EMS 210 MANUFACTURING

PROCESSES AND PRODUCT

DEVELOPMENT

Manufacturing Process and Product 1

Development
 Description
• The course introduce various manufacturing
processes that are used for the production of
different mechanical products.
• In addition, it introduces to students skills
and knowledge on how to develop new
products

Manufacturing Process and Product 2

Development
 Learning outcomes
• Have a broader understanding of the theoretical
knowledge on various manufacturing processes.
• Use the theoretical knowledge of various
manufacturing processes to make the process
choice.
• Make the cost benefit analysis of different
processes, bulk deformation, sheet-metal forming,
machining and joining.
• Understanding the new product introduction
processes

Manufacturing Process and Product 3

Development
 Introduction to the course
• Manufacturing Processes: Refer to the steps
through which raw materials are transformed
into final products.
• The manufacturing process begins with the
creation of the materials from the original
source.
• These materials are then processed/modified
through manufacturing processes to become
the required part.
Manufacturing Process and Product 4
Development
• Any manufacturing processes, and
techniques selected must have to be:
• Technologically acceptable
• Economically viable
• Effectively and efficiently
• Environmental -friendly

Manufacturing Process and Product 5

Development
Manufacturing Process Management
• This mainly refers to planning, coordination
and control of the entire manufacturing in
most profitable way with maximum
satisfaction to the customers by best
utilization of the available resources like man,
machine, materials and money.
• It is possible to manufacture a product of a
given material by several processes

Manufacturing Process and Product 6

Development
Manufacturing Process and Product 7
Development
• The various process routes are different in
respect of principle, technique, quality of
products, time requirement and cost to
manufacture.
• The best one is to be selected based on some
criteria.

Manufacturing Process and Product 8

Development
• To achieve the goal in manufacturing
management process it requires fulfillment of
some of the following objectives:
• Reduction of manufacturing time
• Increase of productivity
• Reduction of manufacturing cost and hence
increase in profit
• Increase in quality and reliability of the
products

Manufacturing Process and Product 9

Development
 Manufacturing processes
• There are various manufacturing processes
existing at present and the number is still
increasing with the growing of science and
technology.
• Manufacturing processes can be broadly
classified into four major groups as follows:

Manufacturing Process and Product 10

Development
• Material removal process: Machining
(Traditional or Non-traditional), Grinding etc.
• Joining process: Welding, brazing, soldering
etc.
• Shaping or forming processes:
Manufacturing a solid product of definite size
and shape from a given material taken in
three possible states:
Manufacturing Process and Product 11
Development
• In solid state – e.g., forging rolling, extrusion,
drawing etc.
• In liquid or semi-liquid state – e.g., casting,
injection molding etc.
• In powder form – e.g. powder metallurgical
process.

Manufacturing Process and Product 12

Development
• This course is organized to cover the
following manufacturing process
• Chapter 1: Material Removal Processes
• Chapter 2: Metal Forming Processes
• Chapter 3: Joining Methods/processes
• Chapter 4: Casting Processes
• Chapter 5: New Product Development

Manufacturing Process and Product 13

Development
 Chapter 1

Material Removal Processes

Manufacturing Process and Product 14

Development
• Material removal process are the one in
which a sharp cutting tool is used
mechanically to cut away material so that the
desired part geometry remains.
• Most of them involve machining processes

Manufacturing Process and Product 15

Development
 MATERIAL REMOVAL PROCESS

Categories:
• Machining–material removal by a sharp cutting tool,
e.g., turning, milling, drilling etc.

• Abrasive processes –material removal by hard, abrasive

particles, e.g., grinding.

• Non-traditional processes –various forms of other than

sharp cutting tool to remove materials
 Machining processes
• Most of the engineering components such as
gears, bearings, clutches, tools, screws and
nuts etc. are manufactured from machining
processes
• Machining is a term used to describe a variety
of material removal processes in which a
cutting tool removes unwanted material from
a work piece to produce the desired shape.

