Advanced Manufacturing Processes- II

UNCONVENTIONAL MACHINING PROCESS

(UCMP)
 Course Objectives (COs):
At the end of the course the student should be able to:
• Difference between conventional and unconventional machining
process.
• Describe the modern machining process and process selection for
different materials.
• Analyze the metallurgical effects of surface after different
unconventional machining processes.
• Metal Removal Rate and surface finish of different materials using
different process parameters.
• Identify the machining characteristics of Mechanical types of
unconventional machining process.
• Identify the machining characteristics of thermal types of
unconventional machining process.
• Describe electro chemical and chemical machining process,
elements, concentration and chemistry of the process.
• Describe the basic mechanism of material removal in EBM & LBM
AMP-II
 Unconventional Machining Process
Module – I

• Introduction: Types of advanced manufacturing

processes; Evolution, need, and classification of
advanced machining processes (AMPs).
 Introduction

Manufacturing processes can be broadly divided

into two groups:
• Primary manufacturing processes
Ex.: Casting, forming, powder metallurgy
• Secondary manufacturing processes
Ex.: Material removal processes such as turning,
milling, drilling, grinding, shaping, planning etc.
 Material removal processes
Material removal processes:
• Conventional Machining Processes
turning, boring, milling, shaping, broaching, slotting,
grinding etc.
• Unconventional Machining Processes
Abrasive Jet Machining (AJM), Ultrasonic
Machining (USM), Water Jet and Abrasive Water Jet
Machining (WJM and AWJM), Electro discharge
Machining (EDM)
 Conventional Machining Processes
The major characteristics of conventional machining are:
• Generally macroscopic chip formation by shear
deformation
• Material removal takes place due to application of cutting
forces – energy domain can be classified as mechanical
• Cutting tool is harder than work piece at room temperature
as well as under machining conditions
 Unconventional machining Process
The major characteristics of Unconventional
machining are:
• Material removal may occur with chip formation or
even no chip formation may take place.
• In UCMP, there may or may not be a physical tool
present.
• In UCMP, the tool need not be harder than the work
piece material.
• Mostly UCMP processes do not necessarily use
mechanical energy to provide material removal. They
use different energy domains to provide machining.
 Classification of UCMP

The broad classification is given as follows:

Mechanical Processes
• Abrasive Jet Machining (AJM)
• Ultrasonic Machining (USM)
• Water Jet Machining (WJM)
• Abrasive Water Jet Machining (AWJM)
 Classification of UCMP contnd…
Electrochemical Processes
• Electrochemical Machining (ECM)
• Electro Chemical Grinding (ECG)
• Electro Jet Drilling (EJD)

Electro-Thermal Processes
• Electro-discharge machining (EDM)
• Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)

Chemical Processes
• Chemical Milling (CHM)
• Photochemical Milling (PCM) etc.
UCMP Examples
 Need for UCMP
WHY DO YOU

NEED

UNCONVENTIONAL

MACHINING

PROCESS