the workpiece is fixed in the tank containing the dielectric fluid. There is almost negligible tool wear, so the cost of tool making is an only one-time investment for mass production. Non-traditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as outlined below. Types, Nomenclature [Diagrams & PDF]. Good for materials that cannot withstand high temperature. As particle impact the work surface, they cause small cracks, and the gas stream carries both the abrasive particles and the fractured (wear) particles away. The unconventional machining is also called as non-traditional machining. The gap between the tool and workpiece is important, thus the downward feed of the tool is controlled by the feed mechanism, which automatically maintains the constant gap. In this process the voltage between 50V and 980V and currents from 0.1A to 500A. The equipment has a • The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the WJM process. EBM can provide holes of any shape by combining beam deflection using electromagnetic coils with high accuracy. [1] The mechanical process is based on the machining done using the high velocity of particle to strike the work piece for the machining. <> In this, the metal removal rate is low and cannot be used for large machining cavities. Materials which cannot be machined by conventional methods are machined by LBM. Designing and making tool is difficult but its life is long recommended only for mass production. In fact, such processes don’t even utilize a so called cutting tool. WJM can be used to cut softer materials like plastic, rubber or wood. Machining is a part of the manufacture of many metal products, but it can also be used on materials such as wood, plastic, ceramic, and composites. 4 0 obj Due to the use of very high temperature at the machining zone, there are chances of deformation of the workpiece in case of these sections. Nontraditional machining can be thought of as operations that do not use shear as their primary source of energy. Bhuvenesh Rajamony. Non-conventional machining utilises other forms of energy. which were presented in this article in a detailed way. EDM process is not capable to produce sharp corners. EBM provides very high drilling rates when small holes with large aspect ratio are to be drilled. Therefore by using unconventional machining the time taken is less and the surface finish and accuracy are excellent. non traditional machining 1. The tool has the same shape as the cavity to be machined. For example, abrasive water jet operations use mechanical energy, but material is removed by erosion. An abrasive gun is used to supply an abrasive slurry, which is a mixture of abrasive grains and the water in between tool and workpiece interface under a pressure. Non-Traditional Machining method is an … The most common material removal processes, sometimes referred to as conventional or traditional machining, are those that mechanically cut away small chips of material using a sharp tool. When these machines are employed, they are many advantages over the traditional machining process. This whole setup is fitted inside an enclosure, which carries good quality reflecting surface inside. This process cannot be applied to the large-sized workpiece, as size for the workpiece is helpless by the size of setup. The high cost of the equipment and necessary regular maintenance applicable to any equipment using the vacuum system. In this process, the metal removing is the same as that of the EDM process but the method of generation of heat is different. • Ultrasonic Machining (USM) and Waterjet Machining (WJM) are typical examples of single action, mechanical non traditional machining processes. Electrically non-conducting materials cannot be processed by EDM. Modification of this process are used for turning, slotting, trepanning, and profiling operation in which the electrode becomes the cutting tool. The anode which is in the form of a beam attracts the electron beam and gradually gets accelerated. <> LBM uses the light energy of a laser beam to remove material by vaporization and ablation. It is mostly used to machining soft materials. Also, machining can be performed on any existing part, like forging or casting. but this is also called non traditional machining. PLAY. Cannot be used for high light reflecting materials. The electron beam machining arrangement is made as shown in the figure. The so-called non-conventional machining techniques can no longer be called 'non traditional', si nce they have wide range of applications. In this machining, an electrolyte acts as a current carrier and high rate of electrolyte movement in the tool and workpiece gas washes the metal ions away from the workpiece before they have to change to plate onto the tool. 2. Mechanical Machining I Jet Machining and Ultrasonic Machining (USM) are typical examples of single action, mechanical non traditional machining processes. It consists of a mixing chamber in which abrasive particle such as aluminium oxide, silicon carbide, diamond powder, glass particles are used. If you want, you can join our community, here is the link to our Facebook group. Maintain the high degree of dimensional accuracy, so it is recommended for tool and die making. So now, we hope that we have clear all your doubts about Unconventional Machining Process. You have entered an incorrect email address! The unconventional machining use for the machine the hard and brittle materials such as carbides, stainless steel, Hastelloy, nitralloy, waspalloy, and any other that cannot be machined by a conventional process using the conventional machines such as lathe , milling , shaper , planer etc. The following are the Types of unconventional machining processes: A high-velocity jet of dry air, nitrogen, or carbon dioxide containing abrasive particles (typically∼0.025mm) is aimed at the workpiece surface under controlled conditions. 