INSTITUTE – UIET

DEPARTMENT - MECHANICAL
Bachelor of Engineering (Mechanical Engineering)
Subject Name – Non Traditional Machining (MEC-422)

DISCOVER . LEARN . EMPOWER

 NON TRADITIONAL MACHINING
Course Outcome

CO Title Level
Number

CO1 Remember
Lerner will understand the concept of non-traditional techniques.

CO2 Understand
To understand the application of mechanical energies such as ultrasonic energy for
machining purpose.

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 1.1.1What is
non traditional
machining?
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
tool in the conventional sense.
Conventional Machining VS Non-
Conventional Machining
• The cutting tool and workpiece are always in
physical contact, with a relative motion against
each other, which results in friction and a
significant tool wear.
• In non-traditional processes, there is no
physical contact between the tool and
workpiece.
• Material removal rate of the traditional
processes is limited by the mechanical
properties of the work material. Non-traditional
processes easily deal with such difficult-to-cut
materials like ceramics and ceramic based tool
materials, fiber reinforced materials, carbides,
titanium-based alloys.
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Continue….
• In traditional processes, the relative motion between the tool and work piece is
typically rotary or reciprocating.

• Machining of small cavities, slits, blind or through holes is difficult with

traditional processes, whereas it is a simple work for some non-traditional
processes.

• Traditional processes are well established, use relatively simple and inexpensive
machinery and readily available cutting tools.

• Non-traditional processes require expensive equipment and tooling as well as

skilled labor, which increases significantly the production cost.

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1.1.2 Cutting Tools
• One of most important components in machining process
• Performance will determine efficiency of operation
• Two basic types (excluding abrasives)
• Single point and multiple point
• Must have rake and clearance angles ground or formed on them.

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1.1.3 Why Nontraditional Processes Are Important?
• Need to machine newly developed metals and non-metals with special
properties that make them difficult or impossible to machine by
conventional methods
• Need for unusual and/or complex part geometries that cannot easily be
accomplished by conventional machining
• Need to avoid surface damage that often accompanies conventional
machining

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Continue…
• Very high hardness and strength of the material. (above 400 HB.)
• The work piece is 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.

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 1.1.4 CLASSIFICATION OF NONTRADITIONAL
MACHINING

I. Mechanical Energy Processes

II. Electrochemical Machining Processes
III.Thermal Energy Processes
IV.Chemical Machining

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1.1.5 Mechanical Energy Processes

• Ultrasonic Machining
• Water Jet Cutting
• Abrasive Water Jet Cutting
• Abrasive Jet Machining

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1.1.6 Electrochemical Machining Processes
• Electrical energy used in combination with chemical
reactions to remove material
• Reverse of electroplating
• Work material must be a conductor
• Processes:
• Electrochemical machining (ECM)
• Electrochemical deburring (ECD)
• Electrochemical grinding (ECG)
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1.1.7 Thermal Energy Processes
• Very high local temperatures
• Material is removed by fusion or vaporization
• Physical and metallurgical damage to the new work
surface.
• In some cases, resulting finish is so poor that
subsequent processing is required

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1.1.8 Thermal Energy Processes
• Electric Discharge Machining
• Electric Discharge Wire Cutting
• Electron Beam Machining
• Laser Beam Machining
• Plasma Arc Machining

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1.2.1 Mechanical Energy Techniques
• It is characterized by the fact that the material removal is due
to the application of mechanical energy in the form of high
frequency vibrations or kinetic energy of an abrasive jet.
• Ultrasonic machining
• Water jet cutting
• Abrasive water jet cutting
• Abrasive jet machining

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1.2.2 Ultrasonic Machining
History
• The roots of ultrasonic technology can be traced back to research on
the piezoelectric effect conducted by Pierre Curie around 1880.

• He found that asymmetrical crystals such as quartz and Rochelle salt

(potassium sodium titrate) generate an electric charge when
mechanical pressure is applied.
• Conversely, mechanical vibrations are obtained by applying electrical
oscillations to the same crystals.

