NON TRADITIONAL

MACHINING TECHNIQUES
INTRODUCTION TO NON TRADITIONAL
MACHINIING TECHNIQUES

By
Mr. Vaddi Thulasikanth
Assistant Professor
Manufacturing processes can be broadly divided into
two groups
1.Primary manufacturing processes
This provide basic shape and size to the material as per
designer‘s requirement.Eg.Casting, forming, powder
metallurgy

2.Secondary manufacturing processes.

This provide the final shape and size with tighter
control on dimension and surface characteristics etc.

Material removal processes are mainly the secondary

manufacturing processes
Material removal processes are divided into mainly two
groups.
1.Conventional Machining Processes
These processes mostly remove material in the form of chips
by applying forces on the work material with a wedge shaped
cutting tool that is harder than the work material
Eg. turning, boring, milling, shaping, broaching, slotting,
grinding etc. 
2.Non-Traditional Manufacturing Processes
It 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.
Eg. AJM, EDM,ECM, LBM, EBM etc.
 Needs for Non Traditional Machining
•Extremely hard and brittle materials are difficult to
machine by traditional machining processes.

• When the work piece is too flexible or slender to

support the cutting or grinding forces.

• When the shape of the part is too complex.

• Intricate shaped blind hole – e.g. square hole of 15 mm

x15 mm with a depth of 30 mm .

• Deep hole with small hole diameter – e.g. φ 1.5 mm

hole with l/d = 20 .
• Machining of composites.
 Sources or Energy of Metal Removal
•Mechanical - erosion of work material by a high Velocity
stream of abrasives or fluid (or both) is the typical form of
mechanical action
•Electrical - electrochemical energy to remove material
(reverse of electroplating)
•Thermal –thermal energy usually applied to small portion of
work surface, causing that portion to be removed by fusion
and/or vaporization
•Chemical –chemical etchants selectively remove material
from portions of work part, while other portions are protected
by a mask
 PROCESS SELECTION

1.Physical Parameters
2.Shapes to be machined
3.Process Capability or Machining Parameters
4.Economic Consideration
1.Physical Parameters
2. Shapes to be machine
Material applications of various machining
methods
Material applications of various machining methods
3. Machining characteristics/Process Capabilities

The various machining characteristics and process

capabilities that are governing Non-Traditional
Manufacturing Techniques are
(i)Metal removal rate
(ii) Tolerance maintained
(iii) Surface finish obtained
(iv) Depth of surface damage
(v) Power required for machining
Comparison of process capabilities of different
Non-Traditional Machining
 4.Economic Consideration
The economics of the various processes are analysed on the basis of following
factors
(i) Capital cost (ii) Tooling cost
(iii) Consumed power cost (iv) Metal removal rate efficiency
(v) Tool wear.
COMPARISION OF TRADITIONAL AND NON-TRADITIONAL
MACHINING TECHNIQUES
S.No TRADITIONAL MACHINING NON TRADITIONAL MACHINING
1 Macroscopic size chip formation Microscopic size chip formation
There may be a physical tool present There may not be a physical tool
2 eg.Cutting tool present except in ECM
Cuttting tool is harder than work piece
at room temperature and machining There may not be a physical tool
3 condition present except in ECM
Matertial removal takes place due to
cutting action. It falls in mechanical They fall in different energy domain.
4 energy domain. Mechanical, thermal and chemical
5 Direct contact of tool and work No direct contact of tool and work
6 Lower accuracty and surface fininsh Higher accuracty and surface fininsh
Tool life is less due to high surface
7 contact and wear Tool life is more.
Higher waste of material due to high Lower waste of material due to low
8 wear wear
9 Lower capital cost Higher capital cost
10 Easy set up of equipment Complex set up of equipment
Limitations
1.More Expensive
2.MRR is slow
3.AJM, PAM and EBM are not commercially economical process

Advantages
1.Increases Productivity
2.Reduces number of rejected components
3.Close tolerance is possible
4.Tool material need not be harder than work piece.
5.Machined surface do not have residual stresses.
6.Hard materials can be machined easily
REVIEW QUESTIONS

1.Broadly classify the Manufacturing processes.

2.Classify the Material removing processes.
3.List the need for Non-Traditional Machining techniques.
4. What are the basic factors upon which the unconventional
manufacturing processes are classified?
5.Why are the unconventional manufacturing processes not completely
taking over the conventional manufacturing processes ?
6.What are the machining characteristics governing Non-Traditional
Machining? Write the inference of comparison of processes with respect
to above.
7. Distinguish between conventional and unconventional manufacturing
processes
THANK YOU