14 Types of Washers & How They Use? endobj Among them conventional machining processes are age old and at the same time reliable; however, various abrasive cutting processes and so-called non-traditional machining (NTM) processes can also provide similar facility. Learn how your comment data is processed. Cite. Non-conventional machining processes may use chemical or thermal means of removing material. Due to above reason, EDM replacing conventional machining. A hole shape is affected by the depth of the workpiece. It consists of an electromechanical transducer which is connected to an AC supply. Machining of hard and brittle material is possible with good quality of surface finish and accuracy. Types of Unconventional Machining Process, Advantages of the unconventional machining process, Disadvantages of the unconventional machining process, Mechanical energy based unconventional machining process, Chemical energy based unconventional machining, Thermo-electric energy based unconventional machining, What is TIG & MIG Welding: Difference Between TIG and MIG welding, What is Welding? It is suitable for both conducting and non-conducting materials. The gas supply pressure is of the order of 850kPa and jet velocity can be as high as 300 m/s and is controlled by a valve. The most common electric fluid are minerals oil such as kerosene and distilled & deionised water is used in special applications. The velocity transformer which holds the tool firmly. The electrolyte is a highly conductive inorganic salt solution, such as sodium chloride mixed with water or sodium nitrate. Non-traditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be used for traditional manufacturing processes. Very good accuracy and surface finish can be obtained. The electrical discharge machining is also called as electro-discharge or spark erosion machining based on the erosion of metal by spark discharges. Non traditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as outlined below. In ultrasonic machining, ultrasonic waves are produced by means of magnetostrictive effects which is converted into mechanical vibration. Non-Traditional machining can also be called as _____ a) Contact Machining b) Non-contact machining c) Partial contact machining d) Half contact machining View Answer. Just after the cathode, there is a grid. All non-conducting materials cannot be machined. The laser is man-made ruby crystal, containing chromium or Aluminium oxide. A) Automobile B) Aerospace C) Medical D) All of the mentioned Answer: D. 4. The cathode is made of tungsten or tantalum. From the mixing chamber, the mixture is supplied to the nozzle which is the high strength of a material i.e., tungsten carbide. The tip of the tool vibrates at a frequency of 20kHz and low amplitude (0.0125mm – 0.075mm). A person who specializes in machining is called a machinist.A room, building, or company where machining is done is called a machine shop.Much of modern-day machining is carried out by computer numerical control (CNC), in which computers are … The slurry may have to be replaced frequently. Special processing is a new process developed in recent decades. With ever increasing demand for manufactured goods of hard alloys and metals, such as Inconel 718 or titanium, more interest has gravitated to non-conventional machining methods. The adequate form of the high value of MRR can be achieved as compared to other non-conventional machining processes. It is different from traditional processing methods that use tools, abrasives, etc. If you like our article then please share it with your friends. Chemical energy based unconventional machining, The electrochemical-based unconventional machining process, Thermo-electric energy based unconventional machining. Industry professionals and materials engineers will also find Nontraditional Machining Processes to be a source of ideas and processes for development and industrial application. Saif M. is a Mechanical Engineer by profession. such as turning, drilling, shaping and milling. Depth of Cut - measured along workpiece normal Step over Distance - (also called radial depth of cut)- Measured in tangent plane of workpiece and perpendicular to cutter travel or workpiece feed s is step over distance d is … Non-Traditional machining can also be called as? The unconventional machining it uses some form of energy for metal removal there is no direct contact between the tool and workpiece. endobj In NTM processes, neither shearing occurs nor chips form. There is no use of force, no direct contact between tool and workpiece. Redressing of the tool is required for deep holes. Notify me of follow-up comments by email. So the newer machining processes developed are often called"Non Traditional machining process " or "Unconventional machining process".In this employs some form of energy like mechanical chemical thermal electro chemical etc.for cutting the material. If you have still any doubts about the “Types of Unconventional Machining Process” you can contact us or ask in the comments. Initial cost and cost of the tool is very high, frequency tool replacement is required as a tool wear takes place in this operation. 