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Introduction to Nonconventional
Machining Process

Contents

01 • Introduction

02 • History of machining

03 • Material Removal Processes

04 • Classifications of Nonconventional Machining

05 • Cutting Conditions

06 • Conventional vs. Nonconventional

07 • The Need of Nonconventional machining

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Introduction

Stone Age Blacksmithing

History of Machining

The meaning of the term machining has evolved over the past two
centuries as technology has advanced.

18th century 19th century After World war 2

Machinist Conventional Machining Nonconventional Machining

simply meant a person who
built or repaired machines,
done by hand using
processes such as the carving
of wood.
during the Machine Age, machining
referred to the machine that used
with a sharp cutting tool to remove
material to achieve the desired
geometry.
With the advent of new technologies in
machining, "conventional machining" can be
used to differentiate those classic
technologies from the newer ones.

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Material Removal Processes
Material
Removal
Processes
Material Removal Processes
• Conventional Machining:
Turning Machine
Single point cutting tool
removes material from a
rotating workpiece to form a
cylindrical shape
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Turning Machine • Wasteful of material
Milling Machine
• Time consuming
Conventional Machining Drilling Machine
Grinding Machine • High skills
Shaping Machine • limitations of process
EDM
LBM
Nonconventional Machining PAM
ECM
WJM
Milling Machine Drilling Machine Grinding Machine Shaping Machine
Rotating multiple-cutting- Used to create a round It is an abrasive machining It is a type of machine tool
edge tool is moved across hole, usually by means of a process that uses a that uses linear relative
work to cut a plane or rotating tool with two grinding wheel as the motion between the
straight surface cutting edges cutting tool. workpiece and a single-point
cutting tool to machine a
linear toolpath.
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Classifications of Nonconventional Machining

• Classification of Nonconventional processes is carried out depending on the

nature of energy used for material removal.

Mechanical Electrochemical Thermal Chemical

Processes Processes Processes Processes

Classifications of Nonconventional Machining

• Mechanical Processes:
High velocity abrasives or liquids (or both) remove materials

Abrasive Jet Water Jet Ultrasonic Abrasive Water

Machining Machining Machining Jet Machining
(AJM) (WJM) (USM) (AWJM)

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Classifications of Nonconventional Machining

• Electrochemical Processes:
An electrolytic reaction at workpiece surface for removal of material.

Electrochemical Electrochemical Electro Jet

Machining Grinding Drilling
(ECM) (ECG) (EJD)

Classifications of Nonconventional Machining

• Thermal Processes:
• the thermal energy is employed to melt and vaporize tiny particles of material
by concentrating the heat energy on a small area of the workpiece.

Electro-discharge Laser Jet Electron Beam

machining Machining Machining
(EDM) (LJM) (EBM)

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Classifications of Nonconventional Machining

• Chemical Processes:
Remove material from portions of the workpiece, while other portions of the
surface are protected by a mask.

Chemical Milling Photochemical Milling

(CHM) (PCM)

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Cutting Conditions

Ø Cutting Speed (Vc)

Ø Feed (F)
Ø Depth of cut (a)

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Conventional vs Nonconventional

Conventional Nonconventional
There may be a physical tool There may not be a physical tool
present (sharp cutting tools ) present for example in WJM.

The cutting tool and workpiece There is NO physical contact

are always in physical contact between the tool and workpiece

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Conventional vs Nonconventional

Conventional Nonconventional
Cutting tool is harder than There may NOT be a physical
workpiece tool present.

Lower accuracy and surface Higher accuracy and surface

finish. finish

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Conventional vs Nonconventional

Conventional Nonconventional
Mostly do not necessarily use
Primary source of energy :
mechanical energy to provide
mechanical.
material removal.

Higher waste of material due to Lower waste of material due to

high wear. low or no wear.

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Conventional vs Nonconventional

Conventional Nonconventional
Skilled or un-skilled operator Skilled operator required.
may required

Generally they are manual to Generally they are fully

operate. automated process.

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Conventional vs Nonconventional

Conventional Nonconventional
Lower cost Higher cost

Noisy operation Quieter operation

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Conventional vs Nonconventional

Conventional Nonconventional
Tool life is less due to high Tool life is more
surface contact

Easy set-up of equipment. Complex set-up equipment

Material removal rate of the Easily deal with such difficult to

traditional processes is limited cut materials like ceramics

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The need of Nonconventional machining

Extremely hard and The shape of the part

brittle materials is to complex
the workpiece is to flexible or
slender to support the cutting
forces

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Any Question?

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