Non- traditional Manufacturing Processes (MF30604)

Lecture 1 : Introduction

Dr. Venkata Naga Vamsi Munagala

Assistant Professor, MED, IIT KGP.
13/01/2025 Email : vamsi@mech.iitkgp.ac.in 1
Outline

• Objective of the Course

• Syllabus

• Marking Scheme

• Reference Books

• Traditional Manufacturing Processes

• Need of Non-traditional Manufacturing Processes

• Classification of Non-traditional Manufacturing Processes

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 Objectives of the course
• Learn about the basic theory, working principle, and characteristics of nontraditional manufacturing processes.

• Identify critical process variables and their effect on process performance and product quality

• Develop mathematical model relating MRR with machining parameters

• Develop understanding to properly assess the capabilities, limitations, and potentials of nontraditional
manufacturing processes

• Decision for the right choice of machining process for a particular set of material and application.

• Further development of new techniques and improvement of existing methods.

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Syllabus
• Introduction to Modern Manufacturing Processes/ Methods
• Electro Chemical Machining (ECM)
• Electric Discharge Machining
• Laser Beam Machining (LBM)
• Ion-Beam Machining (IBM)
• Electron Beam Machining (EBM)
• Plasma Arc Machining (PAM)
• Abrasive Jet Machining (AJM)
• Water Jet Machining (WJM)
• Abrasive Water Jet Machining (AWJM)
• Ultrasonic Machining (USM)
• Coatings – Thin film and Thick film coatings

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Marking Scheme

1) Mid Semester Exam (30 %)

2) End Semester Exam (50 %)
3) Teacher Assessment (20 %) – Class Test

Class Test 1 - 13th February (Thursday) - 6.30 PM to 7.30 PM - CIC

Class Test 2 - 16th April (Wednesday) - 6.30 PM to 7.30 PM - CIC

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References Books
1. Nontraditional Manufacturing Processes, Gary F. Benedict, Marcel Dekker,Inc

2. Modern Machining Processes, P C Pandey & H S Shan, Tata McGraw-Hill

3. Nonconventional Machining, P K Mishra, Narosa Publishing House

4. Manufacturing Science, Amitabha Ghosh & A K Mallik, Affiliated East-West Press

5. Laser Material Processing, by W M Steen

6. Manufacturing Engineering and Technology by S. Kalpakjain and Steven R. Schmid.

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Introduction

• Basic classification of Manufacturing processes

➢ Primary Manufacturing Process – To impart basic shape and size. E.g. Casting, forming
etc.

➢ Secondary Manufacturing Process – To impart final shape and size with tight control on
shape and dimensions. E.g. Material removal processes i.e. Conventional and
Unconventional processes.

➢ Tertiary Manufacturing Process – Coatings, Final Surface Treatments

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Conventional Machining

• What is conventional machining ?

o Conventional method of machining is :

➢ Material will get removed in the form of chips (subtractive process) – Occurs
due to shear deformation i.e. due to the application of cutting forces.
➢ Sharp tool, in the shape of a wedge and is sufficiently harder than the work
piece (for penetration).
➢ Hold the tool and the work piece rigidly
➢ Embed the tool to a particular depth inside the work piece by penetration
➢ Provide a relative motion to the tool with respect to the work piece 8
Conventional machining – a pictorial view

Relative motion
sometimes referred
as cutting speed
Relative motion

Work piece

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Non-Traditional Machining Processes
• Material removal by chip formation or no chip formation. E.g. In AJM – Chip is
of microscopic (in size); ECM – Electrochemical dissolution.

• Physical tool may be present or absent (E.g. Laser beam machining; WJM –
Flexible tool i.e. water)

• Tool may not be harder than workpiece (if present). E.g. EDM (Electro-
discharge machining) – Cu or Graphite can be used as tool.

• Energy domain – Need not be mechanical. E.g. USM, WJM and AWJM –
Mechanical. ECM – Chemical Dissolution

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Why Non-traditional / non-conventional machining
In many cases
o Parts might be very hard and brittle and fracture prone – Conventional methods of machining
are not possible Or might be too expensive Or not very efficient.
a. Glass
b. Ceramics – metallic carbides, oxides, borides. Example : Tungsten Carbide
c. Difficult to machine high strength materials : Inconel, Ti-alloys

o The machining of complex geometrical features might not be possible by conventional means
E.g. : Sinking operations with non-circular sections

o The work material might be heat sensitive or too delicate (E.g. Composites). Non-conventional
machining with no contact or with minimal pressure.

o Accessibility might be a problem. Remote cutting and grooving.

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Why Non-traditional / non-conventional machining
In many cases of machining
o Surface texture may be a problem. E.g. There might be a requirement to get a surface free of
lay lines.
o The size range of geometrical features to be produced might not be possible by conventional
means.

