Non traditional Machining

1.Defination and purpose of non traditional machining ?

Ans. Non-traditional machining processes, often referred to as Modern machining methods, include a
diverse range of techniques utilising electricity, heat energy, light energy, electrochemical processes,
chemical reactions, sound energy, and specialised mechanical forces to alter materials through removal,
deformation, property changes, or plating.
Purpose :
In the aerospace industry, the demand for high strength at elevated temperatures while maintaining
lightweight characteristics has led to developing and utilising hard titanium alloys, nimonic alloys, and
other high-strength temperature-resistant (HSTR) alloys. Cutting tools with hardness levels between 80
to 85 HRC, which were previously uneconomical to machines using traditional methods, prompted the
development of non-traditional machining approaches.
Many high-tech sectors are relying on HSTR alloys, titanium, stainless steel (SST), nimonic alloys,
ceramics, and semiconductors. These materials are no longer suitable for machining using conventional
methods. Producing and processing parts with complex shapes in HSTR and similarly challenging-to-
machine alloys is cumbersome, time-consuming, and cost-prohibitive using traditional machining
techniques. Innovative product designs and components made from exotic materials with fine finishes
also face economic challenges when approached through traditional machining practices.
2.Classification of non traditional processes with suitable example and appliocation ?
Ans. Mechanical Machining :-In mechanical machining, material removal is achieved through the action
of a high-velocity stream of abrasives or fluid, allowing for the precise removal of excess material.
Notable examples of single-action mechanical non-traditional machining processes include Ultrasonic
Machining (USM) and Waterjet Machining (WJM). WJM utilises a fluid machining medium, while USM
employs solid grains.
Example:-
(i)A cutting tool removes material from a workpiece in the form of chips. The workpiece is clamped in
the milling machine.
(ii)A classic machining technique that involves drilling holes in materials without compromising the
material.
(iii)A material removal process that uses a turning machine or lathe to create rotational parts by cutting
away unwanted material.
Application:-
(i)Machined components are used in many parts of a vehicle, such as engines, steering, and transmission
systems.
(ii)Machining technology is used to produce spare parts for military vehicles and planes. It's also used to
construct consumer drones.
(iii)Machined components are used in medical instruments, surgical tools, implants, and orthopedic
devices.
(iv)Machined components are used in connectors, heat sinks, and enclosures.
(v)Machined components are used in defense equipment, including weapons systems and vehicles.
Electrical Machining:- Non-traditional processes within electrical machining leverage electrical energy to
remove material, operating in contrast to electroplating. Electrochemical machining, for instance,
employs ion transfer within an electrolytic cell to dissolve the machining allowance electrochemically.
Example:-
(i)EM can be used to cut parts with complex machining features, such as sharp corners.
(ii)EM can be used to drill holes with tight tolerances.
(iii)EM can be used to engrave hard materials.
(iv)EM can be used to remove broken tools or fasteners from workpieces.
Application:-
(i) It is used to make holes with sizes that are less than 0.1 mm.
(ii) It is utilized in die sinking or die manufacturing, fixtures, and gauging.
(iii) It is used to make holes in air brakes or pneumatic brakes.
(iv) It is used in press tools and extrusion dies.
(v) It is utilized in die molds for plastics.
Thermal Machining:-Thermal machining utilises thermal energy to shave or cut the workpiece. Typically,
the thermal energy applied to a small section of the work surface is sufficient to cause the fusion or
vaporisation of the material to be removed. The generation of thermal energy requires a complete
conversion of electrical energy.
During machining, various secondary phenomena may occur, such as microcracking, the formation of
heat-affected zones, striations, and more. Heat sources can vary, including plasma in EDM and PBM,
photons in LBM, electrons in EBM, ions in IBM, and more.
Example:-
Plasma Generation: An electrical arc is struck between an electrode and the workpiece. This creates a
high-temperature plasma jet.
Cutting: The plasma jet, which reaches temperatures of up to 30,000°C (54,000°F), is directed at the
material. The intense heat melts the material locally, and a high-velocity gas flow blows the molten
material away, creating a clean cut.
