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21ME751 NTM Introduction

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.

Characteristics of Conventional Processes


Conventional machining processes mostly remove material in form of chips by
applying forces on work material with a cutting tool which is harder than the work material.
Such forces induce plastic deformation within the work piece leading to shear deformation
along the shear plane.

Major characteristics of conventional machining are:

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21ME751 NTM Introduction

 Generally chips are macroscopic and are formed by shear deformation


 Material removal takes place due to application of cutting forces – energy domain can
be classified as mechanical
 Cutting tool must be harder than work piece at room temperature as well as under
machining conditions
 There is a direct physical contact between tool and work
 Material removal rate of the traditional processes is limited by the mechanical
properties of the work material.

Characteristics of Non-Conventional Processes


Non Traditional Machining (NTM) Processes are characterized as follows:
 Material removal may occur with chip formation or even no chip formation may take
place. For example in AJM, chips are of microscopic size and in case of
Electrochemical machining material removal occurs due to electrochemical dissolution
at atomic level
 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.

Need for development of Non-Conventional Processes


The strength of steel alloys has increased five folds due to continuous R and D effort.
In aero-space requirement of High strength at elevated temperature with light weight led to
development and use of hard titanium alloys, nimonic alloys, and other HSTR alloys. The
ultimate tensile strength has been improved by as much as 20 times. Development of cutting
tools which has hardness of 80 to 85 HRC which cannot be machined economically in
conventional methods led to development of non –traditional machining methods.
1. Technologically advanced industries like aerospace, nuclear power, wafer fabrication,
automobiles has ever increasing use of High –strength temperature resistant (HSTR)
alloys (having high strength to weight ratio) and other difficult to machine materials
like titanium, SST,nimonics, ceramics and semiconductors. It is no longer possible to
use conventional process to machine these alloys.

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21ME751 NTM Introduction

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

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21ME751 NTM Introduction

Non-traditional processes requires


Use relative simple and inexpensive
expensive tools and equipment as well as
5 machinery and readily available cutting
skilled labour, which increase the
tools
production cost significantly
6 Capital cost and maintenance cost is Low Capital cost and maintenance cost is High
Traditional processes are well established Mechanics of Material removal of Some
7
and physics of process is well understood of NTM process are still under research
Most NTM uses energy in direct form.
Conventional process mostly uses Eg: laser, Electron beam in its direct
8
mechanical energy forms are used in LBM and EBM
respectively.
Surface finish and tolerances are High surface finish(up to 0.1 micron) and
9
limited by machining inaccuracies tolerances (25 Microns) can be achieved
10 High metal removal rate. Low material removal rate.

Classification of Non Traditional processes:

Classification of Advanced Machining Techniques

Mechanical Electro Chemical Chemical Electro Thermal


Processes Process Process Process

AJM ECM EDM


USM ECG CHM LJM
WJM EJD PCM EBM
AWJM PAM
AFM
MAF

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

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21ME751 NTM Introduction

6. AFM - Abrasive Flow Machining


7. ECM - Electro Chemical Machining
8. ECG - Electro Chemical Grinding
9. EJD - Electro Jet Drilling
10. EDM - Electro Discharge Machining
11. LJM - Laser Jet Machining
12. EBM - Electron beam Machining
13. PAM - Plasma Arc Machining
14. CHM - Chemical Milling
15. PCM - Photo Chemical Milling

History of Non Traditional Processes:


Although, the non-conventional machining processes have created a revolution in the
field of machining technology by the development of idea of various processes were initiated
as early as in nineteen- twenties in USSR.
 1920 - The initiation was first made by Gussev towards the end of 1920 in USSR. He
suggested a method of machining by combination of Chemical and mechanical means.
 1941 - Burgess, American Scientist had demonstrated the possibility of ECM process
by drawing a sharp contrast between the mechanical and electrolyte methods in metal
removal.
 1942 - The idea of Ultrasonic machining was invented by Balamuth. He invented at the
time of investigation of dispersion of solids in Liquids with the help of a vibrating
magneto-strictive nickel tube. However, the origination of the process was made by
Rosenberg
 1943 - DM was developed by B R Lazarenko and N I Lazarenko in USSR. They first
developed the idea of spark erosion machining. In the early nineteen-sixties, the idea of
Ultrasonic machining began to develop in USSR and basis of this development was laid
on extensive investigation that took place in the mechanism of ultrasonic machining
and in the design of Magneto-strictive transducers, converters and wave guides.
 1950 - The basis of laser machining was established by the process which was
developed by Basov, Prokhorov and Fabrikanth in USSR in 1950. 1950 Electro
chemical Grinding has practically been developed in about 1950.
 1960 - The concept of whirling jet machining was innovated.
Many of these new techniques of machining have been developed in last few
decades to meet the challenges put forwarded by rapid development of hard to machine and
high strength temperature resistant (HSTR) alloys. It is anticipated that in near future, these