Ex: Array of micro-holes Ex: Producing holes in stainless steel sheet

Material: Stainless steel In traditional machining: time/hole: 10 min
In modern machining: time/hole: 212 µs
Non-traditional Manufacturing Processes/ Methods
Modern Manufacturing processes employ
• New tools and New forms of energy

Developed as
• Efficient and economic alternatives to
conventional ones. Modern manufacturing process

• Often the first choice for certain technical

requirements. Traditional manufacturing process
Modern Manufacturing Processes differ to Traditional Mfg. Processes in following aspects 
❖ Unconventional Energy Sources : Thermal, Chemical, Kinetic Energy ----
❖ Processing usually not by direct MECHANICAL contact: Nontraditional mechanism of interaction between
the tool and the work piece: Evaporation, Ablation, Melt Ejection, Dissolution, Erosion----
❖ Nontraditional media to transfer energy from the tool to the work piece : Photons, E-beam, Dielectric media,
Electrolytic media, Water, Abrasive slurry.
❖No tool wear.
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Classification of Modern Manufacturing Processes/ Methods
Energy type Mechanics of material Energy source Process
removal
Mechanical Plastic deformation/ Mechanical Conventional machining processes
Erosion Mechanical/fluid • Abrasive jet machining (AJM)
motion • Ultrasonic machining (USM)
• Water jet machining (WJM)
• Abrasive water jet machining (AWJM)
Electrochemical Ion displacement (Electro- Electric current Electrochemical machining (ECM)
chemical Dissolution)
Electrochemical Plastic deformation and Electric current and Electrochemical grinding (ECG)
and Mechanical ion displacement mechanical motion
Chemical Corrosive reaction Corrosive agent Chemical machining (CHM)
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Classification of Modern Manufacturing Processes/ Methods
Energy type Mechanics of Energy source Process
Material Removal
Thermal Fusion and Electric sparks Electric discharge machining (EDM)
vaporization Powerful light radiation Laser beam machining (LBM)
High speed electrons Electron beam machining (EBM)
Ionized substance Plasma arc machining (PAM)
Kinetic energy Atom by atom Ionized substance Ion beam machining (IBM)
knocking

❖Hybrid modern manufacturing processes: Combination of different manufacturing techniques.

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Electron Beam Machining (EBM)
• Electron beam is used for machining.
• Electrons are generated by thermionic emission from hot tungsten cathode.
• Thermionic emission : emission of electrons from an electrode due to its temperature.
thermal energy provided to the charge carrier > work function of the material (binding potential).

HEL

LEL

LEL: Lower energy level/ Ground state, HEL: Higher energy level/ Excited state

: electron , : energy, Fig. Schematic of thermionic emission process

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Electron Beam Machining

Rotating shutter

Fig. Schematic of EBM

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Applications of EBM
EB Drilling: Suitable where large no. of hole are needed

and drilling holes with conventional process is difficult

due to material hardness or hole-geometry.

• Used in aerospace, instrumentation, food , chemical &

textile industries.

• Thousands of tiny holes in Turbine (steel) engine

combustor.
Insulation Sieves for food industry
• Cobalt alloy fiber spinning heads. 12 million holes per square meter
Centrifugal disc for glass
wool production 1805 holes/sec
• Filters used in food processing. 12000 to 45000 holes
https://www.pro-beam.com/en/contractmanufacturing/mikrobohren
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Plasma Arc Machining (PAM)

What is Plasma?
• This is the 4th state of matter –Ionized gas.

Plasma Arc
High temperature ionized gas produced by flowing gas
through the arc established between cathode and work
piece and/or Nozzle.

13/01/2025 Fig. Schematic of plasma arc machining

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Applications of Plasma Arc Machining

• Cutting a wide variety of conducting materials e.g. SS,

Aluminum, Cr-Ni alloys, Copper, titanium, etc..

• Mostly planer cutting

• Contour cutting of complex shape integrated with CNC

Fig. Cutting an alloy sheet
using plasma arc cutting
• Welding of materials such as Titanium, SS etc

• Plasma arc surfacing and spraying

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Non-traditional abrasive machining methods
Vibrates at Ultrasonic
Ultrasonic machining - USM Frequencies (19-25 kHz).
Rotary ultrasonic vibration machining - RUM Amplitude : 10 to 15 µm.
Percussion method of
material removal

Free impact of
abrasive
particles (150- Abrasive Jet machining – AJM
300 m/s)

Abrasive water jet machining - AWJM

Medium : Water ; Speeds : ~800 - 1000 m/s
Practically any material can be removed/machined. 21
Surface Coatings

• Surface properties of an engineering component often influences its performance

apart from material and manufacturing process.

• Coatings are generally used for

➢ Improved wear and corrosion resistance
➢ Reduce friction
➢ Improved oxidation or hot corrosion resistance
➢ Better fatigue resistance
➢ For rebuilding surfaces on worn tools , dies etc.
➢ Modify surface texture
➢ Reduce bacterial attack or growth (anti-bacterial coatings
➢ Aesthetic applications
Examples

Ni-SiC composite Carbon based

coatings composite coatings
Ceramic coatings on turbine
blades

Near Net Shape Production Parts Repair Technology

(www.globalspec.com) (www.cntrline.com)
Coatings classification
• Based on thickness
• Thin film coatings (Coating thickness < 10 microns)
• Thick coatings (Coating thickness > 10 microns)

• Thin film coating techniques

➢ PVD – physical Vapour Deposition
➢ CVD – Chemical Vapour Deposition
➢ ALD – Atomic Layer deposition

• Thick coatings deposition techniques

➢ Thermal spray coating - Plasma spray, HVOF, Cold Spray
➢ Electroplating
➢ Electroless plating
➢ Cladding
➢ Micro arc oxidation (MAO)
 Thank You!

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