Advantages: Plasma cutting can handle a variety of metals, including steel, aluminum, and brass. It is
especially effective for cutting thick materials quickly and with precision.
Application :-
Machining titanium: Thermal assisted machining (TAM) is a good choice for machining titanium alloys,
which are used in bio-implants and require high precision. TAM can increase material removal rate,
improve surface finish, and reduce cutting forces.
Drilling micro-holes: Thermal hybrid machining processes (THMPs) can be used to drill micro-holes in
quartz and glass. THMPs combine EDM with other processes to improve surface integrity and machining
characteristics.
Machining ceramics and diamonds: Thermal machining processes can cut or engrave very hard
materials like ceramics and diamonds.
Machining metal matrix composites: THMPs can be used to machine metal matrix composites.
Dressing grinding wheels: THMPs can be used to dress grinding wheels.
Chemical Machining: - Chemical machining selectively removes material from specific areas of a
workpiece using chemicals that can attack certain components of the material. A mask is employed to
protect other portions of the surface from the chemical action. These non-traditional processes are
primarily classified based on the type of energy utilised for material removal, with their mechanical
nature involving the erosion of work material through a high-velocity stream.
Example:-
Electrochemical machining (ECM):-
A non-traditional machining process that uses electrolysis to remove material from a workpiece
submerged in an electrolyte solution. ECM is often used in the aerospace and defense industries.
Photochemical machining:-
Also known as photo etching, chemical milling, or metal etching, this process uses precision
photolithography and chemistry to produce metal parts.
Chemical etching:-
An economical solution for low volume and prototype metal parts, chemical etching produces complex
parts with precision and fine detail.
Application :
(i)Precision machining of intricate metal parts.
(ii)Production of complex contours and shapes.
(iii)Engraving of designs with high precision.
(iv)Fine finishing and deburring of workpieces.
(v)Stress-free and crack-free component manufacturing through photochemical machining.
(vi)Ideal for micro-detailing on workpieces.
3. Working principle,advantage,limitation and application of Ultrasonic Machining (USM).
Ans. Introduction:-
Ultrasonic machining is a non-conventional machining process in which the abrasivesw particles hits on
the workpiecce & remove the material. This process use abrasive slurry that runs between the tool and
the workpiece. Due to this, the tool and the workpiece not touch with each other.
Working:-
In ultrasonic machining, electric current at high frequency (18kHZ to 40 kHZ) is used to generate
mechanical vibration of low amplitude. The mechanical vibration generated is used for machining the
surface of a part in the presence of abrasive grain particles in the form of slurry.The slurry flows across
the tool and workpiece.When the tool presses against the workpiece, the slurry containing abrasive
particle chips off the materials from the surface.
Application:-
Machining of Non-Conductive Ceramics: Ultrasonic Machining excels in machining non-conductive
ceramics, making it ideal for precision shaping and intricate designs in ceramic components.
Machining Fragile Materials: Materials with high scrap rates, particularly fragile substances, can be
effectively machined using Ultrasonic Machining, ensuring minimal material wastage and precise
outcomes.
Dies for Wire Drawing, Punching, and Blanking: The process is employed to fabricate dies used in wire
drawing, punching, and blanking operations, achieving accuracy and consistency in die production.
Advantage:-
Negligible Heat Generation: Due to the absence of heat generation, Ultrasonic Machining causes
minimal physical changes in the workpiece, ensuring the preservation of material properties and
dimensional stability.
Noiseless Operation: The operation of Ultrasonic Machining is noiseless, making it suitable for
applications where low noise levels are required.
User-Friendly Equipment: The equipment used in Ultrasonic Machining can be operated by both skilled
and unskilled operators, facilitating ease of use and broader applicability.
High Surface Finish and Accuracy: The process delivers excellent surface finish and high accuracy,
ensuring the production of precise and intricately shaped components.
Disadvantage:-
Low Material Removal Rate: Ultrasonic Machining exhibits a relatively low material removal rate
compared to some conventional machining methods, making it less suitable for high-volume material
removal applications.
High Energy Requirement: The process demands a comparatively higher energy input for cutting
operations, which can impact the overall efficiency and operating costs.
