INSTITUTE OF TECHNOLOGY &

MANAGEMENT

SEMINAR PRESENTATION
ON

UNCONVENTIONAL MACHINING PROCESS

SESSION 2017-18

BY-:AKASH PATI TRIPATHIIP

MECHANICAL ENGINEERING(2014-18)
ROLL NO.-1412040009
SECTION –ME D41(4th YEAR)YEAR)
 CONTENT
• INTRODUCTION
• IMPORTANCE OF UNCONVENTIONAL MACHINING
• CLASSIFICATION OF UCM
• NEED OF UCM
• CHEMICAL MACHINING
• EDM
• LBM
• EBM
• WJM
• AJM
• AWJM
 Non-traditional Machining Processes
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 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.
 Non-traditional Machining 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.
 Non-traditional Machining Processes
The major characteristics of Non-conventional machining:

2. In NTM, there may not be a physical tool present. For example in

laser jet machining, machining is carried out by laser beam.
However in Electrochemical Machining there is a physical tool
that is very much required for machining
3. In NTM, the tool need not be harder than the work piece material.
For example, in EDM, copper is used as the tool material to
machine hardened steels.
4. Mostly NTM processes do not necessarily use mechanical energy
to provide material removal. They use different energy domains
to provide machining. For example, in USM, AJM, WJM
mechanical energy is used to machine material, whereas in ECM
electrochemical dissolution constitutes material removal.
 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)
 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.
•Deep hole with small hole diameter – e.g. φ 1.5 mm
hole with l/d = 20
• Machining of composites.
 Chemical Machining

• Oldest nontraditional machining process.

• Material is removed from a surface by
chemical dissolution using chemical
reagents or etchants like acids and
alkaline solutions.
 ELECTRICAL DISCHARGE MACHINING
• Based on erosion of metals by spark discharges.
• EDM system consist of a tool (electrode) and work
piece, connected to a dc power supply and placed in a
dielectric fluid.
• When potential difference between tool and work
piece is high, a transient spark discharges through the
fluid, removing a small amount of metal from the work
piece surface.
• This process is repeated with capacitor discharge
rates of 50-500 kHz.
 ELECTRICAL DISCHARGE MACHINING

• Dielectric fluid – mineral oils, kerosene, distilled and

deionized water etc.
• Role of the dielectric fluid-
• 1. acts as a insulator until the potential is sufficiently
high.
• 2. acts as a flushing medium and carries away the
debris.
• 3. also acts as a cooling medium.
• Electrodes – usually made of graphite.
• EDM can be used for die cavities, small diameter
deep holes , turbine blades and various intricate
shapes.
ELECTRICAL DISCHARGE MACHINING
 LASER BEAM MACHINING
• In LBM laser is focused on the work piece
which melts and evaporates portions of the
work piece.
• Low reflectivity and thermal conductivity of the
work piece surface, and low specific heat and
latent heat of melting and evaporation –
increases process efficiency.
• Application - holes with depth-to-diameter ratios
of 50 to 1 can be drilled. e.g. bleeder holes for
fuel-pump covers, lubrication holes in
transmission hubs.
LASER BEAM MACHINING
 ELECTRON BEAM MACHINING

• Similar to LBM except laser beam is replaced

by high velocity electrons.
• When electron beam strikes the work piece
surface, heat is produced and metal is
vaporized.
• Surface finish achieved is better than LBM.
• Used for very accurate cutting of a wide
variety of metals.
ELCTRON BEAM MACHINING
 WATER JET MACHINING
• Water jet acts like a saw and cuts a narrow
groove in the material.
• Pressure level of the jet is about 400MPa.
• Advantages - no heat produced - cut can be
started anywhere without the need for predrilled
holes - burr produced is minimum -
environmentally safe and friendly manufacturing
• Application – used for cutting composites,
plastics, fabrics, rubber, wood products etc.
Also used in food processing industry.
WATER JET MACHINING
 Abrasive Jet Machining
In Abrasive Jet Machining (AJM), abrasive particles are made to impinge
on the work material at a high velocity. The high velocity abrasive particles
remove the material by micro-cutting action as well as brittle fracture of the
work material.
 Abrasive Jet Machining

• In AJM, generally, the abrasive particles of around 50

μm grit size would impinge on the work material at
velocity of 200 m/s from a nozzle of I.D. of 0.5 mm
with a stand off distance of around 2 mm.
• The kinetic energy of the abrasive particles would be
sufficient to provide material removal due to brittle
fracture of the work piece or even micro cutting by the
abrasives.
Abrasive Jet Machining

AJM set-up
AJM
 Abrasive Jet Machining
Process Parameters and Machining Characteristics
Abrasive : Material – Al2O3 / SiC
Shape – irregular / spherical
Size – 10 ~ 50 μm
Mass flow rate – 2 ~ 20 gm/min
Carrier gas : Composition – Air, CO2, N2
Density – Air ~ 1.3 kg/m3
Velocity – 500 ~ 700 m/s
Pressure – 2 ~ 10 bar
Flow rate – 5 ~ 30 lpm
Abrasive Jet : Velocity – 100 ~ 300 m/s
Mixing ratio – mass flow ratio of abrasive to gas
Stand-off distance – 0.5 ~ 5 mm
Impingement Angle – 600 ~ 900
Nozzle : Material – WC
Diameter – (Internal) 0.2 ~ 0.8 mm
Life – 10 ~ 300 hours
 Abrasive Jet Machining
Modelling of material removal
Material removal in AJM takes place due to brittle fracture of the
work material due to impact of high velocity abrasive particles.

Modelling has been done with the following assumptions:

(i) Abrasives are spherical in shape and rigid. The particles are
characterised by the mean grit diameter
(ii) The kinetic energy of the abrasives are fully utilised in
removing material
(iii) Brittle materials are considered to fail due to brittle fracture
and the fracture volume is considered to be hemispherical with
diameter equal to chordal length of the indentation
(iv) For ductile material, removal volume is assumed to be equal
to the indentation volume due to particulate impact.
Water Jet and Abrasive Water Jet Machining
Water Jet and Abrasive Water Jet Machining
 Water Jet and Abrasive Water Jet
Machining

Advantages of AWJM

• Extremely fast set-up and programming

• Very little fixturing for most parts
• Machine virtually any 2D shape on any material
• Very low side forces during the machining
• Almost no heat generated on the part
• Machine thick plates
Components of AWJM
THANKYOU!!!
ANY QUERY!!