CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

GRT INSTITUTE OF ENGINEERING AND

TECHNOLOGY,TIRUTTANI
DEPARTMENT OF MECHANICAL ENGINEERING
CM387 NON-TRADITIONAL MACHINING
PROCESSES (III YEAR/VSEM)
REGULATION 2021

UNIT-1

INTRODUCTION AND MECHANICAL ENERGY

BASED PROCESSES

 An unconventional machining process (or non-traditional machining process) is a special type

of machining process in which there is no direct contact between the tool and the workpiece.
 In unconventional machining, a form of energy is used to remove unwanted material from a
given workpiece.

Need of unconventional machining processes

 In several industries, hard and brittle materials like tungsten carbide, high speed steels,
stainless steels, ceramics etc., find a variety of applications.
 For example, tungsten carbide is used for making cutting tools while high speed steel is
used for making gear cutters, drills, taps, milling cutters etc.

 If such materials are machined with the help of conventional machining processes, either the
tool undergoes extreme wear (while machining hard workpiece) or the workpiece material is
damaged (while machining brittle workpiece).
 This is because, in conventional machining, there is a direct contact between the tool and the
workpiece. Large cutting forces are involved and material is removed in the form of chips.
 A huge amount of heat is produced in the workpiece. This induces residual stresses, which
degrades the lifeand quality of the workpiece material.

 Hence, conventional machining produces poor quality workpiece with poor surface finish (if
the workpiece is made of hard and brittle material).
 To overcome all these drawbacks, we use unconventional machining processes to machine
hard and brittle materials.
 We also use unconventional machining processes to machine soft materials, in order to get
better dimensional accuracy.

Classification of unconventional machining processes:

Unconventional machining processes can be broadly classified into several types based on four main criteria.

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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

The classification of unconventional machining processes is given below:

1. Based on the type of energy used

1. Mechanical Energy based Unconventional Machining Processes (e.g. Abrasive Jet
Machining, Water Jet Machining)
2. Electrical Energy based Unconventional Machining Processes (e.g. Electrical Discharge
Machining)
3. Electrochemical Energy based Unconventional Machining Processes (e.g. Electrochemical
Grinding)
4. Chemical Energy based Unconventional Machining Processes (e.g. Chemical Machining)
5. Thermo-electrical (or Electro-thermal) Energy based Unconventional Machining Processes
(e.g. Plasma Arc Machining)
2. Based on the source of energy
1. Current
2. Voltage
3. Hydraulic Pressure
4. Pneumatic Pressure
5. Ionized Particles
6. Light
3. Based on the medium of energy transfer
1. Electrons
2. Atmosphere
3. Ions
4. Electrolyte
5. Pressurized gas
6. Water
7. Ultrasonic waves
8. Plasma
9. Laser
10. Chemical reagent
11. Radiation
4. Based on the mechanism of material removal
1. Erosion
2. Electric Discharge
3. Shear
4. Chemical Etching
5. Vaporization
6. Melting
7. Ion Displacement
8. Blasting

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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

1. Mechanical Energy based Unconventional Machining Processes:

 In these processes, unwanted material in the workpiece is removed by mechanical erosion.

The mechanical erosion can be facilitated by using any medium.
 For example, in abrasive jet machining, high velocity abrasive jet is used for eroding material
from the workpiece.
 In water jet machining, high velocity water jet is used for cutting the workpiece material.

The four main mechanical energy based unconventional machining processes are:

1. Abrasive Jet Machining

2. Water Jet Machining or Water Jet Cutting
3. Abrasive Water Jet Machining
4. Ultrasonic Machining

2. Electrical Energy based Unconventional Machining Processes:

 Here, electric spark discharge is used to cut and machine the workpiece. In electrical energy
based processes, no arc is produced (as in arc welding).
 Instead, thousands of sparks are produced every second. These sparks increase the

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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

temperature of the workpiece, melt the unwanted portions and vaporize those portions.
 A dielectric fluid is used for cleaning the workpiece and facilitating a smooth spark discharge.

Processes that come under this category are:

1. Electrical Discharge Machining

2. Wire Cut Electrical Discharge Machining

3. Electrochemical Energy based Unconventional Machining Processes:

In these processes, unwanted portions of the workpiece are removed by electrochemical effect. The
workpiece (in contact with an electrolyte) is machined by ion dissolution. Processes that come under this
category are:
1. Electrochemical Machining
2. Electrochemical Grinding
3. Electrochemical Honing

Chemical Energy based Unconventional Machining Processes:

 Here, chemical energy is used to remove material from the workpiece.

 We know that metal can be easily converted to metallic salt, if suitable reagent is used. Chemical
energybased processes exploit this principle.

 Material is removed by controlled etching of the workpiece in the presence of a reagent known as enchant.

