Unconventional

Machining Process

03:50

Traditional Machining

Traditional, also termed conventional,

machining requires the presence of a tool
that is harder than the workpiece to be
machined.
This tool should be penetrated in the
workpiece to a certain depth. Moreover, a
relative motion between the tool and
workpiece is responsible for forming or
generating the required shape.

03:50

Machining by cutting

During machining by cutting, the tool is penetrated

in the work material to the depth of the cut. Arelative
(main and feed) motion determines the workpiece
geometry required.
The accuracy of the surface profile depends mostly
on the accuracy of the form-cutting tool.
The resistance of the workpiece material to
machining by cutting depends on the temperature
generated at the machining zone.

03:50

03:50

Machining by abrasion

The term abrasion machining usually describes

processes whereby the machining allowance is
removed by a multitude of hard, angular abrasive
particles or grains (also called grits), which may or
may not be bonded to form a tool of definite
geometry.
In contrast to metal cutting processes, during
abrasive machining, the individual cutting edges are
randomly oriented and the depth of engagement
(the undeformed chip thickness) is small and not
equal for all abrasive grains that are simultaneously
in contact with the workpiece.

03:50

Contd

The cutting edges (abrasives) are used to

remove a small machining allowance by the
MA action during the finishing processes
The material is removed in the form of minute
chips, which are invisible in most cases
(Kaczmarek, 1976). Then MA action is
adopted during grinding, honing, and
superfinishing processes that employ either
solid grinding wheels or sticks in the form of
bonded abrasives

03:50

03:50

Why we prefer Nontraditional

Machining?

Traditional machining is most often based on the

removal of material using tools that are harder than
the workpiece.
The high cost of machining ceramics and
composites and the damage generated during
machining are major obstacles to the
implementation of these materials.
In addition to the advanced materials, morecomplex
shapes, low-rigidity structures, and micromachined
components with tight tolerances and fine surface
quality are often needed

03:50

Material removal
processes

03:50

Nontraditional Machining

The absence of any of these elements in any

machining process such as the absence of
tool-workpiece contact or relative motion,
makes the process a nontraditional one.
These methods play a considerable role in
the aircraft, automobile, tool, die, and mold
making industries.

03:50

Nontraditional machining
processes

03:50

Mechanical machining

Ultrasonic machining (USM) and water jet

machining (WJM) are typical examples of
single-action, mechanical, nontraditional
machining processes.
Machining occurs by MA in USM while cutting
is adopted using a fluid jet in case of WJM.

03:50

Contd

The machining medium is solid grains

suspended in the abrasive slurry in the
former, while a fluid is employed in the WJM
process.
The introduction of abrasives to the fluid jet
enhances the cutting in case of abrasive
water jet machining (AWJM) or ice particles
during ice jet machining (IJM)

03:50

Mechanical Nontraditional
Processes

03:50

Thermal machining

Thermal machining removes the machining allowance by melting

or vaporizing the workpiece material.
The source of heat required for material removal can be

the plasma during electrodischarge machining (EDM) and plasma

beam machining (PBM)
photons during laser beam machining (LBM)
electrons in case of electron beam machining (EBM)
ions for ion beam machining (IBM)
While electrodischarge occurs in a dielectric liquid for EDM
ion and laser beams are achieved in a vacuum during IBM and LBM

For each of these processes, the machining medium is different

03:50

Thermal Nontraditional
Machining
Processes

03:50

Chemical and
electrochemical machining

Chemical milling (CHM) and photochemical

machining (PCM), also called chemical
blanking (PCB), use a chemical dissolution
(CD) action to remove the machining
allowance through ions in an etchant.
Electrochemical machining (ECM) uses the
electrochemical dissolution (ECD) phase to
remove the machining allowance using ion
transfer in an electrolytic cell

03:50

Chemical and
electrochemical processes

03:50

Machining accuracies
(Tanigushi, 1983).

03:50

03:50

03:50

03:50

03:50

03:50

03:50