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Continue…
• Frequency values of up to 1Ghz (1 billion cycles per second)
have been used in the ultrasonic industry.
• Today's Ultrasonic applications include medical imaging
(scanning the unborn fetus) and testing for cracks in airplane
construction.
• Piezoelectric transducers employ the inverse piezoelectric
effect using natural or synthetic single crystals (such as
quartz) or ceramics (such as barium titanate) which have
strong piezoelectric behavior

15
1.2.3 Elements of Ultra Sonic Machining

Source :- Internet
16
1.2.4 Mechanism of Material Removal Rate

Source :- Internet
17
1.2.5 Principle of USM
• In the process of Ultrasonic Machining, material is removed
by micro-chipping or erosion with abrasive particles.
• In USM process, the tool, made of softer material than that of
the workpiece, is oscillated by the Booster and Sonotrode at a
frequency of about 20 kHz with an amplitude of about 25.4
um (0.001 in).
• The tool forces the abrasive grits, in the gap between the tool
and the workpiece, to impact normally and successively on
the work surface, thereby machining the work surface.
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Continue…
• During one strike, the tool moves down from its most upper remote
position with a starting speed at zero, then it speeds up to finally reach
the maximum speed at the mean position
• Then the tool slows down its speed and eventually reaches zero again
at the lowest position.
• When the grit size is close to the mean position, the tool hits the grit
with its full speed
• The smaller the grit size, the lesser the momentum it receives from the
tool.

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Continue…
• As the tool continues to move downwards, the force acting on these
grits increases rapidly, therefore some of the grits may be fractured.

• As the tool moves further down, more grits with smaller sizes come in
contact with the tool, the force acting on each grit becomes less.

• Eventually, the tool comes to the end of its strike, the number of grits
under impact force from both the tool and the workpiece becomes
maximum.

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1.2.6 Process Parameter of USM
• Amplitude of vibration (ao) – 15 – 50 μm
• Frequency of vibration (f) – 19 – 25 kHz
• Feed force (F) – related to tool dimensions
• Feed pressure (p)
• Abrasive size – 15 μm – 150 μm
• Abrasive material – Al2O3
- SiC
- B4C
- Boronsilicarbide
- Diamond
Flow strength of work material
Flow strength of the tool material
Contact area of the tool – A
Volume concentration of abrasive in water slurry – C

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1.2.7 Economic Consideration
• Production rates very low.

• Material removal rates low, typically 13mm³/s.

• Linear penetration rates up to 0.4 mm/s.

• Lead time typically days depending on complexity of tool. Special tooling

required for each job.

• Material utilization poor. Scrap material cannot be recycled.

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Continue…….
• High degree of automation possible.
• Economical for low production runs. Can be used for one-offs.
• Tooling costs high.
• Equipment costs generally moderate.
• Direct labor costs low to moderate.

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1.2.8 USM APPLICATION
• Hard, brittle work materials such as ceramics, glass, and
carbides
• Also successful on certain metals, such as stainless steel and
titanium
• Shapes include non-round holes, holes along a curved axis
• “Coining operations” - pattern on tool is imparted to a flat
work surface

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1.2.9 Advantages and Disadvantages of USM

Advantages
• Machined all sorts of hard materials
• Produces fine finished and structured results
• Produces less heat
• Various hole cut shapes due to vibratory motion of the tool

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1.2.10 Advantages and Disadvantages of USM

Disadvantages
• Requires a higher degree of integrity and skills
• No certified record of radiography
• Unnecessary large grain sizes causes defects
• Additional repairs might be required due to spurious signs and
misunderstanding of the process

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1.2.11 ABRASIVE WATER JET MACHINING

Source :- Internet Source :- Internet

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1.2.12 ABRASIVE JET MACHINING

• An unconventional machining process.

• It is the process of removal of materials by
impact erosion through the action of a
concentrated, high velocity of the grit abrasives
entertained in a high-velocity gas stream.

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WHY ABRASIVE JET MACHINING ?

• Since it is an unconventional machining process, so it is used

where conventional machining processes cannot be used, like
in machining of has alloy, naturally, nimonics,etc

• Also it differs from conventional sand blasting process for its

fineness of particle size and controllable machining
parameters.

