NTM, Course code : 18ME641

Module -1

INTRODUCTION TO NTM

Machining is a process of removing excess material from the work piece to obtain the
desired shape and size.
The process is classified into two types:
1. Conventional or traditional machining
2. Unconventional or Non-traditional machining
Conventional or traditional machining makes use of a hard, and a sharp cutting tool to remove
the excess material from the work piece. There are different types of machines designed to hold
the cutting tool and perform the machining operation. Few of them include: lathes, drilling
machines, grinding machines etc. Extremely hard and brittle materials are difficult to machine
by traditional machining processes such as turning, drilling, shaping and milling.

Non-traditional machining processes is defined as a group of processes that remove excess

material by various techniques involving mechanical, thermal, electrical or chemical energy
or combinations of these energies but do not use a sharp cutting tools as it needs to be used
for traditional manufacturing processes.

Non-traditional machining processes also called advanced manufacturing processes or Modern

machining process or Non conventional machining methods. In non -traditional machining
process, conventional tools are not used for metal cutting; instead energy in its direct form is
used.

Non traditional machining processes are employed where traditional machining processes are
not feasible, satisfactory or economical due to special reasons as outlined below.
• Very hard fragile materials difficult to clamp for traditional machining
• When the work piece is too flexible or slender
• When the shape of the part is too complex
History of Non Traditional processes:
Although, the non conventional machining processes have created a revolution in the field of
machining technology by the development of idea of various processes were initiated as early
as in nineteen- twenties in USSR (union of soviet socialist republic).
• 1920 - The initiation was first made by Gussev towards the end of 1920 in USSR. He
suggested a method of machining by combination of Chemical and mechanical means.
His work is basis for all Electro Chemical processes known today.
• 1941- Burgess, American Scientist had demonstrated the possibility of ECM process
by drawing a sharp contrast between the mechanical and electrolyte methods in metal
removal

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• 1942 - The idea of Ultrasonic machining was invented by Balamuth, He invented at the
time of investigation of dispersion of solids in Liquids with the help of a vibrating
magnetostrictive nickel tube However, the origination of the process was made by
Rosenberg
• 1943 - EDM was developed by B R Lazarenko and N I Lazarenko in USSR. They
first developed the idea of spark erosion machining. In the early nineteen-sixties, the
idea of Ultrasonic machining began to develop widely in USSR and basis of this
development was laid on extensive investigation that took place in the mechanism of
ultrasonic machining and in the design of Magneto-strictive transducers, converters and
wave guides.
• 1950 - The basis of laser machining was established by the process which was
developed by Basov, Prokhorov and Fabrikanth in USSR in 1950.
• 1950 - Electro chemical Grinding has practically been developed in 1950.
• 1960 - The concept of whirling jet machining was innovated.
Many of these new techniques of machining have been developed in last few decades to meet
the challenges put forwarded by rapid development of hard to machine and high strength
temperature resistant (HSTR) alloys. It is anticipated that in near future, these new technologies
will find an ever increasing application in all branches of mechanical engineering industry.
Characteristics of Conventional Processes

Conventional machining processes mostly remove material in form of chips by applying forces
on work material with a cutting tool which is harder than the work material. Such forces induce
plastic deformation within the workpiece leading to shear deformation along the shear plane.
Below Figure shows chip formation by shear deformation in conventional machining.

Major characteristics of conventional machining are:

• Generally chips are macroscopic and are formed by shear deformation

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• Material removal takes place due to application of cutting forces – energy domain can
be classified as mechanical, chemical, and thermal.
• Cutting tool must be harder than work piece at room temperature as well as under
machining conditions
• There is a direct physical contact between tool and work
• Material removal rate of the traditional processes is limited by the mechanical
properties of the work material.
Characteristics of Non Conventional Processes
Non Traditional Machining (NTM) Processes are characterized as follows:
• 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
• 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
• 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.
• 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.
Need for development of Non Conventional Processes
The strength of steel alloys has increased five folds due to continuous R and D effort. In aero-
space, requirement of High strength at elevated temperature with light weight led to
development and use of hard titanium alloys, nimonic alloys, and other HSTR alloys. The
ultimate tensile strength has been improved by as much as 20 times. Development of cutting
tools which has hardness of 80 to 85 HRC which cannot be machined economically in
conventional methods led to development of non –traditional machining methods.
1. Technologically advanced industries like aerospace, nuclear power, automobiles has
ever increasing use of High –strength temperature resistant (HSTR) alloys (having high
strength to weight ratio) and other difficult to machine materials like titanium,
nimonics, ceramics and semiconductors. It is no longer possible to use conventional
process to machine these alloys.
2. Production and processing parts of complicated shapes (in HSTR and other hard to
machine alloys) is difficult , time consuming and uneconomical by conventional
methods of machining

