Unconventional Machining Process | Non Traditional Manufacturing

Process | Modern Machining Methods

Mechanical Engineering

Unconventional Machining Process | Non Traditional

Manufacturing Process | Modern Machining Methods
Modern Machining Processes:
In the past two decades some ultra hard and difficult to process of metals and alloys are not easy to
manufacture, but continuous research on this field will produce rapid growth in this modern
machining technology. The concept of material removal by Conventional edged tool machining is
uneconomical for such harder and difficult to manufacturing materials and the degree of accuracy and
surface finish attainable is poor. These edged tools machining involving plastic deformation and
formation of chips has been known to man for several hundred years. The higher strength level would
have a disastrous effect on the total machining bill if there was no corresponding improvement in
machining technology. In view of the significance of this problem, Merchant (1960) highlighted the
need for the development of newer concepts in metal machining; By adopting a integrated plan and
utilizing the results of basic and applied research, it has now become possible to process some of the
materials which were formerly considered to be unmachinable under normal conditions. Some of
these methods have been commercially exploited while others are still in their experimental stages.
The so developed newer machining processes are often called as modern machining processes or
unconventional machining processes. The name unconventional implies that conventional tools are
not engaged for metal cutting; rather energy is utilized in its direct form.
Modern machining processes are classified according to the type of fundamental machining energy
employed, such as mechanical, electrochemical, chemical or thermoelectric.
Classification of Unconventional Machining Processes
Type of Metal Transfer Energy Modern
Energy Removal Media Sources Manufacturing
Mechanisms Process
involved
Abrasive Jet
Machining
(AJM), Ultra
Pneumatic/
High velocity Sonic
Erosion hydraulic
particles Machining
Mechanical pressure
(USM), Water
Jet Machining
(WJM)
Physical Conventional
Shear Cutting tool
contact machining
Electro
Chemical
Electrochemica Ion Machining
Electrolyte High current
l displacement (ECM), Electro
Chemical
Grinding (ECG)
Chemical Ablative Reactive Corrosive Chemical
 Machining
relation environment agent
(CHM)
Ion Beam
Machining
(IBM), Plasma
Ionized
Hot gases Arc Machining
Fusion material High
Electrons (PAM), Electro
voltage
Discharge
Machining
Thermoelectric (EDM)
Laser Beam
Vapourization Radiation Amplified light Machining
(LBM)
Plasma Arc
Ionized
Ion stream Machining
material (PAM)
PROCESS SELECTION
To make effective utilization of advanced machining methods, it is important to know the precise
character of the machining issue. It is to be comprehended that:
(i) these methods cannot replace the conventional machining processes and
(ii) a particular machining method found suitable under the given conditions may not be equally
efficient under different conditions.
A careful assortment of the procedure for a given machining issue is fundamental.

Before selecting the process to be employed, the following aspects must be studied:
(i) Physical parameters.
(ii) Properties of the work material and the shape to be machined.
(iii) Process capability.
(iv) Economic considerations.
When comparing the physical parameters of modern machining processes, it may be noticed that
both EDM and USM require approximately the same power, whereas ECM consumes roughly forty
times more power than EDM. ECM consumes much greater power, it is an excellent method for
drilling long slender holes with length/dia ratio > 20. It can be seen that for the machining of
electrically non-conducting materials, both ECM and EDM are unsuitable, whereas the mechanical
methods can achieve the desired results.