Difficulty in Machining Soft Materials: Soft materials pose challenges in Ultrasonic Machining due to
their susceptibility to deformation and damage under the intense impact of abrasive particles.
4.Working principle,advantage,limitation and application of LASER beam machining?
Ans. Introduction:-
Laser beam machining is a non-conventional machining method in which the operation is performed by
laser light. The laser light has maximum temperature strikes on the workpiece, due to high temp the
workpiece melts. The process uses thermal energy to remove material from a metallic surface.
Working:-
In this process, the Laser Beam is called monochromatic light. It is made to focus on the workpiece to be
machined by a lens to give extremely high energy density to melt and vaporize any material. The Laser
Crystal (Ruby) is in the form of a cylinder with flat reflecting ends which are placed in a flash lamp coil of
about 1000W. The Flash is simulated with the high-intensity white light from Xenon. The Crystal gets
excited and emits the laser beam which is focused on the workpiece by using the lens. The beam
produced is extremely narrow and can be focused on a pinpoint area with a power density of 1000
kW/cm2. as it produces high heat, the portion of the metal is melted.
Laser Beam Machining Application
 The laser beam machining process is used for making very small holes.
 Mass macro machining production.
 LBM is used in surgery.
 Selective heat treatment of materials.
 Complicated welding of non-conductive and refractory materials.
 Micro-drilling operation.
 Photography in medical science.
 Spectroscopic Science.
Laser Beam Machining Advantage
 Any material can be machined including non-metal.
 The production rate is high.
 There is no direct contact between the tool and the work.
 There is no tool wear.
 No mechanical force on the work.
 The heat-affected zone is very small.
Laser Beam Machining Disadvantage
 The overall efficiency of Laser machining is very low.
 It is limited to thin sheets.
 The life of the flash lamp is short.
 It is not possible to remove a large number of metals.
 The machined holes are not round and straight.
5.Working principle,advantage,limitation and application of Electrical Discharge Machining(EDM)?
Ans. Introduction:-
Electrical discharge machining, also known as spark erosion or metal sparking machining, is a non-
conventional machining technique that relies on erosion as its fundamental principle. In electrical
discharge machining, or EDM for short, an electrothermal non-traditional machining process is
employed, utilising electrical energy to create sparks for material erosion. EDM is particularly valuable
for machining challenging-to-work-with materials.
Working:-
Electrical discharge machining operates based on the concept of material removal through the
combination of electrical and thermal energy. Electrical energy is harnessed to generate an electric
spark, and heat is generated as a result of metal erosion. In electrical discharge machining, there is no
physical contact between the tool and the workpiece, making it a non-conventional machining process.
In this process, the tool electrode is connected to the negative (-) terminal of the DC power supply,
while the workpiece is connected to the positive (+) terminal of the DC power supply. Therefore, the
tool functions as the cathode, and the workpiece functions as the anode.
A spark gap of approximately 0.05 to 0.25 mm exists between the tool and the workpiece within the
flow of dielectric fluid. This dielectric fluid serves both as an insulator and a conductor. When the DC
power supply is activated, the tool electrode generates a spark, and this spark travels to the workpiece
through the dielectric fluid, enabling the machining process.
Application:-
(i)Helical profile milling.
(ii)Curved hole drilling.
(iii)Engraving operation on harder materials.
(iv)Drilling for micro holes in the nozzle.
(v)Used in thread cutting.
(vi)Used in wire cutting.
(vii)Rotary form cutting.
(viii)Cutting off operatio.
Advantages of Electrical Discharge Machining
(i)EDM can achieve tight tolerances and intricate shapes with exceptional precision.
(ii)It can be used on a wide range of electrically conductive materials, including metals and alloys.
(iii) EDM produces burr-free and exceptionally smooth surface finishes.
(iv)It is suitable for machining complex and intricate part geometries that are difficult to achieve with
traditional methods.
Disadvantages of Electrical Discharge Machining
(i)Excessive tool wear.
(ii)High power consumption.
(iii)The sharp corner cannot be reproduced.
(iv)High heat development causes a change in the metallurgical properties of materials.
