NURAINI BINTI RUSLAN (S48572)
NUR AMIRAH NASUHA BINTI
MUHAMAD AKBAR (S48527)
AINUL INSYIRAH BINTI ROSLI
(S47830)
LECTURER : DR AIMA
BINTI RAMLI
Non-conventional machining processes which removes
material from an initial workpiece or part.
-Use various energy forms other than sharp cutting tool to
remove excess materials.
ADD A FOOTER 2
• Erosion of work material by a high velocity stream of abrasives
Mechanical or fluid (or both) is the typical form of mechanical action.
• Electrochemical energy to remove material which is the
Electrical reverse of electroplating.
• Chemical etchants selectively remove material from portions of
Chemical workpart, while other portions are protected by a mask.
• Thermal energy applied to small portion of work surface,
Thermal
ADD A FOOTER causing that portion to be removed by fusion or vaporization. 3
Principle : A high speed stream of abrasive
1. Abrasive Jet Machining particles mixed with high pressure air or gas
which is injected on the work piece through
nozzle
Note: Abrasives used - Aluminum Oxide, Silicon
Carbide, Glass Powder, Dolomite. Working
Medium - Dry air, Gases (Nitrogen or carbon
dioxide) 4
Advantages Disadvantages
- Low capital cost - Low metal removal
- Less vibration rate
- No heat generated in - Abrasive powder
the work piece cannot be reused
- Eco friendly - The machining
- Deburring, trimming and - Only one tool is accuracy is poor
deflashing, cleaning, and
polishing. required - Nozzle wear rate is
-Normally used as a finishing high
process rather than cutting
process.
-Work materials: thin flat
stock of hard, brittle
materials (e.g., glass, silicon,
mica, ceramics) 5
Principle :
• - The high velocity of water
jet comes out of the nozzle
and strikes the material.
• - Its kinetic energy is
converted into pressure
energy including high stress
in the work material.
6
Advantages Disadvantages
- No heat generated which - A limited number of
is especially useful for materials can be cut
cutting tool steel and other economically.
metals where excessive - Thick parts cannot be cut
heat may change the by this process
properties of the material. economically and
Mostly used to cut lower - Does not produce any accurately.
strength materials such as dust or particles.
wood, plastics and
aluminum. When abrasives
are added, (abrasive water
jet cutting) stronger
materials such as steel and
tool steel can be cut.
7
Principle:
• A high stream of abrasive
jet particles is mixed with
• pressurized water &
injected through the nozzle
on
• the work piece.
ADD A FOOTER 8
Advantages Disadvantages
- No secondary finishing - Cannot drill flat bottom
required - Cannot cut materials that
- Low cutting forces on degrades quickly with
work pieces moisture
- Limited tooling
requirements
- No heat affected zone
- Eliminates thermal
distortion
- No slag or cutting dross 9
Principle :
• The material is removed by micro-
chipping or erosion with abrasive
particles.
• The tool forces the abrasive grits, in
the gap between the tool and the
work piece, to impact normally and
• successively on the work surface,
thereby machining the
• work surface.
• The tool, made of softer material
than that of the work piece, is
oscillated at high frequency and low
amplitude. 10
Hard, brittle work materials such as ceramics, glass,
and carbides.
Also successful on certain metals, such as stainless
steel and titanium.
Shapes include non-round holes, holes along a
curved axis.
“Coining operations” - pattern on tool is imparted to
a flat work surface.
11
Material is removed by ion
displacement of work piece
material in contact with a
chemical solution.
ADD A FOOTER 12
Principle :
- Material removal by anodic
dissolution, using electrode (tool) in
close proximity to work but separated
by a rapidly flowing electrolyte.
-Based upon Faraday's law of
electrolysis.
-Faraday's law states that the mass of
a metal altered by the electrode is
proportional to the quantity of
electrical charges transferred to that
13
electrode.
-The removal of metal is controlled by the anodic dissolution in the
electrolyte.
-The workpiece acts as the anode
-The tool act as cathode.