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3. Innovative geometric design of products and components made of new exotic materials
with desired tolerance, surface finish cannot be produced economically by conventional
machining.
4. The following examples are provided where NTM processes are preferred over the
conventional machining process:
♦ Intricate shaped blind hole – e.g. square hole of 15 mmx15 mm with a depth of 30 mm with
a tolerance of ±100 microns
♦ Difficult to machine material – e.g. Inconel, Ti-alloys or carbides, Ceramics, composites,
HSTR alloys, etc.
♦ Low Stress Grinding – Electrochemical Grinding is preferred as compared to conventional
grinding
♦ Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20
♦ Machining of composites.

----> The Need for Advanced Machining Processes:

1) Limitations of conventional machining methods
2) Rapid improvements in the properties of material
3) Product requirements:
• Complex shapes
• Machining inaccessible areas
• Low tolerances
• Less number of rejections
• Increased repeatability
• Better surface integrity
• High surface finish
4) High production rate
5) Low cost of production
6) Precision & Ultra precision machining:
7) The following cannot be done by traditional processes:
– Work piece strength and hardness very high, >400HB
– Work piece material too brittle, glass, ceramics, heat-treated alloys
– Work piece too slender and flexible, hard to clamp
– Part shape complex, long and small hole
– Special surface and dimensional tolerance requirements.

Why Nontraditional Processes are Important?

---->Nonconventional machining processes may be used as alternatives to the more
traditional processes for a number of reasons:

1. Machinability of the workpiece material:

Many workpiece materials are difficult to machine by conventional methods because of
high hardness, high thermal resistance, or high abrasive wear.
2. Shape complexity of the workpiece:
For example, it is usually relatively simple to produce a cylindrical hole in a workpiece, but
to produce a square, sharp-cornered hole of similar size is much more difficult.
3. Surface integrity:

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Conventional machining processes can result in surface cracks and residual stresses in the
workpiece. Many nonconventional machining processes can remove material without causing
these effects.
4. Precision:
Many nonconventional processes are capable of high levels of precision which cannot be
achieved by conventional machining.
5. Miniaturization:
Some nonconventional processes are capable of producing very small shape features and
fine detail not possible by conventional machining (e.g., the machining of deep holes with very
small diameters).
6. Automatic data communication and computer integration:
Many non-conventional processes can be, computer-controlled and linked directly to
CAD/CAM systems in an integrated manufacturing environment.

Differences between Conventional and Non conventional machining processes.

Sl.no Conventional process Non Conventional Process
1 The cutting tool and work piece are There is no physical contact between the
always in physical contact with relative tool and work piece, In some non
motion with each other, which results in traditional process tool wear exists.
friction and tool wear.
2 Material removal rate is limited by NTM can machine difficult to cut and
mechanical properties of work material. hard to cut materials like titanium,
ceramics, Stainless steel, composites,
semiconducting materials
3 Relative motion between the tool and Many NTM are capable of producing
work is typically rotary or reciprocating. complex 3D shapes and cavities
Thus the shape of work is limited to
circular or flat shapes. In spite of CNC
systems, production of 3D surfaces is
still a difficult task.
4 Machining of small cavities , slits , blind Machining of small cavities, slits and
holes or through holes are difficult Production of non-circular, micro sized,
large aspect ratio, shall entry angle
holes are easy using NTM
5 Use relative simple and inexpensive Non traditional processes requires
machinery and readily available expensive tools and equipment as well
cutting tools as skilled labor, which increase the
production cost significantly
6 Capital cost and maintenance cost is low Capital cost and maintenance cost is high
7 Traditional processes are well Mechanics of Material removal of Some
established and physics of process of NTM process are still under research
is well understood
8 Conventional process mostly uses Most NTM uses energy in direct form
mechanical energy For example : laser, Electron beam in
its direct forms are used in LBM and
EBM respectively.
9 Surface finish and tolerances are High surface finish(up to 0.1 micron) and
limited by machining inaccuracies tolerances (25 Microns)can be achieved
10 High metal removal rate. Low material removal rate.

