Chapter 6: Introduction to NCMP

06 Hours

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Q.1.1 Need for NCMP

07 Marks

Ans. Need for NCMP

End of 2nd world war brought a new revolution in engineering industry

Many new materials were developed to fulfill the needs of aircraft industry, missile
technology, space research equipment & nuclear industry.

Materials like carbides, tungsten, ceramics, tantalum, beryllium, uranium, nitoalloy,

boron carbides, ruby, quartz, etc are extremely hard & brittle, hence unmachinable by
traditional machining processes.

When conventional methods are tried, it is difficult, time consuming & uneconomical to
machine such materials having low machinability.

Case1: a Contoured die block

Case2: A square hole machining

Case3: Small hole drilling

Fig. 1.1 Case studies for need of NCMP

Case 1: Producing complicated geometries in such harder materials becomes extremely

difficult wit usual methods.

A similar example is machining a complicated turbine blade made of super alloys.

Case 2: This is a case of a square blind hole in any material with higher surface finish of
about 10 micron.

This cant be obtained in foundry (range of surface finish is 1250-2500 microns) or in

forging (range of surface finish is 750-1250 microns).

First a through hole drilling & then plugging to required length increase the production
time unnecessarily.

Also the above discussed methods cant produce a square hole of desired accuracy.

Case 3: for this case preliminary processes like casting & forging are not possible, so
final operation is to be done by drilling.

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

As L/D ratio is more, there may be following difficulties:

a. Drill may brake;
b. Hole may be inclined

From above examples, it is clear that the conventional machining methods (e.g. turning,
milling, grinding, lapping) are to be improved by unconventional machining methods that
can
a. Sustain productivity with increasing strength of work material
b. Maintain productivity with desired shape, accuracy & surface integrity
requirement.

Q.1.2 Differentiate conventional & NCMP

07 Marks

Ans. Differentiation of conventional machining with NCMP

Conventional Machining Processes
It uses cutting tool of fixed geometry

NCMP
It uses some sort of energy along with a tool

Tool should be harder than work material

which doesnt have a fixed geometry

Hardness of tool is independent of work

material hardness
Hard wok materials are difficult or sometimes Almost any known hard work material can be
impossible to cut
Difficult to produce complex profiles
MRR is high
Material is removed in the form of chips

cut
Complex profiles can easily be obtained
MRR is comparatively low
Material is removed by vaporization, chemical

reaction, etc
Higher tool forces are required to cut the Tool force is independent of work material
harder work material
hardness
Very minute holes cant be produced
Very minute holes can easily be produced
e.g. turning, milling, drilling, grinding, etc
e.g. AJM, WJM, USM, EDM, CHM, ECM, etc
--------------------------------------------------------------------------------------------------------------------Q.1.3 Classify NCMPs. Why are these processes called as nonconventional?

07 Marks

Ans. Classification of NCMP

1) NCMP dont use conventional tools for material removal whereas they use some form of
energy like mechanical, chemical, thermal, electrochemical, etc, hence called NCMP.

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

Q.1.4 With neat sketch discuss the working principle of main components of USM

07 Marks

Ans. Working principle of main components of USM

Fig. 1.2 Schematic representation of USM

The term ultrasonic is used to describe a vibratory wave of a frequency above that of the
upper frequency limit of the human ear

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

Elements of USM process:

1. Work Material:

Earlier it was possible to machine only brittle materials, but now material can be removed
from ductile materials in the form of chips as a ductile fracture

So any material can be machined by USM, provided the material should not dissolved in
the slurry media or react with it

However, soft & ductile materials can be more economically machined by other methods

2. Tool cone (Horn) & tool tip:

Tool cone amplifies & focuses mechanical vibratory energy produced by transducer &
imparts this to work piece in such a way that energy utilization is maximum

Horn is simply velocity transformer with the exception that it is made slightly shorter
than the half wavelength

Horn mechanically modifies vibratory energy to give the required force amplitude ratio

Titanium is a good material for horn

Tool tip is attached to base of the cone by silver brazing, soft soldering or by means of
screws

Selection of material for tool is very vital because the cost of making tool & the time
required to change the tools are critical factors in the economics of USM

Tool tip has to withstand vibrations & it should not fail or wear out quickly

Most of the wear of the tool tip occurs at the end whereas wear at sides is ten times less