Manufacturing Process and Product 17

Development
• Machining create a product to higher
accuracy and good surface finish
• Additionally some environment called cutting
fluid is generally used to ease machining by
cooling and lubrication.
• Most of the machining processes can be
accomplished by using machine tools

Manufacturing Process and Product 18

Development
 Machine tools
• Machine tools are machines that are power
operated used to produce products of desired
size, shape and surface finish by removing
excess material from the work piece in the
form of chips with the help of a single pointed
cutting tools

Manufacturing Process and Product 19

Development
 Basic principle of machine tools
• Firmly holding the work and the tool
• Transmit motions to the tool and the work
• Provide power to the tool-work pair for the
machining action.
• Control of the machining parameters, i.e.,
speed, feed and depth of cut.

Manufacturing Process and Product 20

Development
• Basic machine tools are such as lathe
machines, milling machines, drilling machine,
shaping machines… etc.
• Machining processes can be categorized into
two forms:
• Conventional machining operations
• Non conventional operations

Manufacturing Process and Product 21

Development
• Conventional machine tools processes can be
categorized into the following groups:
• Turning and Related Operations
• Drilling and Related Operations
• Milling
• Other Machining Operations

Manufacturing Process and Product 22

Development
 Turning and Related Operations
• Turning –a machining process in which a
single-point tool remove material from the
surface of a rotating work piece. (Lathe)

Manufacturing Process and Product 23

Development
Diagrammatically:

Manufacturing Process and Product 24

Development
Operations related to turning

Manufacturing Process and Product 25

Development
• Facing: Is the process of removing metal from
the end of a work piece to produce a flat
surface.
• Depending on how rough the end of the work
piece was you may need to make 3 or more
passes to get a nice smooth finish across the
face.

Manufacturing Process and Product 26

Development
• Taper turning is a is the gradual reduction in
diameter from one part of a cylindrical work
piece to another part
• Tapers can be either external or internal.
• Contour turning production of the contour
shape on a work piece by controlling the
cutting tool that moves over the surface of a
work part
Manufacturing Process and Product 27
Development
Manufacturing Process and Product 28
Development
• Form turning is a machining process of
creating a desired form on the work piece by
controlling the tool on the surface of the work
piece example:

29
• Chamfering: is the processed of creating a
chamfer at the end of the cylindrical work
piece.
• Cutting off: Is the processes of separating a
work piece into two parts to get the required
product.
• Threading: The process of creating screw
threads on the cylindrical work piece
30
• Threading can be external or internal
• Boring: is the processes of enlarging the size
of the hole that has already been created by
using a single pointed cutting tool
• Drilling is a cutting process that uses a drill
bit to cut or enlarge a hole of a flat or
circular cross-section in solid materials.

Manufacturing Process and Product 31

Development
• Knurling is a manufacturing process, typically
conducted on a lathe, whereby a pattern of
straight, angled or crossed lines is cut or rolled
into the material.
• Knurling is done because gripping surfaces on
measuring tools and all kinds of handles or
grips which have to be gripped firmly, must
have roughened gripping surfaces

Manufacturing Process and Product 32

Development
Manufacturing Process and Product 33
Development
Turning and related operations
done on a lathe machine

Manufacturing Process and Product 34

Development
The bed:
• The bed of Lathe acts as the base on which
the different fixed and operations parts of the
Lathe are mounted
Headstock:
• The head stock is the part of the lathe which
serves as a housing for the driving mechanism
(pulleys, gears and belts) which provide
motion

Manufacturing Process and Product 35

Development
Tail stock
• It is mounted on the bed of the lathe it can
slide along to support the work mounted on
the head stock.
Carriage:
• The lathe carriage it provide motion to the
tool i.e. supporting, guiding and feeding the
tool against the job during the operation of
the lathe.
Manufacturing Process and Product 36
Development
 Drilling and related processes
• Drilling is a cutting process that uses a drill bit
to cut a hole of circular cross-section in solid
materials.
• Drilling produce a hole on the work piece
• The drill bit is a rotary cutting tool used in
drilling operation
• The work piece can be either flat or round.
• Normally the work piece is stationary and the
tool is rotating.
Manufacturing Process and Product 37
Development
• Spot drilling: Involves drilling of a hole that
will act as a guide for drilling the final hole
• Centre drilling: involves drilling a hole that
will act as a center of rotation on the work
piece

Manufacturing Process and Product 38

Development
• Deep hall drilling: Involves drilling of a hole
deeper into the work piece
• Through hole drilling: involves drilling a
through hole on the work piece
• Different drill bits may be used for the
different drilling operations (i.e. drill of
different sizes)

Manufacturing Process and Product 39

Development
Drill geometry

Manufacturing Process and Product 40

Development
Manufacturing Process and Product 41
Development
Other types of drilling

Manufacturing Process and Product 42

Development
•The drill bit is usually a rotary cutting tool,
often multipoint.
•For step drilling the size of the hole is not the
same throughout.