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21ME751 NTM Introduction

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

Physical Parameter of the Process:


The physical parameters of the different NTM are given in the Table 1.0 which indicates
that PAM and ECM require high power for fast machining. EBM and LBM require high
voltages and require careful handling of equipment. EDM and USM require medium power.
EBM can be used in vacuum and PAM uses oxygen and hydrogen gas.

Parameters Non Traditional Machining Process


USM AJM CHM ECM EDM EBM LBM PAM
Potential 220 220 - 10 – 30 100 – 150,000 4500 100
(Volts) 300
Current 12 1 - 10000 50 0.001 2 500
(amps)
Power 2.4 0.22 - 100 2.7 0.15 - 50
(kW)
Gap 0.25 0.75 - 0.2 0.025 100 150 7.5
(mm)
Medium Abrasives Abrasives Liquid Electrolyte Di- Vacuum Air Argon
in water in gas Chemical Electric H2/O2
oil

Shapes Cutting Capability:


The different shapes can be machined by NTM. EBM and LBM are used for micro
drilling and cutting. USM and EDM are useful for cavity sinking and standard hole drilling.
ECM is useful for fine hole drilling and contour machining. PAM can be used for cutting and
AJM is useful for shallow pocketing.

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21ME751 NTM Introduction

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.

Process MRR - Tolerance - Surface Surface Corner


mm3/min µ Finish - µ Damage Radii - mm
Depth - µ
USM 300 7.5 0.2 – 0.5 25 0.025
AJM 0.8 50 0.5 – 1.2 2.5 0.100
ECM 1500 50 0.1 – 2.5 5.0 0.025
ChM 1.5 50 0.4 – 2.5 50 0.125
EDM 800 15 0.2 – 12.5 125 0.025
EBM 1.6 25 0.4 – 2.5 250 2.5
LBM 0.1 25 0.4 – 1.25 125 2.5
PAM 75000 125 Rough 500 --
Conventional 50000 50 0.4 – 5.0 25 0.050
Milling

Economics of the processes:


 High cost of equipment, which typically includes computer control
 May use hard tooling or soft tooling or both
 Low production rates
 Can be used with difficult – to – machine materials
 Highly repeatable
 Typically requires highly skilled operators

Sl. Capital Tooling & Power Tool


Process Efficiency
No. Investment Fixtures Requirement Consumption
1 USM B B B D C
2 AJM A B B D B
3 ECM E C C B A
4 ChM C B D C A
5 EDM C D B D D

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21ME751 NTM Introduction

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

Specific advantages, limitations and applications

Advantages:

 High Accuracy and Surface Finish


 No direct contact of tool and work piece, hence less or zero wear
 Better tool life
 Quieter operation
 Better tolerances can be achieved
 Can machine difficult to cut materials

Disadvantages:

 Higher Capital and maintenance cost


 Complex setup
 Requirement of skilled operator
 Requires expensive tools and equipment which increase the production cost
significantly
 Material removal rate is very low

Applications:

 Production of complex 3D shapes and cavities


 Machining of small cavities, slits and Production of non-circular, micro sized, large
aspect ratio, shall entry angle holes
 Technologically advanced industries like aerospace, nuclear power, automobiles use
HSTR alloys and other difficult to machine materials which are machined using NTM
 Production and processing of complicated shapes and innovative geometric designs
with desired tolerance and surface finish
 Intricate shaped blind hole – e.g. square hole of 15 mmx15 mm with a depth of 30 mm
with a tolerance of +/- 100 microns
 Low Stress Grinding – Electrochemical Grinding is preferred as compared to
Conventional grinding
 Machining of composites, ceramics, carbides, etc.

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