Nonconventional machining process

Introduction

We all know that the term machinability refers to the case with
which a metal can be machined to an acceptable surface finish.

 Nontraditional machining processes are widely used to

manufacture geometrically complex and precision parts for
aerospace, electronics and automotive industries .
 The requirements that lead to the development of
nontraditional machining.

 Very high hardness and strength of the material.

 The work piece: too flexible or slender to support the cutting or
grinding forces.
 The shape of the part is complex, such as internal and external
profiles, or small diameter holes.
 Surface finish or tolerance better than those obtainable
conventional process.
 Temperature rise or residual stress in the work piece are
undesirable.
Advantages of Non-conventional machining:

 High accuracy and surface finish

 Less/no wear

 Tool life is more

 Quieter operation
Disadvantages of non-conventional machining:

 High cost

 Complex set-up

 Skilled operator required

Ultrasonic Machining

 In UM the tip of the tool vibrates at low amplitude and at high

frequency. This vibration transmits a high velocity to fine
abrasive grains between tool and the surface of the work piece.
 Material removed by erosion with abrasive particles.
 The abrasive grains are usually boron carbides.
 This technique is used to cut hard and brittle materials like
ceramics, carbides, glass, precious stones and hardened steel.
Ultrasonic Machining
 Water Jet Machining

 High pressure water (20,000-60,000 psi)

 Induct abrasive into stream
 Tight tolerances achievable
 Can cut extremely thick parts (5-10 inches
possible)
Water Jet Machining Products
Electro-Chemical Machining (ECM)

 Works on the principle of

electrolysis
 Die is progressively lowered into
workpiece as workpiece is
dissociated into ions by
electrolysis
 Low DC voltage, very High
current (700 amps)
 Used to machine Dies, easily
deformable and bittle materials.
Electrochemical grinding
 Combines electrochemical machining with conventional grinding
• Grinding wheel is the cathode
• Metal bonded wheel with diamond or Al2O3 abrasive
• Majority of material removal from electrolytic action (95%) therefore
very low wheel wear
• Much faster than conventional grinding
• Used to grind brittle and thin jobs.
 Electrical Discharge Machining (EDM)

 The tool acts as a cathode (typically copper

and graphite) is immersed in a Dielectric
fluid with conductive workpiece
 DC voltage 40-400V is applied.
 Sparking at around 12,000 deg F.
 Cycle repeated at 200,000-500,000 Hz
 Dielectric:
 Acts as an insulator
 Cools tool and workpiece
 Flushes out debris from work area
Die Sinker vs. Wire EDM

 Die sinker EDM

 The die sinks into the part as it
sparks away the workpiece
 Most common Injection molding
die process
 Wire EDM
 The electrode is a wire that
traverses through the part
 Common for Extrusion Dies
EDM Products
Conclusion

Non Conventional machining processes are used when

required attributes are impossible to achieve with
traditional machining processes.