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1.2.13 SETUP OF AJM PROCES

Source :- Internet
30
1.2.14 Mechanism of material removal
• In this process, a gas (nitrogen or carbon dioxide or air), is supplied
under pressure (2-8kg/sq.cm) is supplied and after filter and regulator,
it is passed to a mixing chamber (containing abrasive particles)
vibrating at 50c/sec.

• From the mixing chamber , the gas along with the abrasive particles of
size 10-50 micro-mt. passes on to a nozzle having its tip of tungsten
carbide and diameter around 0.45mm , with a velocity of 150-
300m/sec.

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Continue…….
• The air consumption is of the order of 0.6 cu-m/hr.
• The nozzle tip distance is of the order of 0.81mm
• The abrasive powder feed rate is controlled by the amplitude of
vibration of the mixing chamber.
• The relative motion between the nozzle and the work piece is obtained
by cams, pantographs to control size and shape of cut.
• Dust removal equipment is also incorporated to protect the
environment.

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1.2.15 Process Variables in Abrasive water jet machining

• Carrier gas
• Shape of cut
• Nozzle design
• Work material
• Type of abrasive
• Stand-off distance
• Size of abrasive grain
• Velocity of abrasive jets
• Mean of abrasive particle/unit volume of the carrier gas

33
1.2.16 EFFECT OF VARIOUS PARAMETERS ON MATERIAL

Source :- Internet
34
Continue…….

Source :- Internet 35
1.2.17 ABRASIVES USED IN ABRASIVE JET MACHINING

• ABRASIVES: GRAIN SIZE(micron)

• Alumina 10,27,50
• Silicon carbide -do-
• Sodium bicarbonate 27
• Dolomite 66
• Glass beads 0.635-1.27mm

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1.2.18 CHARACTERISTICS OF THE PROCESS

1. Size of abrasive Around 25 micro-mt.

2. Flow rate 3-20 g/min.
3. Life of nozzle WC(12-30 hrs),sapphire(300 hrs).
4. Tolerance + or – 0.05mm
5. Surface roughness 0.15-0.2 micro-m with particles of size 10micro-
m, 0.4-0.8 micro-m.
6. Work material Hard and brittle materials like glass, ceramics,
mica, etc.
7. Machining operations Drilling , cutting , deburring , cleaning.
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1.2.19 APPLICATIONS

• Used for abrading and frosting glass more economically as compared

to etching or grinding.
• For cleaning of metallic smears on ceramics, oxides on metals,
resistive coatings, etc.
• Cutting and machining of fragile material like Ge, Si, etc.
• For deburring small hole in hypodermic needles and for small milled
slots in hard metallic components.
• Register treaming can be done very easily and micro-module
fabrication for electrical contact, semiconductor processing can also be
done effectively.

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1.2. 20 ADVANTAGES

• Ability to cut fragile, brittle or heat sensitive material without

damage.
• Ability to cut intricate holes in materials of any hardness.
• Low capital cost.
• Can cut materials without damage because there is no heating
of the working surface.

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1.2.21 DISADVANTAGES

• Slow material removal rate.

• Low accuracy (0.1mm) due to stray cutting.
• Abrasives get embedded on the material surface, if it is
soft.
• Abrasives powder cannot be refused.

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1.2.22 WATER JET MACHINING

Source :- Internet Source :- Internet

41
 1.2.23 INTRODUCTION OF WJM
 Key element in WJM is a jet of water.
 Water jet travels at velocities as high as 900 m/s (approximately Mach 3).
 When the water stream strikes a work piece surface, the erosive force of water
removes the material rapidly.
 The water, in this case, acts like a saw and cuts a narrow groove in the work piece
material.
 True cold cutting process – no HAZ (Heat Affected Zones), mechanical stresses or
operator and environmental hazards

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1.2.24 PRINCIPLE
• The water jet machining involves directing a high pressure (150-1000 MPa) high
velocity (540-1400 m/s) water jet (faster than the speed of sound) to the surface to
be machined. The fluid flow rate is typically from 0.5 to 2.5 l/min
• The kinetic energy of water jet after striking the work surface is reduced to zero.
• The bulk of kinetic energy of jet is converted into pressure energy.
• If the local pressure caused by the water jet exceeds the strength of the surface
being machined, the material from the surface gets eroded and a cavity is thus
formed.
• Water is the most common fluid used, but additives such as alcohols, oil products
and glycerol are added when they can be dissolved in water to improve the fluid
characteristics.

