TOOL ROOM 2 NOTES
CHAPTER 11: NON-CONVECTIONAL MACHINING
Specific Objectives:
➢ Outline non-convectional machining processes.
➢ Illustrate diagrammatically non-convectional machining processes.
➢ Explain the operation of non-convectional machining plant.
➢ Explain care and maintenance of non-convectional plant.
Introduction
-Non-convectional machining involves processes that remove excess materials by various
techniques involving mechanical, thermal, electrical or chemical or combinations of these
energies.
-these processes are usually applied where other available machining processes are not feasible,
satisfactory or economical.
Reasons for using non-convectional machining processes:
(a) When machining very hard fragile materials that are difficult to be clamped.
(b) When the workpiece is too flexible or slender.
(c) When the shape of the workpiece is too complex for other convectional machining.
Characteristics of convectional machining
❖ Generally macroscopic chip formation by shear formation.
❖ Material removal takes place due to application of cutting forces.
❖ The cutting tool is generally harder than the material under machining.
Non-convectional machining processes.
1. Electro-discharge machining process.
➢ This is commonly used non-convectional machining processes
➢ It utilizes thermoelectric process to erode undesired materials from the workpiece
by a series of sparks between the workpiece and electrode.
Figure 11.: electrical-discharge machining process
Working operation of electric-discharge machining:
Electric-discharge removes materials by discharging an electrical current across a small
gap between the tool (cathode) and the workpiece (anode).
The high voltage passing through the gap induces electric field in it.
The induced electric field causes electric sparks that removes small amount of
material from the surface of the workpiece.
Application of Electro-discharge machining:
▪ Applied to machine hard workpiece materials.
Advantages of electro-discharge machining:
(i) Material of any hardness can be machined.
(ii) No burrs are left in the machined surface.
(iii) Thin and fragile workpiece materials can be machined.
(iv) Complex internal shapes can be machined.
Limitations of electro-discharge machining:
(a) It can be only applied in electrically conductive materials.
(b) The material removal process is quite slow. (c) Unwanted corrosion and
overcutting of material can occur.
2. Electro-chemical machining process.
✓ The electro-discharge machining is a material removal process based on the principle of
reverse electroplating.
Figure 11.2: Electro-chemical machining
✓ the ECM tool is positioned very closed to the workpiece and low voltage current is
passed between tool and workpiece material.
✓ In ECM, particles move from anodic materials (workpiece) towards cathodic material
(machining tool). A current of electrolyte fluid carries away from the depleted material
before reaching the machining tool.
Advantages of Electro-chemical machining:
(a) The components are not subjected to thermal stresses.
(b) No tool wear during ECM process.
(c) Fragile workpiece can be easily machined.
(d) High surface finish can be achieved by ECM process.
(e) Complex shaped workpiece materials can be machined.
Limitations of Electro-chemical machining:
(a) ECM process is not suitable for production of flat and sharp corners of the workpiece.
(b) ECM process is limited to only some metals.
3. Chemical machining process.
❖ This involves controlled dissolution of workpiece material by means of strong chemical
reagent.
❖ In this process, the material is removed from the selected areas of workpiece by
immersing it in a chemical reagent such as acids and alkanines.
Figure 11.3: Chemical machining
❖ The chemical compositions are maintained at the required conditions of temperature.
Working operation of chemical machining
✓ The surface of workpiece is degreased and cleaned thoroughly to ensure for adhesion of
masking material and uniform material removal.
✓ The masking material is applied on the surface of the workpiece where it is not intended
for material.
✓ The exposed surfaces are then machined chemically.
✓ After machining, the part should be washed thoroughly to prevent further reactions.
Application of chemical machining:
❖ Applied in aerospace industry to remove shallow layers of materials from large aircraft
components.
4. Ultrasonic machining processes:
✓ Ultrasonic machining is a mechanical material removal process used to erode holes or
cavities on hard or brittle workpiece by using shaped tools.
✓ The hard particles in a slurry are accelerated towards the workpiece surface by a tool
oscillating at the frequency of approximately 100hz. Through the repeated abrasions, the
tool machines a cavity of a cross-section identical to it.
Figure 11.4: Ultrasonic machining
Application of ultrasonic machining
✓ Applied in making non-round shapes in hard and brittle materials.
Advantages of Ultrasonic Machining:
(a) Any material can be machined.
(b) Produces high quality and good surface finish on the workpiece.
Limitations of ultrasonic machining:
(a) USM has a higher power consumption. (b)
Tool wears fast in USM.
5. Laser-beam machining processes
It is a thermal material removal process that utilizes a high energy , coherent light beam to
melt and vaporizes particles on the surfaces of metallic and non-metallic wiorkpiece
materials.
The lasers can be used to cut, drill, weld and mark.
Figure 11.5: Laser Beam machining
When the power supply is switched on, the current flows through the circuit system and
radiations are initiated with the laser discharge.
The 100% reflecting mirror creates a beam of light that hits the special lens. The lens
focuses the beam of light.
The energy in terms of focused light hits the workpiece and melts the material at the point
of contact.
Advantages of Laser beam machining:
(a) The fragile materials can be machined easily.
(b) Very hard and abrasive materials can be cut
(c) Laser beam machining is a flexible approach of workpiece materials.
(d) High accuracy parts can be machined.
(e) No tool wear
Limitations of Laser beam machining:
(a) Uneconomical on massive production.
(b) High initial cost
(c) High maintenance cost
(d) Ineffective for machining extremely thick workpiece materials.
6. Abrasive-water jet machining process:
✓ Abrasive-waterjet machining is a machining process in which water jet contains abrasive
particles such as silicon dioxide that can increase material removal rate.
✓ The abrasive waterjet cutting can be applied on hard materials, ceramics and soft
materials.
Figure 11.7: Abrasive jet machining
❖ The abrasive waterjet machine has some features like , mixing tube and guard.
❖ In this process, high velocity water exiting the jewel creates a vacuum which sucks
abrasive from abrasive line, which mixes with water in the mixing tube to form a high
velocity abrasive beam. ❖ The created abrasive beam is directed to point on the
workpiece to be machined.
Application of abrasive-water jet machining ❖ Highly applied used
in aerospace, automotive and electronic industries.
Advantages of abrasive waterjet machining (a)
No secondary finishing operations are required.
(b) Limited tooling requirements.
(c) Eliminates thermal distortions.
(d) Workpiece can quickly be machined.
Limitations of abrasive-water jet machining
(a) It cannot drill flat bottom.
(b) It cannot cut materials which degrade quickly with moisture.