3. [Short and Complete Guide], Heat Treatment Processes: Types, Methods, Procedure, Applications (PDF), What is Shaper Machine and The 4 Major Types of Shaper Machines, Cams and Followers: How they Work? In this article, we will discuss what is unconventional machining process and its 9 Types of unconventional machining processes. <> which is used to perform the work on the workpiece. A valuable amount of non-productive pump down period for attaining the desired vacuum. Keywords. Non traditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as outlined below. These materials are widely used in the field of the nuclear industry, space research, missile technology and in other industries which requires high strength to weight ratio, heat-resisting quality, hardness and toughness. The basic EDM system consists of the shaped tool (electrode) and the workpiece, connected to a DC supply and placed in a dielectric (electrically non-conducting) fluid. Heat affected zone in EBM is less due to shorter pulse. He is also an author and editor at theengineerspost.com. Nontraditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as outlined below. stream It is pumped at a high rate through the passage in the tool. When the potential difference between the tool and workpiece is high, spark discharges through the fluid, removing a very small amount of metal from the work surface. Ability to cut the heat sensitive materials. A laser is an optical transducer which converts the electrical energy into coherent light. (A) Contact Machining (B) Non-contact machining (C) Partial contact machining (D) Half contact machining Answer B. MCQ No - 4. Basic principle: Laser machining technology has the advantages of less waste o… Non-traditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to … This site uses Akismet to reduce spam. The tool and workpiece should be chemically still with the electrolyte solution. It has the ability to cut hard materials such as composites, ceramics, and glass. Non-Traditional machining can also be called as _____ A) Contact Machining B) Non-contact machining C) Partial contact machining D) Half contact machining Answer: B. Subscribe to our newsletter to get notified when we upload new posts. Air or gas may be nitrogen or carbon dioxide is used to mix with the abrasive particles. I The machining medium is solid grains suspended in an abrasive slurry in the former, while a uid is employed in the Jet machining process. %PDF-1.5 endobj %µµµµ Further since the machining unit (minimum controllable amount of material that can be removed) in EEM is 0.01 µm or less, it can be called atomic unit material processing. The spark gap normally varies from 0.005mm to 0.50mm. This process not suitable for mass production because of the high maintenance requirement. 90% of metal is removed by electro chemical action and 10% of metal is removed by the abrasive action of the grinding wheel. Metal is removed from the surface of the work piece by electro chemical action and also by abrasive action of a grinding wheel. 3. Non traditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as outlined below. He completed his engineering studies in 2014 and is currently working in a large firm as Mechanical Engineer.  Very hard fragile materials difficult to clamp for traditional machining  When the workpiece is too flexible or slender  When the shape of the part is too complex The application of heat is very focused in case of LBM as compared to EDM. Electro Chemical Grinding (ECG) Electro chemical grinding is also called electrolytic grinding. From the nozzle, the abrasive particles with velocity 150 to 300m/min are made impact the workpiece due to the high-velocity metal removed from the workpiece with no contact with the tool. Extremely hard and brittle materials can be easily machined. MRR achieved in EDM process is enough lower than the MRR in case of the conventional machining process, so it cannot be taken as an alternative to conventional machining processes at all. Non-traditional machining is also called advance manufacturing process. The beam is pulsed so that the released energy results in an impulse against the work surface that does melting and evaporation. ... includes torch cutting, electrical discharge machining or EDM, and high-energy beam machining. The unconventional machining is also called as non-traditional machining. How it works? <>/ExtGState<>/ProcSet[/PDF/Text/ImageB/ImageC/ImageI] >>/MediaBox[ 0 0 612 792] /Contents 4 0 R/Group<>/Tabs/S>> In this process, the coherent or consistent light beam is focused optically for a particular period of time. The tool is made up of brass, copper, bronze, or stainless steel. A DC power supply in the range of 5 – 25 V maintains densities, which for most of the application are 1.5 – 8A/mm² of the active machined surface. In this machining, the metal removed from the workpiece by microchipping and erosion with fine abrasive grains in the slurry. 1 0 obj A high negative bias is applied to this grid so that the electrons generated by this cathode do not diverge and approach the next element. The process is environmentally friendly as it is noiseless without any chemical reactions and heating. A machining process is called non-traditional if its material removal mechanism is basically different than those in the traditional processes, i.e. The EDM process can be used on any materials that are an electrical conductor. So, fragile and brittle materials can also be processed. Answer: b Explanation: Tool and work piece are at a distance apart in this type of machining. Several types of non-traditional machining processes have developed to better machining condition. The accurate feed rate of the tool is required. Water Jet Machining (WJM) also called water jet cutting, is a non-traditional machining process in which high-velocity jet of water is used to remove materials from the surface of the workpiece. to directly remove excess material using mechanical energy. EDM refers to a non-traditional machining method, which removes a workpiece with the use of thermal energy. • Very hard fragile materials difficult to clamp for traditional machining Fine holes can be drilled easily and accurately. No use of heat, so mechanical and thermal remaining stresses are absent in the workpiece. Unconventional or nontraditional machining processes are used when one or more of the following occur: ... Electrical-Discharge Machining (EDM) is also called. Special processing refers to those processing methods that are not in the traditional processing technology category. 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