 Chemical machining, chemical milling and photochemical milling (PCM) are the processes that come
under this category.

5. Thermo-electrical (or Electro-thermal) Energy based Unconventional

Machining Processes:

 Unwanted portions of a metal can be easily removed, if it is melted or vaporized. Thermo-

electrical energy based unconventional machining processes make use of this principle.

 In these processes, electrical energy is converted to a huge amount of heat by some means.
This heat is applied on a small region of the workpiece.

 That particular region is either melted or vaporized. By this way, material is removed.

The following are some of the important thermo-electrical energy based unconventional machining
processes:

1. Plasma Arc Machining

2. Electron Beam Machining
3. LASER Beam Machining
4. Ion Beam Machining
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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

Material and Method of Machining

PROCESS SELECTION

Based on the following points:

1. Physical Parameters
2. Shapes to be machined
3. Process Capability or Machining Characteristics
4. Economic Considerations

Physical Parameters

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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

Shapes to be machined

Process Capability or Machining Characteristics

1. Material Removal rate

2. Tolerance Maintained
3. Surface Finish
4. Depth of surface Damage
5. Power required for machining

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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

Process Economy

Advantages of UCM
 High Accuracy and surface finish in process
 Less Rejected pieces
 Increase productivity
 Tool material need not be harder than work piece material.
 Easy to machine harder and brittle materials
 There is no residual stresses in the machined material

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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

Disadvantages of UCM

1. More expensive process

2. Low Material Removal Rate (MRR)
3. AJM, CHM , PAM and EBM are not commercially economical Process

MECHANICAL BASED MACHINING PROCESSES

ABRASIVE JET MACHINING

Abrasive Jet Machining (AJM), is a

mechanical energy based unconventional machining
process used to remove unwanted material from a
given work piece. The process makes use of an
abrasive jet with high velocity, to remove material
and provide smooth surface finish to hard metallic
work pieces.

Parts & Usages

1. Abrasive jet: It is a mixture of a gas (or air) and abrasive particles. Gas used is carbon-di-oxide or
nitrogen or compressed air. The selection of abrasive particles depends on the hardness and Metal
Removal Rate (MRR) of the workpiece. Most commonly, aluminium oxide or silicon carbide
particles are used.
2. Mixing chamber: It is used to mix the gas and abrasive particles.
3. Filter: It filters the gas before entering the compressor and mixing chamber.
4. Compressor: It pressurizes the gas.
5. Hopper: Hopper is used for feeding the abrasive powder.
6. Pressure gauges and flow regulators: They are used to control the pressure and regulate the flow
rate of abrasive jet.
7. Vibrator: It is provided below the mixing chamber. It controls the abrasive powder feed rate in the
mixing chamber.
8. Nozzle: It forces the abrasive jet over the workpiece. Nozzle is made of hard and resistant material
like tungsten carbide.

Working:
 Dry air or gas is filtered and compressed by passing it through the filter and compressor. A pressure
gauge and a flow regulator are used to control the pressure and regulate the flow rate of the compressed
air. Compressed air is then passed into the mixing chamber.

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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

 In the mixing chamber, abrasive powder is fed. A vibrator is used to control the feed of the abrasive
powder. The abrasive powder and the compressed air are thoroughly mixed in the chamber.
 The pressure of this mixture is regulated and sent to nozzle.

 The nozzle increases the velocity of the mixture at the expense of its pressure. A fine abrasive jet is
renderedby the nozzle. This jet is used to remove unwanted material from the workpiece.

Operations that can be performed using Abrasive Jet Machining (AJM):

The following are some of the operations that can be performed using Abrasive Jet Machining:

1. Drilling
2. Boring
3. Surface finishing
4. Cutting
5. Cleaning
6. Deburring
7. Etching
8. Trimming
9. Milling

Advantages of Abrasive Jet Machining:

 Surface of the workpiece is cleaned automatically.

 Smooth surface finish can be obtained.
 Equipment cost is low.
 Hard materials and materials of high strength can be easily machined.

Disadvantages of Abrasive Jet Machining:

 Metal removal rate is low

 In certain circumstances, abrasive particles might settle over the workpiece.
 Nozzle life is less. Nozzle should be maintained periodically.
 Abrasive Jet Machining cannot be used to machine soft materials.

Process parameters
Process parameters of Abrasive Jet Machining (AJM) are factors that influence its Metal Removal Rate
(MRR). In a machining process, Metal Removal Rate (MRR) is the volume of metal removed from a given
workpiece in unit time.