(v)The workpiece must be an electrical conductor.

Wire EDM
In Wire EDM, a thin wire acts as the electrode and is continuously fed through the workpiece. The wire
is electrically charged and, as it traverses the workpiece, generates a series of spark discharges. This
process excels in precision and is particularly suited for creating intricate shapes and small parts.
Capabilities and Applications of Wire EDM Machines:
(i)Eases the production process.
(ii)Offers high-speed machining.
(iii)Requires minimal maintenance.
6.Working principle,advantage,limitation and application of Electrochemical Machining
processes(ECM)?
Ans. Introduction:-
Electrochemical machining is a process of removing metal by an electrochemical process. It is generally
used for mass production and is used for working extremely hard materials or materials that are difficult
to machine by conventional methods.
Working:-
Electrochemical Machining (ECM) involves a series of well-coordinated steps to achieve precise material
removal. The iron workpiece is securely positioned on the workpiece holding table, and the tool is
brought close to it. Both the cathode (tool) and anode (iron workpiece) are immersed in a solution of
NaCl (common salt). The power supply connects the cathode and anode to its negative and positive
terminals. The electrolyte from the reservoir tank is continuously pumped into the gap between the tool
and the workpiece with the help of a circulating pump. The tool feed system advances the tool towards
the workpiece.
During the process, specific anodic and cathodic reactions take place, leading to the controlled
dissolution of material at the atomic level. The ECM process ensures an excellent surface finish and
stress-free surface, making it highly advantageous. The uniform gap between the tool and workpiece
allows the cavity to accurately replicate the tool's shape. Sludge is separated from the electrolyte using a
centrifuge, and the electrolyte is filtered and recirculated for further machining. This systematic
approach in ECM delivers outstanding results and offers flexibility in tool geometry.
Electrochemical Machining Advantages

Advantages of Electrochemical Machining include: (i) ECM enables the effortless manufacturing of
complex and concave curvature parts using concave and convex tools, expanding the possibilities for
intricate component designs.
(ii)This machining process allows the production of more intricate geometries using a single connected
CNC machine, reducing the need for multiple setups and increasing efficiency.
(iii)ECM exhibits negligible tool wear, allowing the same tool to be used for producing an infinite number
of components, leading to cost savings and enhanced productivity.
(iv)With no direct contact between the tool and work material, ECM avoids forces and residual stresses,
ensuring precision and minimising the risk of damage to the workpiece.
Some disadvantages include:
Corrosion Risk: The use of saline (acidic) electrolyte in ECM can lead to corrosion of the tool, workpiece,
and equipment, necessitating careful material selection and maintenance.
High Energy Consumption: ECM has high specific energy consumption, which can result in increased
operational costs.
Limitation to Conductive Materials: ECM can only machine electrically conductive work materials,
restricting its application to non-conductive materials.
Electrochemical Machining Applications:
Die Sinking and Hole-Contouring: Electrochemical Machining is extensively used for precise die sinking
and hole-contouring operations in various industries.
Electrochemical Grinding: By combining ECM with grinding processes, using a negatively charged
abrasive grinding wheel, material removal and grinding operations can be efficiently performed, known
as electrochemical grinding.
Complex Cavity Cutting: ECM is employed to cut complex cavities, drill deeper, and create irregular-
shaped holes in intricate structures, such as jet engine turbine blades.
1.Additive Manufacturing: Concept,Advantages,Disadvantages,Applicaation.
Ans. Concept of Additive Manufacturing: Additive Manufacturing (AM), also known as 3D printing,
refers to a group of manufacturing techniques that build objects layer by layer from a digital model.
Unlike traditional subtractive manufacturing processes, which involve removing material from a solid
block, AM works by adding material only where needed, allowing for greater precision and design
flexibility. The process can use a variety of materials, including plastics, metals, ceramics, and even
biological materials.
Advantages:-
Design Flexibility:
AM allows for complex geometries and shapes that would be difficult or impossible to achieve with
traditional manufacturing methods. This includes intricate internal structures, complex curves, and
customized parts.