43
Manufacturing Process and
Product Development
• Counter boring is a cylindrical flat-bottomed
drill that enlarges another coaxial hole
• A countersinking a conical hole cut into a
manufactured object, or the cutter used to cut
such a hole.
• Reaming enlarge the size of a previously
formed hole by a small amount but with a
high degree of accuracy to leave smooth side

Manufacturing Process and Product 44

Development
Machine tools for drilling

Manufacturing Process and Product 45

Development
 Milling operations
• Milling: A process in which a rotating multi-tooth
cutter removes materials while traveling along the
workpiece.
• In peripheral milling (also called plain milling), the
axis of cutter rotation is parallel to the workpiece
surface.
• In face milling the axis of the cutter rotation is
perpendicular to the surface of the workpiece.
Milling operation

Manufacturing Process and Product 47

Development
 Milling Operations

Figure (a) Schematic illustration of conventional milling and climb milling. (b) lab-milling
operation showing depth-of-cut, d; feed per tooth, f; chip depth-of-cut, tc; and workpiece
speed, v. (c) Schematic illustration of cutter travel distance, lc, to reach full depth-of-cut.
 Column-and-Knee Type Milling Machines

Schematic illustration of (a) a horizontal-spindle column-and-knee type milling

machine and (b) vertical-spindle column-and-knee type milling machine.
 Milling and Milling Machine
Milling Machines
The basic components of milling machines are as follows:
•Worktable: On which the workpiece is clamped on slot.
•The table moves longitudinally relative to the saddle.
•Saddle: supports the table and can move in the transverse
direction.
•Knee: supports the saddle and gives the table vertical
movement so that the depth of cut can be adjusted and
workpieces with various heights can be accommodated.
•Overarm: used on horizontal machines; it is adjustable to
accommodate different lengths.
• Head: contains the spindle and cutter holders.
In vertical machines, the head may be fixed or
can be adjusted vertically, for cutting tapered
surfaces.

Manufacturing Process and Product 51

Development
 Bed-type Milling Machine

Schematic illustration of a bed-type milling machine.

 Milling and Milling Machine
Design And Operating Guidelines
• Use standard milling cutters as much as possible
• Workpiece should be sufficiently rigid to minimize
any deflections resulting from clamping and cutting
forces
Milling equations
 Other machining operations
Shaping and planning
• Shaping and planning are two very similar cutting
operations which only differs in the kinematics of the
process
• Planning- the primary cutting motion is perfumed by
the work and feed motion is imparted to the cutting
tool
• In shaping the primary motion is performed by the
tool and the feed by the work piece.
• Sawing: Cutting metal into pieces
• E.g. Hack sawing, and Circular sawing

55
Manufacturing Process and Product
Manufacturing Process and Product 56
Development
Manufacturing Process and Product 57
Development
 Grinding
• Grinding is a material removal and surface
generation process used to shape and finish
components made of metals and other
materials.
• The precision and surface finish obtained
through grinding can be up to ten times better
than with either turning or milling.

Manufacturing Process and Product 58

Development
Manufacturing Process and Product 59
Development
 Cutting Fluids
• During any machining or metal cutting
process, enough heat is evolved in cutting
zone.
• To remove this heat from cutting zone, soluble
oils are used as cutting fluid during machining.
• They cool the work-piece and tool and thus
relieved them from overheat.
• Air circulation is required so as to remove the
heat by evaporation.