Some of the important process parameters of abrasive jet machining:

1. Abrasive mass flow rate

2. Nozzle tip distance

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CM387 NON-TRADITIONAL MACHINING PROCESSES UNIT-I

3. Gas Pressure
4. Velocity of abrasive particles
5. Mixing ratio
6. Abrasive grain size

Abrasive mass flow rate:

 Mass flow rate of the abrasive particles is a major process parameter that influences the metal
removal ratein abrasive jet machining.
 In AJM, mass flow rate of the gas (or air) in abrasive jet is inversely proportional to the mass flow
rate of the abrasive particles.
 Due to this fact, when continuously increasing the abrasive mass flow rate, Metal Removal Rate
(MRR) first increases to an optimum value (because of increase in number of abrasive particles
hitting the workpiece) and then decreases.
 However, if the mixing ratio is kept constant, Metal Removal Rate (MRR) uniformly increases with
increase in abrasive mass flow rate.

Nozzle tip distance:

 Nozzle Tip Distance (NTD) is the gap provided between the nozzle tip and the workpiece. Up
to a certain limit, Metal Removal Rate (MRR) increases with increase in nozzle tip distance.
 After that limit, MRR remains constant to some extent and then decreases. In addition to
metal removal rate, nozzle tip distance influences the shape and diameter of cut.
 For optimal performance, a nozzle tip distance of 0.25 to 0.75 mm is provided.

Gas pressure:

Air or gas pressure has a direct impact on metal removal rate. In abrasive jet machining, metal
removal rate is directly proportional to air or gas pressure.

Velocity of abrasive particles:

Whenever the velocity of abrasive particles is increased, the speed at which the abrasive particles hit
the workpiece is increased. Because of this reason, in abrasive jet machining, metal removal rate increases
with increase in velocity of abrasive particles.

Mixing ratio:

Mixing ratio is a ratio that determines the quality of the air-abrasive mixture in Abrasive Jet
Machining (AJM). It is the ratio between the mass flow rate of abrasive particles and the mass flow rate of
air (or gas). When mixing ratio is increased continuously, metal removal rate first increases to some extent
and then decreases.

Abrasive grain size:

Size of the abrasive particle determines the speed at which metal is removed. If smooth and fine
surface finish is to be obtained, abrasive particle with small grain size is used. If metal has to be removed rapidly,
abrasive particle with large grain size is used.
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 ABRASIVE WATER JET MACHINING (AWJM)

Abrasive Water Jet Machining (AWJM) is a

mechanical energy based non-traditional machining process
used to cut and machine soft and non-metallic materials. It
involves the use of high velocity water jet to smoothly cut a
soft workpiece. It is similar to Abrasive Jet Machining
(AJM).

In abrasive water jet machining, high velocity water jet is

allowed to strike a given workpiece. During this process, its
kinetic energy is converted to pressure energy. This induces a
stress on the workpiece. When this induced stress is high
enough, unwanted particles of the workpiece are
automaticallyremoved.

Reservoir: It is used for storing water that is to be used in the machining operation.
Pump: It pumps the water from the reservoir.
Intensifier: It is connected to the pump. It pressurizes the water acquired from the pump to a desired level.
Accumulator: It is used for temporarily storing the pressurized water. It is connected to the flow regulator
through a control valve.
Control Valve: It controls the direction and pressure of pressurized water that is to be supplied to the nozzle.
Flow regulator: It is used to regulate the flow of water.

Nozzle: It renders the pressurized water as a water jet at high velocity

Working of Abrasive Water Jet Machining (AWJM):

 Water from the reservoir is pumped to the intensifier using a hydraulic pump.
 The intensifier increases the pressure of the water to the required level. Usually, the water is
pressurized to 200 to 400 MPa.
 Pressurized water is then sent to the accumulator. The accumulator temporarily stores the pressurized
water.
 Pressurized water then enters the nozzle by passing through the control valve and flow regulator.
 Control valve controls the direction of water and limits the pressure of water under permissible
limits.
 Flow regulator regulates and controls the flow rate of water.
 Pressurized water finally enters the nozzle. Here, it expands with a tremendous increase in its kinetic
energy. High velocity water jet is produced by the nozzle.
 When this water jet strikes the workpiece, stresses are induced. These stresses are used to remove
material from the workpiece.
 The water used in water jet machining may or may not be used with stabilizers. Stabilizers are
substances that improve the quality of water jet by preventing its fragmentation.
 For a good understanding of water jet machining, refer the schematic diagram above.

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Advantages of Water Jet Machining (AWJM):
1. Abrasive Water jet machining is a relatively fast process.
2. It prevents the formation of heat affected zones on the workpiece.
3. It automatically cleans the surface of the workpiece.
4. AWJM has excellent precision. Tolerances of the order of ±0.005″ can be obtained.
5. It does not produce any hazardous gas.
6. It is eco-friendly.