Construction of tungsten carbide tool is very difficult, also its cost is high

So tough, malleable materials such as alloy steel & stainless steel prove satisfactory

3. Abrasive slurry: Some of the abrasives used in USM are:

a) Aluminium oxide (alumina): Alumina wears fast & soon loses its cutting power
Alumina is best for cutting glass, germanium & ceramics
b) Boron carbide: Boron is the most expensive abrasive material but best suited for
cutting tungsten carbide, tool steels & precious stones
c) Silicon carbide: Silicon finds maximum applications
Boron silicon carbide is a new promising abrasive which has an abrasive powder 8-12
percent greater than that of boron carbide
d) Diamond dust: Diamond & rubies are nicely cut by using diamond powder which
ensures good accuracy, surface finish & cutting rates
Coarse grades are good for roughing whereas
Finer grades are used for finishing
Surface roughness of machined face is governed by the work material, roughness on
tool surface, vibration amplitude, fineness of abrasive & efficient slurry circulation
4. Liquid media:

Abrasives are suspended in liquid. So liquid should perform following functions:

a) Acts as an acoustic (related to sound) bond between the work piece & vibrating tool
b) Helps in efficient transfer of energy between work & tool

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

c) Acts as a coolant
d) Provides a medium to carry the abrasives to cutting zone
e) Helps to carry away the worn abrasives & swarf
Characteristics of good liquid media:
a) Density approximately equal to that of the abrasive
b) Good wetting properties to wet the tool, work & abrasives
c) High thermal conductivity for efficient removal of heat from cutting zone
d) Low viscosity to carry the abrasives down the sides of hole between the tool &
work
e) Noncorrosive properties to avoid corrosion of work & tool
Water is frequently used as a liquid media since it satisfies most of the above
mentioned requirements
Some inhibitor is added in water to increase its cutting ability
5. Ultrasonic machine: It consist of following subparts:
a) Tool feed mechanism: It performs following functions:

Bring the tool very slowly close to the work piece

Provide adequate cutting force & sustain this during cutting

Decrease the force at a specified depth

Overrun a small distance to ensure the required hole size at the exit

Return the tool to original position

b) Abrasive feed system: Abrasive slurry can be supplied by hand in a small machine,
but for machine of higher power, a centrifugal pump is used to supply the slurry
through a nozzle. Another effective method of supplying the slurry to the cutting zone
is via hallow tool or holes in the work piece
c) Concentrator/Resonator: Since the required level of vibrations at the end of tool is
more, the transducer vibrations need to be amplified & this is done by a concentrator
which is also called as a mechanical amplifier
--------------------------------------------------------------------------------------------------------------------Q.1.5 Write applications of USM

07 Marks

Ans. Applications of USM

1. USM finds its applications in processing materials that cant be machined by
conventional tools. Generally USM is used for machining of brittle materials
2. Manufacture of hard alloy wire drawing, punching & blanking dies, also making small
complicated dies & punches of steel
3. Machining semiconducting materials such as germanium & silicon
4. Machining ferrite & other special metallo-ceramic materials used in electrical
installations
5. Making instruments & optical parts of glass, quartz, fluoride & barium titanate
6. Making components of porcelain & special ceramics
7. Cutting accurate shallow holes of rectangular or other section in cemented & nitride steel
8. Cutting of industrial diamonds

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

9. Grinding glass, quartz & ceramics

10. Cutting holes with curved or spiral center line & cutting threads in glass & mineral or
metallo-ceramic
11. Machining of tungsten & other hard carbides & gem stones such as synthetic ruby for the
preparation of jewels for watch & timer movements
12. Small holes up to 0.050 mm in diameter can be cut
--------------------------------------------------------------------------------------------------------------------Q.1.6 Explain the construction & working of ECM equipment.

07 Marks

Ans. Construction & working of ECM equipment:

Fig.1.3. Schematic diagram of ECM equipment

ECM is controlled removal of metal by anodic dissolution in an electrolyte solution & is

based on Michael Faradays law of electrolysis.

In ECM, work material is made as anode by connecting to positive terminal whereas tool
is made as cathode by connecting to negative terminal of a 2-30 volt D.C. supply. The
unit is capable to deliver high current of around 10000 A.