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Conventional machining Non-conventional machining

1. Conventional method of machining is by
mechanical energy, through the use of a
physical force which shears the chips.
2. It is not a micromachining.
3. Accuracy is less.
4. High hardness cannot be machined.
5. Any intricate shapes cannot be machined.
1. The type of energy used and the
mechanism of metal removal is by abrasive
erosion, ion-displacement, fusion etc.
2. It is a micromachining.
3. Accuracy is more.
4. Any hardness can be machined.
5. Intricate shapes can be machined.

----> Classification:
Non-traditional machining processes are classified, according to nature of the energy
employed in machining
❖ Thermal and Electro thermal energy
❖ Chemical and Electrochemical energy
❖ Mechanical energy
1) Thermal and Electro thermal energy:
Thermal energy employed to melt and vaporize tiny bits of work material by concentrating
the heat energy on the small area of the work piece. By a continued repetition of this process
the required shape is machined.
Processes that utilize thermal energy include:
❖ Electrical discharge machining (EDM),
❖ Laser beam machining (LBM) ,
❖ Plasma arc welding (PAM),
❖ Electron beam machining(EBM)

2) Chemical OR Electrochemical energy:

Material is removed from the work surface by chemical dissolution using chemical reagents
or etchants like acids and alkaline solutions
Processes that utilize chemical energy include:
❖ Chemical machining (milling and blanking),
❖ Electrochemical machining (ECM).
❖ Electrochemical grinding (ECG) ,
❖ Electrochemical honing (ECH)
❖ Chemical deburring (ECD)

3) Mechanical energy:
The material is removed by the mechanical erosion of the work piece material.
The various processes that utilize mechanical energy include:
❖ Ultrasonic machining (USM),
❖ Abrasive jet machining (AJM),
❖ Water jet machining (WJM)

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Classifications of Advanced Machining Processes

Type of energy Mechanism of Transfer media Energy source Process

metal removal
Mechanical Erosion High velocity Pneumatic/hydraulic AJM, USM,
particles pressure WJM
shear Physical contact Cutting tool Conventional
machining
electrochemical Ion displacement electrolyte High current ECM, ECG
Chemical Ablative relation Reactive Corrosive agent CHM
environment
Thermoelectric fusion Hot gases Ionized material IBM, PAM
electrons High voltage EDM
Vaporization Radiation Amplified light LBM
Ion stream Ionized stream PAM

Write a note on process selection.

To make efficient use of modern machining processes, it is necessary to know the exact nature
of the machining problem. Before selecting the process to be employed, the following aspects
must be studied:
❖ Physical parameters
❖ Properties of the work material and the shape to be machined.
❖ Process capability
❖ Economic considerations
❖ Physical parameter of the process:
The physical parameters of the different NTM are given in the Table below. This indicates that
PAM and ECM require high power for fast machining. EBM and LBM require high voltages
and require careful handling of equipment. EDM and USM require medium power. EBM can
be used in vacuum and PAM uses oxygen and hydrogen gas.

Physical parameters of the modern machining processes

Parameters USM AJM ECM CHM EDM EBM LBM PAM

Potential 220 220 10 - 45 150,000 4500 100
(V)
Current 12 (AC) 1.0 10,000 - 50 0.001 2 500 (DC)
(Amp) (DC) (pulsed (pulsed (average
DC) DC) 200
peak)
Power (W) 2400 220 1,00,000 - 2700 150 - 50,000
(average
200
peak)
Gap (mm) 0.25 0.75 0.2 - 0.025 100 150 7.5
Medium Abrasive Abrasive Electrolyte Liquid Liquid vacuum Air Argon or
in water in gas chemical dielectric hydrogen

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
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roughly forty times more power than EDM

