Need of AMPs:1) As for different materials we dont require same machining process and parameters.

Therefore
some specific time or cost saving machining processes. Eg:- plastic when compared to any metal.
2) When hardness of workpiece increases than tool material.
3) Higher accuracy or tolerances.
4) Complex shapes of product requires AMPs.
5) For better surface finish (even upto nano level).
6) Less defects eg:- no microcracks, less HAZ etc.
7) Higher production rates and low costs of machining, difficult to machine materials.

Limitations of AMPs:1)
2)
3)
4)

Expensive
Require skilled labour.
They do have high accuracy but they operate slowly. That leads to lower production rates.
Also as material hardness increases the cutting time decreases, which also leads to lower
production rates.
5) Maximum time these AMPs are used for specific metals/non-metals, alloys or superalloys only
and they cant be used to machine other materials.
6) As workpiece hardness increases these AMPs require much superior quality of tool material.

Classification of AMPs:1) Mechanical energy processes

a) Ultrasonic machining
b) Abrasive jet machining
c) Water jet machining
d) Abrasive water jet machining
2) Thermal energy processes
a) Electric discharge machining
b) Electron beam machining
c) Laser beam machining
d) Thermal spraying
3) Electrochemical and chemical energy processes
a) Electrochemical machining
b) Electrochemical grinding
c) Chemical machining

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.
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.
5. NTM processes provide higher dimensional accuracies. In NTM processes like USM cavities
approximately of the same dimensions as of the tool can be obtained.

Characteristics of Conventional machining processes:1. There is a macroscopic chip. In conventional machining processes, there is a macroscopic chip
formation.
2. The chip formation takes place due to shear deformation.
3. There is a requirement of the cutting tool and the cutting tool needs to be harden than the work
piece.
4. Material removal takes place because of application of the cutting force. The force is being
imparted on the tool because of the cutting process and the energy domain of conventional
machining process is mechanical in nature.
5. Lower dimensional accuracy is obtained as there is high surface roughness value associated with
conventional machining processes.