These two electrodes are separated by an IEG (inter electrode gap) of about 0.1-0.5 mm
& immersed in an electrolyte solution (e.g. sodium chloride, sodium nitrate or a
combination of above salts, sodium sulphate, hydrochloric acid, sulphuric acid or sodium
hydroxide, etc).

Fig.1.4. Electro-chemical machining: (a) Initial condition, (b) Final condition

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

When an electrical potential of about 20 volt is applied between the electrodes, the ions
existing in the electrolyte migrate towards the oppositely charged electrodes.

Positively charged ions are attracted towards cathode whereas negatively charged ions are
attracted towards anode.

This initiates the flow of current in the electrolyte.

The rate at which the ins arrive at their respective electrodes determine the density of
current & varies in direct proportion with applied voltage, the number of ions present
(which is proportional to the concentration of electrolyte), the gap between the electrodes.

ECM equipment consists of a suitable fixture, electrolyte flow system, electrolyte

filtration unit, D.C. power source & feed control system.

Insulation is provided on the side of tool electrode to prevent undesired machining.

The tool in most of the cases is hallow to allow the electrolyte flow in the machining
zone & thus removes eroded particles.

The reaction products along with the electrolyte flow into the electrolyte tank & then the
reaction products are separated from the electrolyte with the help of micro filter or by a
centrifuge.

Then the filtered electrolyte is pumped with metered quantity into the system for reuse.

As material is removed from work surface, the IEG goes on increasing. So to maintain
the IEG constant tool should be feeded towards the work.

The work is mounted on a suitable fixture which is insulated from main body of machine.

A fan is provided to constantly remove the gases evolved during the reaction at cathode.

Power supply is the, most expensive single item of the installation.

An adequate protective circuit is necessary for the transformer, rectifier & the machine
itself against overload & short circuit conditions.

The short circuit condition can occur accidentally for following various reasons:
1. since the IEG is too low, so mishandling or wrong fitting of electrodes
2. accumulation of conductive debris in the IEG or
3. Malfunction of IEG control system.

--------------------------------------------------------------------------------------------------------------------Q.1.7 Write applications of ECM.

07 Marks
Ans. Applications of ECM:

Fragile parts, which are otherwise not easily machinable, can be shaped by ECM.

Facing and turning of complex 3 dimensional surfaces.

Die sinking, particularly deep narrow slots and holes.

Profiling and any odd shape contouring.

Multiple hole drilling.

Trepanning.

ECM is being widely used in industries related to space vehicles, aeronautics, nuclear
technology, automobiles, turbines, etc.

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

Thin wall mechanical slotting of collets, makes it difficult for manufacturing and costly,
can be replaced by EC-sinking where parts could be finished in one operation without
burrs, deformation and stress.

Grinding.

Broaching.

Honing.

Deburring.

Cutting off.

Surfacing.

Sawing.

--------------------------------------------------------------------------------------------------------------------Q.1.8 Explain the common processing steps in Chemical machining.

07 Marks

Ans. The common processing steps in Chemical milling or Chemical machining:

Clean the surface of work material with alkaline solution & then wash with fresh water.

The cleaning operation is carried out to remove the oil, grease, dust, rust or any substance
from the surface of material.

A good cleaning process produces a good adhesion of the masking material.

Chemical cleaning is necessary to ensure even & proper adhesion of maskant on the
entire work surface.

There are two cleaning methods; mechanical and chemical methods.

The most widely used cleaning process is chemical method due to less damages occurred
comparing to mechanical one.

Ultrasonic cleaning machine is applied with using special cleaning solution and heating is
beneficial during the cleaning process.

The type of cleaning (vapor decreasing, alkaline solution, etc) to be used depends upon
the kind of maskant, kind of work material & required machined depth.

However, cleaning of porous work material is rather difficult.

Apply a thin coating of maskant by spraying liquid maskant on work surface or deep the
work in a container containing liquid maskant and then dry it as shown in Fig.1.5(Step 1).

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

Fig.1.5. The processing steps in Chemical machining

The selected masking material should be readily strippable mask, which is chemically
impregnable and adherent enough to stand chemical abrasion during etching.

Then remove the maskant from the work surface where machining is to be done by using
any maskant removal method (cut & peel, screening or photo resist) as shown in Fig.1.5
(Step 2).