Manufacturing Process and Product 60

Development
• They also protecting layer over the machined
WP and save it from rust and corrosion
• The efficient way of applying cutting fluids is
to use a pump, tray and reservoir, to give a
slow continuous stream over the cutting
action

Manufacturing Process and Product 61

Development
 Commonly cutting fluids
• For Mild Steel: Soluble oil Straight, Water base
mainly grinding
• Aluminum alloys: Paraffin
• Cast iron: Dry
• Brass - Copper and Bronze: Dry

Manufacturing Process and Product 62

Development
 Functions of cutting fluids
• Cutting fluid washes away the chips and hence
keeps the cutting region free.
• It helps in keeping freshly machined surface
bright by giving a protective coating against
atmospheric, oxygen and thus protects the
finished surface from corrosion.
• It decreases wear and tear of cutting tool and
hence increases tool life.
Manufacturing Process and Product 63
Development
• It improves machineability and reduce power
requirements
• It prevents expansion of work pieces.
• It cools the tool and work piece and remove
the generated heat from the cutting zone.
• It decreases the friction between the tool and
the WP

Manufacturing Process and Product 64

Development
 Cutting Tools Materials
• Cutting tools materials are used in making
tools for various machining processes.
• The most common cutting tool material is
carbon steel.
• Different cutting tools materials are
highlighted below:
1. High-speed steels
2. Cast-cobalt alloys
3. Carbides
Manufacturing Process and Product 65
Development
4. Coated tools
5. Aluminum-based ceramics
6. Cubic boron nitride
7. Silicon-nitride- ceramics based
8. Diamond
9. Whisker-reinforced materials

Manufacturing Process and Product 66

Development
 1. High Speed Steel (HSS)
• HSS tools were developed to machine at
higher speeds than was previously possible with
carbon steels (low speeds)
• Characteristics: Can be hardened to various
depths, have good wear resistance and are
inexpensive
• Uses: Suitable for: interrupted cuts and
machines subject to vibration.

Manufacturing Process and Product 67

Development
 Two basic types of HSS:
• Molybdenum (M-series: 10% Mo; other
alloys: Cr, V, W, Co):
• Higher abrasion resistance than T-series, less
distortion during heat treatment, less
expensive ⇒ comprise 95% of HSS
• Tungsten (T-series: 12-18% W ; other alloys:
Cr, V, Co)
• HSS can be treated to improve performance:
e.g. Coating and surface treatment (to
improve hardness, wear resistance)
Manufacturing Process and Product 68
Development
 2. Cast-cobalt Alloys
• Cast-cobalt alloys (mostly Co, also: Cr, W)
• Characteristics: high hardness, good wear
resistance, maintain hardness at elevated
temperatures (hot hardness)
• Drawbacks: not as tough as HSS, sensitive to
impact forces, less suitable than HSS for
interrupted cutting operations
• Applications: used for deep/large cuts (high f
& V: twice larger > HSS).
Manufacturing Process and Product 69
Development
 3. Carbides
• AKA cemented/sintered carbides
• Characteristics: High hardness over a wide
range of temperatures compared to HSS &
Cast-Co alloys where only low V possible, High
elastic modulus, High thermal conductivity,
Low thermal expansion
• Applications: Cost-effective tool & die
materials for many applications
Manufacturing Process and Product 70
Development
• There are two groups uncoated carbides)
• Tungsten Carbide
• Titanium Carbide

Manufacturing Process and Product 71

Development
• Tungsten carbide (WC) (have tungsten-
carbide particles bonded together in a cobalt
matrix (i.e. sintering process)
• As C content increases (typically: 6-16%), then
strength, hardness, and wear resistance of WC
(decrease) ↓
• Yet toughness (increase) ↑because of the
higher toughness of C
• Applications: used for cutting steels, cast irons
and abrasive nonferrous materials
• Have largely replaced HSS due to better
performance
Manufacturing Process and Product 72
Development
 Titanium carbides
• Consists of a nickel–molybdenum matrix
• Wear resistance is greater then WC, but is not
tough
• Applications: machining hard materials (steels
and cast irons), cutting at speeds greater than
those suitable for tungsten carbide