Customization:
AM can easily produce one-off parts or small batches tailored to specific requirements, making it ideal
for bespoke or customized products (e.g., medical implants, prosthetics, or personalized consumer
products).
Reduced Material Waste:
Since AM adds material layer by layer, it generates minimal waste compared to subtractive methods,
which involve cutting away material from a solid block. This is particularly advantageous for high-cost
materials.
Disadvantages:-
Material Limitations:
While AM can work with a variety of materials, there is still a limited range of materials available
compared to traditional manufacturing methods. The properties of AM materials might not always
match those of traditionally manufactured ones, especially for high-performance applications.
Speed for Large-Scale Production:
While AM is fast for prototyping and small runs, it can be slow for large-scale production, especially
when producing large or complex parts. The layer-by-layer process can take a significant amount of time
for larger objects.
Surface Finish and Post-Processing:
AM parts often require post-processing, such as sanding, polishing, or heat treatments, to improve
surface finish or mechanical properties. The surface quality directly from the printer may not always
meet the standards of traditional manufacturing.
Cost of Equipment:
Application:-
Aerospace:
AM is used to create lightweight, high-performance components with complex geometries, such as
engine parts, brackets, and custom tooling. NASA and companies like Boeing and GE Aviation use AM for
producing metal parts that are both strong and lightweight.
Medical and Healthcare:
Additive manufacturing plays a significant role in creating personalized medical devices, prosthetics, and
implants. For example, 3D-printed custom implants and surgical guides are used in orthopedics, dental
surgery, and reconstructive surgery.
Automotive:
AM is employed for prototyping vehicle parts, producing lightweight components, and manufacturing
small batches of customized or high-performance parts. Automotive manufacturers use AM to test new
designs quickly and refine their production processes.
2.Working principle of 3d printing ?
Ans. . 1.Designing the 3D Model
The process begins with creating a digital 3D model of the object to be printed. This model can be
designed using computer-aided design (CAD) software or obtained through 3D scanning. The digital
model is then converted into a format suitable for 3D printing, commonly the STL (stereolithography) or
OBJ file format.
2. Slicing the Model
Before printing, the 3D model is sliced into thin horizontal layers. This slicing is done using specialized
software called a slicer. The slicer software generates the instructions (G-code) that tell the printer how
to move and deposit material to build each layer of the object.
The number of layers depends on the resolution of the printer and the thickness of each layer. Finer
layers result in better detail but may take longer to print.
3. Material Deposition
The 3D printer uses a variety of materials, which can be in the form of filament (for FDM/FFF), liquid
resin (for SLA), powder (for SLS), or even metal powder (for metal 3D printing). The printer adds material
layer by layer, following the instructions provided by the slicing software.
Fused Deposition Modeling (FDM): This is the most common 3D printing technology, where
thermoplastic filament (such as PLA, ABS, or PETG) is heated and extruded through a nozzle. The
material is deposited layer by layer, and each layer fuses with the previous one as it cools and solidifies.
Stereolithography (SLA): This method uses a liquid resin that is selectively cured by a laser or light
source, layer by layer. The resin hardens where the light hits, gradually building up the object.
Selective Laser Sintering (SLS): In this method, powdered material (often plastic, metal, or ceramic) is
selectively fused using a laser. The laser sinters (fuses) the particles of the powder to form each layer,
with new layers of powder being spread over the surface after each pass.
Material Jetting (MJ): This involves spraying droplets of material (usually photopolymer) which are then
cured by UV light. This technique is capable of high-resolution prints and can use multiple materials
simultaneously.
4. Layer-by-Layer Construction
The printer builds the object by adding one layer of material at a time. Each layer is bonded to the
previous one, and once all the layers are deposited, the object is complete.
The printing process can take anywhere from a few minutes to several hours or days, depending on the
size and complexity of the object, as well as the type of material and print resolution.
5. Post-Processing
Once printing is complete, some objects require post-processing steps such as removal of support structures
(if used), sanding, polishing, curing (in the case of SLA prints), or painting.
For certain technologies like SLA or Material Jetting, the object may be submerged in a cleaning solution to
remove any uncured resin or excess material.