Then deep the work in an etchant bath & let it be there for the desired duration so as to
occur etching.

To avoid uneven removal of material from work surface, the fresh etchant is either
continuously sprayed or the work is submerged in etchant bath.

To increase the material removal rate, the etchant is agitated & if necessary heated
sometimes.

In case of debonding of maskant, stray etching would occur.

Material removal in CHM takes place both downward & lateral from the exposed surface.

Downward material removal is called as depth of cut or machined depth whereas lateral
material removal is called as undercut as shown in Fig. 1.5 (Step 3).

The extent of undercut depends upon the factors like depth of cut, the type & strength of
etchant & the work material.

The strength of contaminated etchant with the reaction products can be maintained by
proper filtration, adding unused fresh chemicals as well as by periodically replacing a
certain percentage of used etchant by a fresh one.

Then take out the work from the etchant bath & remove the maskant form work surface
as shown in Fig. 1.5 (Step 4).

Then wash the work thoroughly under fresh water.

--------------------------------------------------------------------------------------------------------------------Q.1.9 Explain the working principle of CHM

07 Marks

Ans. The working principle of Chemical machining:

In ancient days, the CHM was used by artists for engraving metals.

Fig.1.6. Working principle of Chemical machining

CHM is a process used to remove unwanted material by dissolution of work in an acidic

or alkaline etchant solution in a controlled manner.

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

In CHM, following processing steps are carried out:

1. Clean the surface of work material with alkaline solution & then wash with fresh
water to remove the oil, grease, dust, rust or any substance from the surface of
material.
2. Apply a thin coating of mask by spraying liquid mask on work surface or deep the
work in a container containing liquid mask and then dry.
3. Then remove the mask from the work surface where machining is to be done by using
any mask removal method (cut & peel, screening or photo resist).
4. Then deep the work in an etchant bath & let it be there for the desired duration so as
to occur etching. To avoid uneven removal of material from work surface, the fresh
etchant is either continuously sprayed or the work is submerged in etchant bath. To
increase the material removal rate, the etchant is agitated & if necessary heated
sometimes.
5. Material removal in CHM takes place both downward & lateral from the exposed
surface.
6. Downward material removal is called as depth of cut or machined depth whereas
lateral material removal is called as undercut as shown in Fig.1.6
7. The extent of undercut depends upon the factors like depth of cut, the type & strength
of etchant & the work material.

Fig.1.7. Definition of undercut & machined depth in chemical machining

8. The strength of contaminated etchant with the reaction products can be maintained by
proper filtration, adding unused fresh chemicals as well as by periodically replacing a
certain percentage of used etchant by a fresh one.
9. Then take out the work from the etchant bath & remove the mask form work surface
and finally wash the work thoroughly under fresh water.
--------------------------------------------------------------------------------------------------------------------Q.1.10 Explain mechanism of material removal in EDM

07 Marks

Ans. Mechanism of material removal in EDM

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

Fig.1.8. Schematic diagram of EDM with ionization

Fig.1.9. Tool & work surfaces under microscope

Through any machined surface may appear smooth but asperities & irregularities are
always present as shown in Fig.1.8.

As a result the local gap varies & at a given instant it is minimum at one point say at
point A.

When a suitable voltage is built up across tool & work, an electrostatic field of sufficient
strength is established, causing cold emission of electrons from cathode at point A.

These liberated electrons accelerate towards anode

After gaining a sufficient velocity, electrons collide with molecules of dielectric fluid
(kerosene), breaking them into electrons & metal positive ions.

Electrons so produced also accelerate & may ultimately dislodge (force out of position
occupied) the other electrons from dielectric fluid molecules.

Ultimately, a narrow column of ionized dielectric fluid molecules is established at point A

connecting the two electrodes (causing an avalanche of electros, since the conductivity of
ionized column is very large, which is normally seen as spark)

As a result of this spark, a compressive shock wave is generated & a very high
temperature (8000-120000C) is developed on the electrodes.

This high temperature causes melting & vaporization of the electrode materials & molten
metal is evacuated by a mechanical blast, resulting in small crater on both the electrodes
at point A.

As soon as this happens, the gap between the electrodes at point A increases & the next
location of shortest gap is somewhere else (say at point B).

