Introduction To NTM-1st Module-Notes

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Introduction To NTM-1st Module-Notes

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Non Traditional Machining-BME405A Dept.

of Mechanical Engineering

Module 1
INTRODUCTION TO NON TRADITIONAL MACHINING

INTRODUCTION

In the early stage of mankind, tools were made of stone for the item being made. When iron tools were
invented, desirable metals and more sophisticated articles could be produced. In twentieth century products
were made from the most durable and consequently, the most unmachinable materials. In an effort to meet
the manufacturing challenges created by these materials, tools have now evolved to include materials such
as alloy steel, carbide, diamond and ceramics. The conventional manufacturing processes in use today for
material removal primarily rely on electric motors and hard tool materials to perform tasks such as sawing,
drilling and broaching.

Conventional forming operations are performed with the energy from electric motors, hydraulics and gravity.
Likewise, material joining is conventionally accomplished with thermal energy sources such as burning gases
and electric arcs. In contrast, non-traditional manufacturing processes harness energy sources considered
unconventional by yesterday’s standards. Material removal can now be accomplished with electrochemical
reaction, high temperature plasmas and high-velocity jets of liquids and abrasives. Materials that in the past
have been extremely difficult to form, are now formed with magnetic fields, explosives and the shock waves
from powerful electric sparks. Material-joining capabilities have been expanded with the use of high
frequency sound waves and beams of electrons and coherent light.

• With the development of technology, more and more challenging problems are faced by the
scientists and technologists in the field of manufacturing.
• The difficulty in adapting the traditional manufacturing processes can be attributed mainly to the
following basic sources:
(i) New materials with low machinability.
(ii) Dimensional and accuracy requirements.

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Non Traditional Machining-BME405A Dept. of Mechanical Engineering

(iii) A higher production rate and economy.

• The many new materials and alloys that have been developed for specific uses possess a very
low machinability. Producing complicated geometries in such materials becomes extremely difficult
with the usual methods. Also, sometimes the combination of the material properties and the job
dimensions is such that the use of the traditional processes becomes impossible. Examples of these
types of jobs are machining a complicated turbine blade made of super alloys, and producing
holes and slots (both through and blind) in materials such as glass and semiconductors. At times,
the job becomes difficult because of the dimensional complications. So, drilling a noncircular hole or a
micro hole becomes problematic (and sometimes impossible) if the traditional processes are used.
Apart from the situations cited, higher production rate and economic requirements may demand
the use of non traditional (or unconventional) machining processes.

• To tackle such difficult jobs, two approaches are possible, viz

i) A modification of the traditional processes (eg: hot machining) and

ii) The development of new processes.

Non-traditional 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.
Extremely hard and brittle materials are difficult to machine by traditional machining processes such as
turning, drilling, shaping and milling. Non traditional machining processes, also called advanced
manufacturing processes, are employed where traditional machining processes are not feasible,
satisfactory or economical due to special reasons as outlined below.

• Very hard fragile materials difficult to clamp for traditional machining.

• When the workpiece is too flexible or slender
• When the shape of the part is too complex

Several types of non-traditional machining processes have been developed to meet extra required
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Non Traditional Machining-BME405A Dept. of Mechanical Engineering

machining conditions. When these processes are employed properly, they offer many advantages over
non-traditional machining processes. The common non-traditional machining processes are described in
this section.

Definition:
A machining process is called non-traditional if its material removal mechanism is basically different
than those in the traditional processes, i.e. a different form of energy (other than the excessive forces
exercised by a tool, which is in physical contact with the work piece) is applied to remove the excess
material from the work surface, or to separate the workpiece into smaller parts.

NEED FOR DEVELOPMENT OF NON CONVENTIONAL PROCESSES:

The strength of steel alloys has increased five folds due to continuous R and D effort. In aero-space
requirement of High strength at elevated temperature with light weight led to development and use of hard
titanium alloys, nimonic alloys, and other HSTR alloys. The ultimate tensile strength has been improved
by as much as 20 times. Development of cutting tools which has hardness of 80 to 85 HRC which cannot
be machined economically in conventional methods led to development of non –traditional machining
methods.
1.Technologically advanced industries like aerospace, nuclear power, ,wafer fabrication, automobiles
has ever increasing use of High –strength temperature resistant (HSTR) alloys (having high strength to
weight ratio) and other difficult to machine materials like titanium, SST, nimonics, tungsten,
molybdenum, columbium, ceramics and semiconductors. It is no longer possible to use conventional process
to machine these alloys.
2.Production and processing parts of complicated shapes (in HSTR and other hard to machine
alloys) is difficult , time consuming an uneconomical by conventional methods of machining
3.Innovative geometric design of products and components made of new exotic materials with
desired tolerance , surface finish cannot be produced economically by conventional machining.
4.The following examples are provided where NTM processes are preferred over the
conventional machining process:
• Intricate shaped blind hole – e.g. square hole of 15 mm x 15 mm with a depth of 30 mm with a
tolerance of 100 microns.
Difficult to machine material – e.g. Inconel, Ti-alloys or carbides, Ceramics, composites , HSTR alloys,
stellites etc.,
• Low Stress Grinding – Electrochemical Grinding is preferred as compared to conventional grinding.
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Non Traditional Machining-BME405A Dept. of Mechanical Engineering

• Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20
• Machining of composites.

DIFFERENCES BETWEEN CONVENTIONAL AND NON

CONVENTIONAL MACHINING PROCESSES.
Description (CONVENTIONAL) (NON CONVENTIONAL) Non
Traditional Machining Traditional Machining

1. Physical contact between the Always present absent

cutting tool and work piece

2. Friction present absent

3. Tool wear exists Rarely exist
4. Material Removal rate Limited by the mechanical Easily deal with such difficult to
properties of the work material cut materials
5. Chip formation Present in the form of sand grain Rarely present in the form of
and powder like structure microscopic size
6. Machining of 3D surfaces Difficult task Easy task
7. Machining of unusual and difficult easy
complex shapes
8. Machining of small cavities, Difficult work Simple work
slits, blinds or trough holes
10. Skilled Labour Not required required

11. Product cost Less more

12. Initial cost Less more
13. Accuracy and surface finish low high
14. Economical For small production of less For mass production of long
duration duration

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Non Traditional Machining-BME405A Dept. of Mechanical Engineering

Classification of NTM processes

Classification of NTM processes is carried out depending on the nature of energy used for material
removal.

Mechanical Processes
> Abrasive Jet Machining (AJM)
> Ultrasonic Machining (USM)
> Water Jet Machining (WJM)
Electrochemical Processes
> Electrochemical Machining (ECM)
> Electro Chemical Grinding (ECG)
> Electro Jet Drilling (EJD)
Electro-Thermal Processes
> Electro-discharge machining (EDM)
> Laser Jet Machining (LJM)
> Electron Beam Machining (EBM)
Chemical Processes
> Chemical Milling (CHM)
> Photochemical Milling (PCM)