Manufacturing Process and Product 73

Development
 4. Coated Tools
• New alloys and engineering tools materials
developed to have high strength and
toughness
• Problem: chemically reactive with tool
materials-difficulty in machining these
materials
• Characteristics: Lower friction, higher
resistance to wear and cracking, acting as a
diffusion barrier, higher hot hardness and
impact resistance
Manufacturing Process and Product 74
Development
 Common coating materials are:

• Titanium nitride (TiN)

• Titanium carbide (TiC)
• Titanium carbonitride (TiCN)
• Aluminum oxide (Al2O3)

Manufacturing Process and Product 75

Development
 Coated tools should have the
following characteristics
1. High hardness: At high temp - resist wear
2. Chemical stability of work piece – resist wear
3. Low thermal conductivity: prevent rise in tool
temp.
4. Compatibility and good bonding to substrate
(i.e. tool material) - prevent flaking

Manufacturing Process and Product 76

Development
 5. Aluminum Based
• These are Ceramic tool materials consist of
fine-grained and high-purity aluminum oxide
• Additions of titanium carbide and zirconium
oxide improve toughness and thermal shock
resistance
• Applications: used in high-speed cutting (e.g.
turning)
• Characteristics: Alumina-based ceramic tools
have high abrasion resistance and hot
hardness, have low toughness
Manufacturing Process and Product 77
Development,
• Cermet's: Consist of ceramic particles in a
metallic matrix e.g. cermet: 70% Al2O3 + 30%
TiC
• Weakness: They are brittle, expensive and
have limited usage, Performance is between
ceramics and carbides
• Application: high-speed finishing cuts

Manufacturing Process and Product 78

Development
 6. Silicon-nitride-based Ceramics
• Silicon-nitride (SiN) based ceramic tool
materials consist of silicon nitride with various
additions of aluminum oxide, yttrium oxide
and titanium carbide
• Characteristics: Tools have high toughness,
hot hardness, good thermal-shock resistance
• Due to chemical affinity to iron at elevated
temperature, SiN-based tools are not suitable
for machining steels
Manufacturing Process and Product
Development
 7. Diamond
• Diamond: hardest of all known tool materials
• Characteristics: low friction, high wear
resistance, ability to maintain a sharp cutting
edge, result in good surface finish and high
dimensional accuracy.
• Applications: best used with soft nonferrous
alloys
• Also used with abrasive nonmetallic and
metallic materials
• Weakness: brittle
80
Manufacturing Process and Product
Development
 8. Whisker-reinforced Materials and
Nanomaterials
• Reinforced materials and nanomaterials
improve tool performance, increase wear
resistance, and enhance properties:
• Characteristics: High fracture toughness,
Resistance to thermal shock, Cutting-edge
strength, Creep resistance, Hot hardness

Manufacturing Process and Product 81

Development
• Whiskers: used for reinforcing fibers in
composite tools e.g. Si-carbide whiskers: 5-100
цm long, diameter: 0.1-1 ц m
• Nanomaterials: also becoming important in
tools e.g. carbides, ceramics; applied as thin
coating
• Increase tool life without coolant (i.e. dry
machining)

Manufacturing Process and Product 82

Development
 CUTTING TOOL CLASIFICATION

1. Single-Point Tools
• One dominant cutting edge
• Point is usually rounded to form a nose radius
• Turning uses single point tools

2. Multiple Cutting Edge Tools

• More than one cutting edge
• Motion relative to work achieved by rotating
• Drilling and milling use rotating multiple cutting edge
tools
 CUTTING TOOL
Two basic types :
•Single point tool – turning, boring, shaping, planing
•Multiple cutting edge tool – drilling, milling, broaching, sawing

(a) A single‑point tool showing rake face, flank, and tool point
(b) a helical milling cutter, representative of tools with multiple cutting edges.
 CUTTING CONDITION IN MACHINING
• Three dimensions of a machining process:
– Cutting speed v – primary motion
– Feed f – secondary motion
– Depth of cut d – penetration of tool below original work
surface
• For certain operations, material removal rate can be computed as
MRR = v f d
where v = cuttingMRR (mm3/s) = v(mm/s) x f(mm) x
d(mm).
speed; f = feed; d = depth of cut
 DEFINITION OF TERMS
Speed (V)
-Relates velocity of the cutting tool to the work piece

Feed (f)
-Amount of material removed per revolution or per pass of the
tool over the work piece. linear translation of tool with respect
to the work piece.