Therefore, when the cycle is repeated, the next spark will occur at point B.

In this way, the sparks wander all over the electrodes surface & ultimately, the process
result in a uniform gap.

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

So, depending on the negative electrode (tool) shape, an impression is created on the
other electrode (work).

Comparatively less material is removed from cathode (tool) in comparison with

anode (work) due to following reasons:

1. The momentum with which + ions strike cathode surface is much less than the
momentum with which the electrons stream impinges on the anode surface though the
mass of individual electron is less than that of + ions.
2. The pyrolysis of dielectric (normally a hydrocarbon) creates a thin film of carbon on
cathode.
3. A compressive force is developed on the cathode surface by the spark which helps to
reduce tool wear
4. Most of EDM operations r conducted with electrodes (tool & work) immersed in liquid
dielectric (kerosene)
5. The mechanism of sparking is similar except that dielectric is contaminated with
conductive particles
-----------------------------------------------------------------------------------------------------------Q.1.11With the help of schematic diagram, explain EDM equipment
Or
Explain in detail the process principles for EDM

07 Marks

Ans. EDM equipment

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

Fig.1.10. Working principle of EDM with schematic diagram

Tool electrode:

Design the tool having mirror image as that of shape required in work as shown in Fig.
1.10.

So tool shape changes as per the shape required in work.

Copper, brass, tungsten, tungsten copper alloys, cast iron, steel, zinc based alloys,
aluminium, copper graphite, etc are the commonly used materials for tool electrode.

Tool material should be electrically conductive.

1) Work material:

Any complicated profile can be produced in any material irrespective of its hardness.

Work material should be electrically conductive.

2) Tool Holder & Feed Mechanism:

Tool holder is required for holding the tool firmly.

Tool should be brought fast/ gradually towards the work material before starting the
process

Also, spark gap should be maintained throughout the process.

As the metal gets removed from work surface, spark gap gets increased; hence tool must
be feeded towards the work to maintain spark gap.

Servo control mechanism takes care of all above mentioned functions.

3) Fixture:

Suitable fixture is required to firmly support work throughout the process.

4) Pump:

Fresh dielectric is to be pumped from reservoir to machining area.

5) Reservoir:

Reservoir is required to store the dielectric (kerosene).

6) D.C. Power supply:

A D.C. power supply of 50-300 V & 0.5400 A is required.

7) Dielectric fluid:

Hydrocarbons (petroleum) oils, kerosene, transformer oil, paraffin oil, lubricating oil,
mineral oil, etc can be used as dielectric fluids.

8) Spark gap:

For generation of spark, a constant gap is to be maintained between tool & work surface,
which is called as spark gap.

Spark gap range from 0.013 to 0.13 mm.

--------------------------------------------------------------------------------------------------------------------Q.1.12. Write applications of EDM

07 Marks

Ans. Applications of EDM:

1. EDM is used for manufacture of tools having complicated profiles
2. EDM is economically better for making stamping tools, wire drawing & extrusion dies,
forging dies, intricate mould cavities, etc

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.

3. EDM is extensively used for machining exotic materials used in aerospace industries,
refractory metals, hard carbides & hardenable steels.
4. Slender, fragile & delicate work material such as copper parts for fitting into vacuum
tubes & webs or fins can be machined.
5. Broken taps or drills can readily be removed from work material.
6. Drilling of micro-holes, thread cutting, helical profile milling, rotary forming, and curved
hole drilling.
7. EDM can be applied to all electrically conducting metals and alloys irrespective of their
melting points, hardness, toughness, or brittleness.
8. EDM can be economically employed for extremely hardened work piece.
9. Since there is no mechanical stress present (no physical contact), fragile and slender work
places can be machined without distortion.
10. Hard and corrosion resistant surfaces, essentially needed for die making, can be
developed by EDM.
11. Irregular, tapered, curved, as well as inclined holes can be produced by EDM.
12. Creating cooling channels in turbine blades made of hard alloys is a typical application of
EDM drilling.
13. Use of NC system enabled large numbers of holes to be accurately located.
14. Other applications: deep, small diameter holes using tungsten wire as tool, narrow slots,
cooling holes in super alloy turbine blades, and various intricate shapes.

College: MGM

Subject: NCMP

Faculty: SHATALWAR B.J.