NTM - 21me751
NTM - 21me751
NTM - 21me751
MODULE 1
INTRODUCTION:
Introduction to Non-traditional machining, Need for Non-traditional machining process,
Comparison between traditional and non-traditional machining, general classification of Non-
traditional machining processes, classification based on nature of energy employed in
machining, selection of non-traditional machining processes, Specific advantages, limitations
and applications of non-traditional machining processes. 08 hours
INTRODUCTION TO NTM
Types of Manufacturing Processes:
Manufacturing processes can be broadly divided into two groups:
Primary manufacturing processes
Secondary manufacturing processes.
The Primary manufacturing process provides basic shape and size to the material as per
designer’s requirement. For example: Casting, forming, powder metallurgy processes provide
the basic shape and size.
The Secondary manufacturing processes provide the final shape and size with tighter
control on dimension, surface characteristics etc. Most of Material removal processes are
mainly the secondary manufacturing processes.
Material removal processes can be further divided into mainly two groups
Conventional Machining Processes
Non-Traditional(Non-Conventional Manufacturing Processes
Examples of conventional machining processes are turning, boring, milling, shaping,
Broaching, slotting, grinding, etc.
Examples of Non-conventional (unconventional) are Abrasive Jet Machining (AJM),
Ultrasonic Machining (USM), Water Jet and Abrasive Water Jet Machining (WJM and
AWJM), Electro-discharge Machining (EDM), Electro chemical machining.
2. Production and processing parts of complicated shapes (in HSTR and other hard to
machine alloys) is difficult, time consuming and uneconomical by conventional
methods of machining
3. Innovative geometric design of products and components made of new exotic materials
with desired tolerance, surface finish cannot be produced economically by conventional
machining.
4. The following examples are provided where NTM processes are preferred over the
conventional machining process:
♦ Intricate shaped blind hole – e.g. square hole of 15 mmx15 mm with a depth of 30
mm with a tolerance of +/- 100 microns
♦ Difficult to machine material – e.g. Inconel, Ti-alloys or carbides, Ceramics,
Composites, HSTR alloy satellites etc.
♦ Low Stress Grinding – Electrochemical Grinding is preferred as compared to
Conventional grinding
♦ Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20
♦ Machining of composites
Sl.
Conventional Process Non Conventional Process
No.
The cutting tool and work piece are always
There is no physical contact between the
in physical contact with relative motion with
1 tool and work piece; In some non-
each other, which results in friction and tool
traditional process tool wear exists.
wear.
NTM can machine difficult to cut and
Material removal rate is limited by hard to cut materials like titanium,
2
mechanical properties of work material. ceramics, nimonics, SST, composites,
semiconducting materials
Relative motion between the tool and work
is typically rotary or reciprocating. Thus the
Many NTM are capable of producing
3 shape of work is limited to circular or flat
complex 3D shapes and cavities
shapes. In spite of CNC systems, production
of 3D surfaces is still a difficult task.
Machining of small cavities, slits and
Machining of small cavities , slits ,
Production of non-circular, micro sized,
4 blind holes or through holes are
large aspect ratio, shall entry angle holes
difficult
are easy using NTM
ABREVIATIONS USED:
1. AJM - Abrasive Jet Machining
2. USM - Ultrasonic Machining
3. WJM - Water Jet Machining
4. AWJM - Abrasive Water Jet Machining
5. MAF - Magnetic Abrasive Finishing
new technologies will find an ever increasing application in all branches of mechanical
engineering industry.
Selection of Process:
The correct selection of the non-traditional machining methods must be based on the
following aspects:
1. Physical parameters of the process
2. Shape to be machined
3. Process capability
4. Economics of the processes
Process Capability:
The process capability of NTM is given in Table 2.0 EDM which achieves higher
accuracy has the lowest specific power requirement. ECM can machine faster and has a low
thermal surface damage depth. USM and AJM have very material removal rates combined with
high tool wear and are used non metal cutting. LBM and EBM are, due to their high penetration
depth can be used for micro drilling, sheet cutting and welding. CHM is used for manufacture
of PCM and other shallow components.
6 EBM D B B E A
7 LBM C B A E A
8 PAM A B A A A
9 Conventional B B B A B
A – Very Low Cost; B – Low Cost; C – Medium; D – High Cost; E – Very High Cost
Advantages:
Disadvantages:
Applications: