is limited.
4. High power consumption.
5. The initial equipment cost is higher than the conventional machine tools.
6. The process is unsuitable for heavy metal removal.
7. For maintaining an efficient cutting action the slurry may have to be replaced
periodically.
8. It is difficult to machine softer materials.
Applications :
1. Several machining operations like turning, threading, grinding, milling etc.
2. Machining of hard to machine and brittle materials.
3. Dentistry work—to drill fine holes of desired shape in teeth.
4. Tool and die making, specially wire drawing and extrusion dies.
 Abrasive Jet Machining

➢ In this machining, a concentrated stream of abrasive particles like

aluminum oxide, silicon carbide, diamond powder, glass particles, etc is
forced to strike a piece of the workpiece at high velocity.
➢ These high velocity abrasive particles cut the metal into small pieces.
Working Procedure of Abrasive Jet Machining
➢ Firstly in abrasive jet machining air or gas like nitrogen, carbon dioxide, etc compressed in a gas compressor.
Where the density and pressure of the gas increases.
➢ Now it sends the compressed gas to the filtration unit, from where the dust and other suspended particles are
removed.
➢ Then It sends the clean gas to the dryer where its moisture is absorbed.
➢ Now, this clean and dry gas is sent to the mixing chamber where the abrasive particles are found in the
abrasive feeder. (abrasive particles are about 10 to 50 micrometer bit size)
➢ Now, these high pressure (about 850 kPa) abrasive particles and gas are sent to the nozzle (the nozzle diameter
ranges from about 0.18 to 0.80 mm), where its pressure energy is converted into kinetic energy.
➢ The velocity of the abrasive particles leaving the nozzle ranges from about 150 to 300 m/s.
➢ The distance between the workpiece and the nozzle (tungsten) is about 2 mm.
➢ Now, these high velocity abrasive particles are strikes on the workpiece.
➢ These high velocity abrasive particles remove the material through micro-cutting action as well as by brittle
fractures of the work material.
Characteristics of AJM :

Material removal : By impinging abrasive grains at high speed.

Critical parameters : Abrasive flow rate and velocity, nozzle tip distance, abrasive grain size
Advantages :

1. Low capital investment required.

2. Brittle materials of thin sections can be easily machined.

3. Intricate cavities and holes of any shape can be machined in materials of any hardness.

4. There is no direct contact between the tool and workpiece.

5. Normally inaccessible portions can be machined with fairly good accuracy.

Disadvantages :
1. Low metal removal rate.
2. Unsuitable for machining of ductile materials.
3. The abrasive powder used in the process cannot be reclaimed or reused.
4. Machining accuracy is relatively poorer.
5. There is always a danger of abrasive particles getting embedded
Applications
1. To machine hard and brittle materials
2. Fine drilling and micro welding
3. Machining of semiconductors
4. Machining of intricate profiles
5. Surface etching
6. Surface preparation
7. Cleaning and polishing of plastics, nylon and teflon