43
1.2.25 Equipment Used
• Typical work materials involve soft metals, paper, cloth, wood, leather,
rubber, plastics, and frozen food. If the work material is brittle it will
fracture, if it is ductile, it will cut well .
Water jet Machining consists of:
• Hydraulic Pump
• Intensifier
• Accumulator
• High Pressure Tubing
• Jet Cutting Nozzle
• Catcher

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1.2.26 SCHEMATIC LAYOUT OF WJM

Source :- Internet
45
1.2.27 HYDRAULIC PUMP

 Powered from a 30 kilowatt (kW) electric motor

 Supplies oil at pressures as high as 117 bars.
 Compressed oil drives a reciprocating plunger pump termed an intensifier.
 The hydraulic pump offers complete flexibility for water jet cutting and
cleaning applications.
 It also supports single or multiple cutting stations for increased machining
productivity.

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1.2.28 ITENSIFIER
 Accepts the water at low pressure(typically 4 bar) and expels it, through an
accumulator, at higher pressures of 3800 bar.
 The intensifier converts the energy from the low-pressure hydraulic fluid into
ultrahigh-pressure water.
 The hydraulic system provides fluid power to a reciprocating piston in the
intensifier center section.
 A limit switch, located at each end of the piston travel, signals the electronic
controls to shift the directional control valve and reverses the piston direction.
 The intensifier assembly, with a plunger on each side of the piston, generates
pressure in both directions.

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Continue…….

 As one side of the intensifier is in the inlet stroke, the opposite side is
generating ultrahigh-pressure output.
 During the plunger inlet stroke, filtered water enters the high-pressure
cylinder through the check value assembly.
 After the plunger reverses direction, the water is compressed and exits
at ultrahigh pressure

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1.2.29 ACCUMULATOR

 Maintains the continuous flow of the high-pressure water and

eliminates pressure fluctuations.
 It relies on the compressibility of water (12 percent at 3800 bar) in
order to maintain a uniform discharge pressure and water jet velocity,
when the intensifier piston changes its direction.

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1.2.30 HIGH PRESSURE TUBING
 Transports pressurized water to the cutting head.
 Typical tube diameters are 6 to 14 mm.
 The equipment allows for flexible movement of the cutting head.
 The cutting action is controlled either manually or through a remote-
control valve specially designed for this purpose.

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1.2.31 JET CUTTING NOZZLE
 Nozzle provides a coherent water jet stream for optimum cutting of
low-density, soft material that is considered un machinable by
conventional methods.
 Nozzles are normally made from synthetic sapphire.
 About 200 h of operation are expected from a nozzle, which becomes
damaged by particles of dirt and the accumulation of mineral deposits
on the orifice due to erosive water hardness.
 A longer nozzle life can be obtained through multistage filtration,
which removes undesired solids of size greater than 0.45 μm.
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1.2.32 CATCHER

 Acts as a reservoir for collecting the machining debris entrained in the

water jet.
 Moreover, it reduces the noise levels [105 decibels (dB)] associated
with the reduction in the velocity of the water jet from Mach 3 to
subsonic levels

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1.2.33 Parameters of WJM

Source :- Internet 53
1.2.34 Mechanism of Material removal

• Water jets alone (without abrasives) can be used for cutting.

Thin jets of high pressure and high velocity have been used
to cut materials such wood, coal, textiles, rocks, concrete,
asbestos.
• The mechanism of material removal rate is by erosion. When
high pressure water jet emerges of a nozzle, it attains a large
kinetic energy.