Disadvantages of Abrasive Water Jet Machining:

1. Only soft materials can be machined.

2. Very thick materials cannot be easily machined.
3. Initial investment is high.

Applications of Abrasive Water Jet Machining:

1. Abrasive Water jet machining is used to cut thin non-metallic sheets.

2. It is used to cut rubber, wood, ceramics and many other soft materials.
3. It is used for machining circuit boards.
4. It is used in food industry.

ULTRASONIC MACHINING (USM)

Principle:

 Working principle of Ultrasonic Machining or Ultrasonic Impact Grinding is described with

the help of a schematic diagram. The shaped tool under the actions of mechanical vibration
causes the abrasive particles dipped in slurry to be hammered on the stationary work piece.
 This causes micro-indentation fracture on the material. Small abraded particles are removed
along the surface which is perpendicular to the direction of the tool vibration. When the
material is removed a cavity of the same profile of the tool face is formed.
 The abrasive particles gradually erode as the machining process continues. As a result fresh
abrasiveparticles are needed to be supplied in the machining zone.
 Abrasive particles associated with the liquid are fed to the m/c zone and it ensures the
removal of the worn out grains and material.

Machining Time
The machining time of the ultrasonic grinding depends on the frequency of the vibration, material
properties and grain size. The amplitude of the vibration may vary from 5 to 75 µm and frequency may vary
from 19~25 kHz. Ample static force is also required to hold the job against the machining tool. A continues
flow of abrasives suspension is also mandatory.

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Process parameters

1. Amplitude of vibration (15 to 50 microns), Frequency of vibration (19 to 25 kHz).

2. Feed force (F) related to tool dimensions, Feed pressure
3. Abrasive size, Abrasive material ** Al203, SiC, B4C, Boron silicon Carbide, Diamond.
4. Flow strength of the work material, Flow strength of the tool material
5. Contact area of the tool, Volume concentration of abrasive in water slurry
6. Tool ------------------------ a. Material of tool
b. Shape
c. Amplitude of vibration
d. Frequency of vibration
e. Strength developed in tool
7. Work material -------- a. Material b. Impact strength c. Surface fatigue strength
8. Slurry ---------------------- a. Abrasive – hardness, size, shape and quantity of abrasive flow
b. Liquid – Chemical property, viscosity, flow rate
c. Pressure
d. Density

Advantages of USM:
1. It can be used to drill circular or non-circular holes on very hard materials like stones, carbides,
ceramics and other brittle materials.
2. Non-conducting materials like glass, ceramics and semi precious stones can also be machined.

Disadvantages of USM:
1. It can be proved slower than the conventional machining processes.
2. Creating deep holes is difficult because of the restricted movement of the suspension.
3. It is arduous to select the perfect tool geometry for creating hole of certain dimension. The holes created
may be of larger sizes because of side cutting.
4. High tool wear because of continues flow of abrasive slurry.
Applications:

1. Hard and brittle materials can be machined like tungsten carbide, diamond and glass. These are difficult to
machine in conventional machining process.
2. Wire drawing dies of tungsten carbide can be drilled by this process.
3. Circular as well as non-circular holes can be done with straight or curved axes.
4. It has been proved successful in machining geranium, silicon quartz and synthetic ruby etc.

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TRANSDUCER
Transducer is a device which is used to convert one form of energy in to another form of energy.

Types - Magnetostrictive transducer and piezoelectric transducer

Magnetostrictive transducer

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The Longitudinal Extension and contraction of the Rod AB produce an EMF in the coil L2

Advantages – Magnetostrictive Transducer

Disadvantages – Magnetostrictive Transducer

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PIEZOELECTRIC TRANSDUCER
Piezoelectric transducers are a type of electro acoustic transducer that convert the electrical charges
produced by some forms of solid materials into energy. The word "piezoelectric" literally means electricity
caused by pressure.

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TOOL HOLDER OR HORN.

The tool holder holds and connects the tool to the

transducer. It virtually transmits the energy and in some cases,
amplifies the amplitude of vibration. Material of tool should
have good acoustic properties, high resistance to fatigue
cracking. Due measures should be taken to avoid ultrasonic
welding between transducer and tool holder. Commonly used
tool holders are Monel, titanium, stainless steel. Tool holders
are more expensive, demand higher operating cost.

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TOOL FEED MECHANISM

The feed mechanism of an ultrasonic machine must perform the following functions:

1. Bring the tool slowly to the work piece to prevent breaking.

2. The tool must provide adequate cutting force and sustain it during the machining
operation.

3. The cutting force must be decreased when the specified depth is reached.

4. Overrun a small distance to ensure the required hole size at the exit.

5. The tool has to come back to its initial position after machining is done.

Type

There are four types of feed mechanism which are commonly used in USM:

1. Gravity feed mechanism

2. Spring loaded feed mechanism

3. Pneumatic or hydraulic feed mechanism

4. Motor controlled feed mechanism.

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