❖ SHAPES CUTTING CAPABLITY
The different shapes can be machined by NTM. EBM and LBM are used for micro drilling and
cutting. USM and EDM are useful for cavity sinking and standard hole drilling. ECM is useful
for fine hole drilling and contour machining. PAM can be used for cutting and AJM is useful
for shallow pocketing
Shape applications of modern machining processes
Through
Holes Through cavities Surfacing
cutting
Precision small
Standard
process holes Surfaces
Double
Dia Dia Length Length Precision Standard of shallow deep
contouring
<0.025 >0.025 <20 >20 revolution
mm mm Dia Dia
USM - - A C A A C - C -
AJM - - B C C B - - A -
ECM - - A A B A A B A A
CHM B B - - C B - - A -
EDM - - A B A A B - C -
LBM A A B C C C - - A B
PAM - - B - C C - C A A
NOTE
A Good B Fair C Poor

❖ PROCESS CAPABILITY
EDM which achieves higher accuracy and it has the lowest specific power requirement. ECM
can machine faster and has a low thermal surface damage depth. USM and AJM have high
material removal rates combined with high tool wear and are used for non-metal cutting. Due
to the high penetration depth LBM and EBM are used for micro drilling, sheet cutting and
welding. CHM is used for manufacture of shallow components.
Process capability
process Metal Tolerance Surface Surface Corner radii
removal rate μ finish CLA damage mm
mm3/min μ depth
μ
USM 300 7.5 0.2-0.5 25 0.025
AJM 0.8 50 0.5-1.2 2.5 0.1
ECM 1500 50 0.1-2.5 5.0 0.025
CHM 15.0 50 0.4-2.5 50 0.125
EDM 800 15 0.2-12.5 125 0.025
EBM 1.6 25 0.4-2.5 250 2.5
LBM 0.1 25 0.4-1.25 125 2.5
PAM 75,000 125 Rough 500 -
Conventional 50,000 50 0.4-5.0 25 0.05
milling of
steel

The process capabilities of modern machining methods have been compared in Table. It is
to be noted that although ECM results in excellent surface finish, it can cause extensive
surface damage as compared to AJM or USM
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Process economy
process Capital Tooling and Power Efficiency Tool
investment fixtures requirement consumption
USM B B B D C
AJM A B B D B
ECM E C C B A
CHM C B D C A
EDM C D B D D
EBM D B B E A
LBM C B A E A
PAM A B A A A
Conventional B B B A B
machining
NOTE
A very good B low C Medium D High E Very high

----> Advantages of Non-Traditional Machining Processes:

• Difficult to machine materials can be machined with unconventional process
• Machining materials in the complex shapes is possible with unconventional process
• Economical for mass Production for long duration
• High strength to weight ratio, hardness and heat-resisting materials
can be machinedwith unconventional process
• High accuracy and surface finish
• Material removed without mechanical contact with the work piece. (ECM, EDM,
LBM, CHM)
• Material removal rate is independent of work piece hardness. (ECM, LBM, EDM)
• Tool material need not be harder than the work piece material.
(ECM, LBM, EDM,CHM, USM)
• Tool wear is not a problem. (ECM, LBM, CHM)
• Ability to machine any material. (LBM)
• Burr-free machining (ECM, EDM, CHM)
• Stress-free machining. (ECM, ECG, CHM)
• Uniform material removal over the entire area simultaneously (ECM, CHM)
• Superior surface integrity possible. (ECM, CHM, ECG)
• Intricately shaped, very hard and fragile materials can be machined. (USM)
• Finely focused micro-machining possible. (EDM, LBM, EBM)
• Micro-hole drilling at shallow entrance angles possible. (EDM, ECM, LBM, EBM)
• Easy compatibility with numerical control and mini-computer
controls. (ECM, EDM,LBM, EBM)

----> Limitations of Non-Traditional Machining Process

• Work piece and tool must be electrically conductive (e.g. EDM, ECM)
• The depth of cut is limited (e.g. LBM)
• Recast or heat-affected zones (HAZ) or surfaces produced may be
troublesome (e.g.EDM, LBM, EBM)
• For this purpose, the compatibility of the process with the metallurgical
state of the work- piece materials can be studied before using a particular
non-traditional machining process for production work

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• There may be taper in the sidewalls of holes or cavities (e.g. EDM, LBM)
• Most of these limitations can be overcome and controlled, so that the
advantages can be obtained with good product quality assurance

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