Depth of Cut (d)

-Distance the tool has plunged into the surface.

Material Removal Rate (MRR)

-Mass of material removed per unit machining time
CUTTING CONDITION FOR TURNING

Speed, feed, and depth of cut in turning.

 CUTTING MODEL
Orthogonal Machining Oblique Machining

Cutting edge is perpendicular Cutting edge is oblique to the

to the direction of cutting speed direction of cutting speed
 ORTHOGONAL CUTTING MODEL
• Simplified 2-D model of machining that describes the mechanics of machining fairly
accurately.
• uses wedge-shaped tool, cutting edge normal to direction of cutting speed. Chip is
formed by shear deformation along shear plane, oriented at angle  with surface of
work.

Orthogonal cutting: (a) as a three‑dimensional process (b) two dimensions side view
 Chip Thickness Ratio

to
r 
tc

where r = chip thickness ratio; to = thickness of the chip prior to

chip formation; and tc = chip thickness after separation

• Chip thickness after cut always greater than before, so

chip ratio always less than 1.0.

• Orthogonal cut has width dimension, w.

Manufacturing Process and Product 91
Development
 Determining Shear Plane Angle
• Geometry cutting model allows to establish relationship between
the chip thickness, rake angle, and shear plane angle.
• ls = length of the shear plane, therefore to = ls sin  and tc = ls cos (
– α).

ls sin  sin 
r 
ls  cos(   ) cos(   )
• This can be arranged to determine the shear plane angle  as follow:

r cos 
tan  
1  r sin 
where r = chip ratio, and  = rake angle
 Shear Strain in Chip Formation

Figure show shear strain during chip formation: (a) chip formation depicted
as a series of parallel plates sliding relative to each other, (b) one of the plates
isolated to show shear strain, and (c) shear strain triangle used to derive strain
equation.
 Shear Strain
•Shear strain in machining can be computed from the following equation,
based on the preceding parallel plate model:

 = tan( - )AC
+ cot AD  DC
  
BD BD
Where  = shear strain,  = shear plane angle, and  = rake angle of cutting tool
 Examples
In machining operation that approximates orthogonal cutting, the cutting tool has a rake
angle = 10°. The chip thickness before the cut t o = 0.5 mm and the chip thickness after the
cut tc = 1.125 mm. Calculate the shear plane angle and the shear strain in the operation.

to
The chip thickness ratio, r
tc
r= 0.5
1.125
= 0.444

The shear plane angle r cos 

tan  
1  r sin 

tan  = 0.444 (cos 10)

1 – 0.444 (sin 10)
 = 25.4 °

Shear strain  = tan( - ) + cot 

= tan (25.4 - 10) + cot 25.4
= 0.275 + 2.111
= 2.386
 Chip Formation

Figure show view of chip formation, showing shear zone rather than shear
plane. Also shown is the secondary shear zone resulting from tool‑chip
friction.
 Chip Formation

Four Basic Types of Chip in Machining :

• Discontinuous chip
• Continuous chip
• Continuous chip with Built-up Edge (BUE)
• Serrated chip
Discontinuous Chip
• Brittle work materials
• Low cutting speeds
• Large feed and depth of
cut
• High tool‑chip friction
 Continuous Chip

• Ductile work materials

• High cutting speeds
• Small feeds and depths
• Sharp cutting edge
• Low tool‑chip friction
 Continuous with BUE

• Ductile materials
• Low‑to‑medium cutting
speeds
• Tool-chip friction causes
Tool
portions of chip to adhere
to rake face
• BUE forms, then breaks off,
Build up edge cyclically.
Serrated Chip

• Cyclical chip forms with

alternating high shear
strain then low shear
strain
• Associated with difficult-
to-machine metals at high
cutting speeds
 Forces Acting on Chip
• Friction force F and Normal force to friction N
• Shear force Fs and Normal force to shear Fn

Figure shows forces in metal cutting: (a) forces acting on the chip in
orthogonal cutting
 Cutting Force and Thrust Force
• F, N, Fs, and Fn cannot be directly measured
• Forces acting on the tool that can be measured:
– Cutting force Fc and Thrust force Ft

Figure shows forces in metal

cutting: forces acting on the
tool that can be measured
 Power and Energy Relationships
• A machining operation requires power.

