NONTRADITIONAL MACHINING

Chapter 26

Manufacturing Processes, 1311

Dr Simin Nasseri
Southern Polytechnic State University

1
 Machining Processes

Traditional Chip Removal Nontraditional Machining


• Turning  Sawing

Ultrasonic
Electrical Discharge
• Milling  Broaching
 Electro-arc
• Drilling  Planing  Optical Lasers
• Boring  Grinding  Electrochemical
• Reaming  Honing  Chem-milling
• Shaping  Lapping  Abrasive Jet Cutting
 Electron Beam Machining
 Plasma Arc Machining

Manufacturing Processes
Prof Simin Nasseri
Nontraditional
Machining

3
NONTRADITIONAL PROCESSES

A group of processes that remove excess

material by various techniques involving
mechanical, thermal, electrical, or
chemical energy (or combinations of these
energies).

They do not use a sharp cutting tool in the

conventional sense.

Manufacturing Processes
Prof Simin Nasseri
Importance of Nontraditional Processes
 Need to machine newly developed metals and
non‑metals with special properties that make them
difficult or impossible to machine by conventional
methods.

 Need for unusual and/or complex part geometries that

cannot readily be accomplished by conventional
machining.

 Need to avoid surface damage that often accompanies

conventional machining.

Manufacturing Processes
Prof Simin Nasseri
Classification of Nontraditional Processes
Mechanical ‑ typical form of mechanical action
is erosion of work material by a high velocity
stream of abrasives or fluid (or both).
Electrical ‑ electrochemical energy to remove
material (reverse of electroplating).
Thermal – thermal energy usually applied to
small portion of work surface, causing that
portion to be fused and/or vaporized.
Chemical – chemical etchants selectively
remove material from portions of workpart,
while other portions are protected by a mask.

Manufacturing Processes
Prof Simin Nasseri
Nontraditional Processes
Mechanical Energy Processes:
 Ultrasonic Machining
 Water Jet Cutting
 Abrasive Water Jet Cutting
 Abrasive Jet Machining
Electrochemical Processes:
 Electrochemical Machining (ECM)
 Electrochemical Deburring (ECD)
 Electrochemical Grinding (ECG)
Thermal Energy Processes:
 Electric Discharge Machining (EDM)
 Electric Discharge Wire Cutting
 Electron Beam Machining
 Laser Beam Machining
 Plasma Arc Machining
 Conventional Thermal Cutting Processes
Chemical Processes:
 Chemical Milling
 Chemical Blanking
 Chemical Engraving
 Photochemical Machining

Manufacturing Processes
Prof Simin Nasseri
Electrochemical Processes

8
Electrochemical Machining Processes

Electrical energy used in combination with

chemical reactions to remove material

 Reverse of electroplating

 Work material must be a conductor

Manufacturing Processes
Prof Simin Nasseri
 Electrochemical Machining (ECM)
Material removal by anodic dissolution, using electrode
(tool) in close proximity to work but separated by a
rapidly flowing electrolyte.

Figure 26.5
ElectroChemical
Machining (ECM).

Manufacturing Processes
Prof Simin Nasseri
ECM Operation
Material is deplated from anode workpiece (positive
pole) and transported to a cathode tool (negative
pole) in an electrolyte bath.

Electrolyte flows rapidly between two poles to carry

off deplated material, so it does not plate onto
tool.

Electrode materials: Copper, brass, or stainless

steel.

Tool has inverse shape of part

 Tool size and shape must allow for the gap
(tool should be smaller)

Manufacturing Processes
Prof Simin Nasseri
ECM Applications
 Die sinking - irregular shapes and
contours for anodic, plastic molds, and
other tools
 Multiple hole drilling - many holes can be

 
drilled simultaneously with ECM
 Holes that are not round, since rotating
                        
drill is not used in ECM

Manufacturing Processes
Prof Simin Nasseri
Thermal Energy Processes

13
Thermal Energy Processes - Overview
Very high local temperatures
 Material is removed by fusion or vaporization.

These processes cause physical and metallurgical

damage to the new work surface.

In some cases, resulting finish is so poor that

subsequent processing is required.

Manufacturing Processes
Prof Simin Nasseri
Electric Discharge Processes
Metal removal by a series of discrete electrical
discharges (sparks) causing localized temperatures
high enough to melt or vaporize the metal.

Can be used only on electrically conducting work

materials.

Electric Discharge Machining or EDM is one of the most widely

used nontraditional processes

Manufacturing Processes
Prof Simin Nasseri
 Electric Discharge Machining (EDM)
 Shape of finished work surface produced by a shape of electrode
tool.
 Sparks occur across a small gap between tool and work.
 Requires dielectric fluid, which creates a path for each discharge as
fluid becomes ionized in the gap.

Figure 26.8 Electric discharge machining (EDM): (a) overall setup, and (b) close ‑up
view of gap, showing discharge and metal removal.
Manufacturing Processes
Prof Simin Nasseri
Work Materials in EDM
 Work materials must be electrically
conducting.
 Hardness and strength of work material
are not factors in EDM.
 Material removal rate depends on melting
point of work material.

Manufacturing Processes
Prof Simin Nasseri
EDM Applications
 Tooling for many mechanical processes: molds and dies
 Molds for plastic injection molding, extrusion dies,
wire drawing dies, forging and heading dies, and
sheetmetal stamping dies
 Production parts: delicate parts not rigid enough to
withstand conventional cutting forces, hole drilling where
hole axis is at an acute angle to surface, and machining
of hard and exotic metals

Manufacturing Processes
Prof Simin Nasseri
Irregular outline cut from a
solid slab by wire EDM (photo
courtesy of LeBland Makino
Machine Tool Co.).

Manufacturing Processes
Prof Simin Nasseri