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Continue….
• High velocity jet strikes the work
piece, its kinetic energy is
converted into pressure energy
including high stresses in the
work material.
• When the induced stress
exceeds the ultimate shear
stress of the material, rupture
takes place

Source :- Internet
55
1.2.35 PROCESS PARAMETERS
JET NOZZLE
 Standoff distance - Gap between the jet nozzle
(0.1–0.3 mm diameter) and the workpiece (2.5
– 6 mm).
 However for materials used in printed circuit
boards, it may be increased to 13 to 19 mm.
 But larger the standoff distance, smaller would
be the depth of cut.
 When cutting fiber-reinforced plastics, reports
showed that the increase in machining rate and
use of the small nozzle diameter increased the
width of the damaged layer.

Source :- Internet
56
1.2.36 JET FLUID
 Typical pressures used are 150 to 1000 MPa to provide 8 to 80 kW of
power.
 For a given nozzle diameter, increase in pressure allows more power to be
used in the machining process, which in turn increases the depth of the cut.
 Jet velocities range between 540 to 1400 m/s.
 The quality of cutting improves at higher pressures by widening the
diameter of the jet and by lowering the traverse speed.
 Under such conditions, materials of greater thicknesses and densities can be
cut.

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Continue….

 Moreover, the larger the pump pressure, the greater will be

the depth of the cut.
 The fluid used must possess low viscosity to minimize the
energy losses and be noncorrosive, nontoxic, common, and
inexpensive.
 Water is commonly used for cutting alloy steels.

58
2.37 WORKPIECE
 Brittle materials will
fracture, while ductile ones
will cut well.
 Material thicknesses range
from 0.8 to 25 mm or more.
 Table below shows the
cutting rates for different
material thicknesses
Source :- Internet
59
1.2.38 APPLICATIONS
 WJM is used on metals, paper, cloth, leather, rubber, plastics, food, and ceramics.
 It is a versatile and cost-effective cutting process that can be used as an alternative to traditional
machining methods.
 It completely eliminates heat-affected zones, toxic fumes, recast layers, work hardening and
thermal stresses.
 It is the most flexible and effective cleaning solution available for a variety of industrial needs.
 Moreover, harder materials exhibit a better edge finish.
 Typical surface finishes ranges from 1.6 μm root mean square (RMS) to very coarse depending on
the application.
 Tolerances are in the range of  25 µm on thin material.

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1.2.39 CUTTING
 WJM is limited to fibreglass and corrugated wood.
 Figure shows typical example of water jet cutting of water jet cutting
of marble and application in the food industry.

Source :- Internet Source :- Internet

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1.2.40 DRILLING

• The process drills precision-angled and -shaped

holes in a variety of materials for which other
processes such as EDM or EBM are too
expensive or too slow.

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1.2.41 ADVANTAGES
 It has multidirectional cutting capacity.
 No heat is produced.
 Cuts can be started at any location without the need for predrilled
holes.
 Wetting of the workpiece material is minimal.
 There is no deflection to the rest of the workpiece.
 The burr produced is minimal.
 The tool does not wear and, therefore, does not need sharpening.
 The process is environmentally safe.

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Continue….
 Hazardous airborne dust contamination and waste disposal problems
that are common when using other cleaning methods are eliminated.
 There is multiple head processing.
 Simple fixturing eliminates costly and complicated tooling, which
reduces turnaround time and lowers the cost.
 Grinding and polishing are eliminated, reducing secondary operation
costs.
 The narrow kerf allows tight nesting when multiple parts are cut from
a single blank.

64
1.2.42 LIMITATIONS
 Very thick parts can not be cut with water jet cutting and still hold
dimensional accuracy. If the part is too thick, the jet may dissipate
some, and cause it to cut on a diagonal, or to have a wider cut at the
bottom of the part than the top. It can also cause a rough wave pattern
on the cut surface.
 It is not suitable for mass production because of high maintenance
requirements.

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 FAQ
• Are there materials that cannot be processed by means of
the ultrasonic machining?
• How can I determine whether my application will require
abrasive
• What is unique about waterjet compared to other cutting
technologies?

66
 REFERENCES

1. http://mechanicalinventions.blogspot.in/2014/12/abrasive-jet-
machining-ajm-process.html.
2. Advanced Manufacturing Processes by VK Jain
3. Manufacturing Engineering and Technology by Kalpakjian.
4. http://mechteacher.com/water-jet-machining/

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 THANK YOU

For queries
Email: vijay.mech@cumail.in