• The power to perform machining can be computed

from:
Pc = Fc v

where Pc = cutting power; Fc = cutting force (N); and

v = cutting speed (m/s)
 Examples
Continuing from the previous examples, determine cutting power and specific energy to
perform the machining process if the cutting speed = 100 m/min. Summarizing the data
and results from previous examples, to = 0.5 mm, w = 3.0 mm, Fc = 1557 N.

Power in the operation, Pc = F c v

= 1557 N x 100 m/min
= 155,700 N-m/min
= 155,700 J/min
= 2595 J/s
= 2595 W
Specific energy, Fc
U
to w
= 1557
(3)(0.5)
= 1038 N/mm2
 Non-traditional Machining Processes
• Machining processes can be broadly divided into
two groups:
a) Conventional machining processes
b) Non-Traditional Manufacturing Processes or non-
conventional Manufacturing processes
• Conventional Machining Processes mostly
remove material in the form of chips by applying
forces on the work material with a cutting tool
while NTM process uses other mechanism to
remove unwanted material from the W/P.
 Non-traditional Machining Processes
The major characteristics of Non-conventional machining:
• 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.
 Classification of NTM processes
Classification of NTM processes is carried out depending on the nature of
energy used for material removal.
1. Mechanical Processes
• Abrasive Jet Machining (AJM)
• Ultrasonic Machining (USM)
• Water Jet Machining (WJM)
• Abrasive Water Jet Machining (AWJM)
2. Electrochemical Processes
• Electrochemical Machining (ECM)
• Electro Chemical Grinding (ECG)
• Electro Jet Drilling (EJD)
3. Electro-Thermal Processes
• Electro-discharge machining (EDM)
• Laser Jet Machining (LJM)
• Electron Beam Machining (EBM)
4. Chemical Processes
• Chemical Milling (CHM)
• Photochemical Milling (PCM)
 Mechanical Energy (NTM) Processes
• In these processes, unwanted material in the
work piece is removed by mechanical erosion.
• The mechanical erosion can be facilitated by
using any medium. For example,
• In abrasive jet machining high velocity
abrasive jet is used for eroding material from
the work piece.
• In water jet machining high velocity water jet
is used for cutting the workpiece material.
Manufacturing Process and Product 109
Development
Example water jet

Manufacturing Process and Product 110

Development
 Electrical Energy NTM Processes
• Here, electric spark discharge is used to cut and
machine the work piece.
• In electrical energy based processes thousands of
sparks are produced every second.
• These sparks increase the temperature on the work
piece, melt the unwanted portions and vaporize
those portions.
• A dielectric fluid is used for cleaning the work piece
and facilitating a smooth spark discharge.
•
Manufacturing Process and Product 111
Development
Electro discharge machining
process

Manufacturing Process and Product 112

Development
• A metal wire electrode with de ionized water
is used to machine metal by the heat
produced from electric sparks

Manufacturing Process and Product 113

Development
 Electrochemical Energy NTM Processes

• In these processes, unwanted portions of the

work piece are removed by electrochemical
effect.
• The work piece (in contact with an
electrolyte) is machined by ion dissolution

Manufacturing Process and Product 114

Development
Manufacturing Process and Product 115
Development
 Chemical Energy NTM Processes
• Here, chemical energy is used to remove
material from the work piece.
• Material is removed by controlled etching of
the work piece in the presence of a chemical
reagent known as etchant.
• Special coating called maskant is needed
to protect area of the metal that is not
machined

Manufacturing Process and Product 116

Development
Manufacturing Process and Product 117
Development
 Needs for Non Traditional Machining

• Extremely hard and brittle materials or Difficult to

machine materials are difficult to machine by
traditional machining processes.
•When the shape of the part is too complex.
• Intricate shaped blind hole – e.g. square hole of 15
mmx15 mm with a depth of 30 mm
• Deep hole with small hole diameter – e.g. φ 1.5 mm
hole with l/d = 20
• Machining of composites.