-The electrodes should be placed closely with a gap of about 0.5 mm .
-The anodes and cathodes should be immersed into electrolyte.
14
ADD A FOOTER 15
Advantages Disadvantages
- Wear and tool tear is - Non conducting materials
negligible. cannot be machined.
- Machining is done at low - More space is required
voltage. - Power consumption is 100
- Intricate and complex times more than
shapes can be machined conventional machining.
easily. - Constant monitoring is
- No burrs are produced. required.
16
– To machine complicated profiles like jet engine
blades, turbine blades, turbine wheels
– To drill small deep holes in nozzles
– To machine cavities and holes of irregular shapes
– To machine blind holes and pockets in forging dies
– To machine hard and heat resistant materials
17
Materials that cannot be easily
shaped due to their extreme
hardness can be ground.
Example : Cemented carbides,
Hardened steel
• Principle
Work is machined by the
combined action of
electrochemical effect and
conventional grinding operation.
ADD A FOOTER 18
19
Advantages Disadvantages
- Tool wear is negligible. - Initial cost is high.
- Work is free of surface - Power consumption is
cracks and not high.
subjected to any - Non-conductive
structural changes. materials cannot be
- Burr and stress free machined.
– Best suited for high components are - Maintenance cost is
precision grinding of produced. high.
hard metals. - Good surface is - Preventive measures
obtained. are needed against
– Also suited to cut corrosion of electrolyte.
thin sections of hard
materials without any
damage.
20
Adaptation of ECM to
remove burrs or round
sharp corners on holes in
metal parts produced by
conventional through-hole
drilling.
21
ADD A FOOTER 22
Chemical Machining (CHM) –also called as Chemical Milling
23
1. Residual stress relieving: If the part to be machined has residual stresses
from the previous processing, these stresses first should be relieved in order
to prevent warping after chemical milling.
2. Preparing: The surfaces are degreased and cleaned thoroughly to ensure
both good adhesion of the masking material and the uniform material
removal.
3. Masking: Masking material is applied (coating or protecting areas not to be
etched).
4. Etching: The exposed surfaces are machined chemically with etchants.
5. Demasking: After machining, the parts should be washed thoroughly to
prevent further reactions with or exposure to any etchant residues. Then the
rest of the masking material is removed and the part is cleaned and 24
inspected.
Advantages Disadvantages
- Burr free component - MRR is low.
are produced. - Manufacturing cost
- Most difficult to is high.
machine - Large floor area is
components are needed.
machine.
-Used in - Not possible tp
manufacturing burr - High surface finish is produce sharp
free components. obtained. corners
-Applied where the - Stress free
depth of metal components are
removal is critical to produced.
few microns and the
tolerance are close 25
1. Laser–Beam Machining Principle:
(LBM)
• -It is an optical transducer that converts
• -The term laser stands for light electrical energy into a highly coherent
amplification stimulated emission of light beam
radiation. • -A laser light beam is monochromatic
(single wave length) and highly
collimated (the light rays in the beam are
almost perfectly parallel)
• -Using conventional optical lenses, a
laser can be focused onto a very small
spot with high power densities.
26
Advantages Disadvantages
- Very hard and - Uneconomic on high
abrasive material volumes compared
can be cut. to stamping.
- Sticky materials are - Limitations on
also can be cut by thickness due to
- LBM can make very
accurate holes as small this process. taper.
as 0.005 mm in refractory - It is a cost effective - High maintenance
metals ceramics, and cost.
composite material
and flexible process.
without warping the
work pieces. This
process is used widely
for drilling. 27
Applications: Principle:
• -One of several industrial processes • -It uses a high velocity stream od
that use electron beams
electrons focused on the
• -Heat treating, welding and free foam
fabrication.
workpiece to remove material by
melting and vaporization.
• -An electron beam gun generates
a continuous stream of electrons
that accelerated to approximately
75% of the speed of light focused
through an electromagnetic lens
on the work surface.
28
• -A plasma is a superheated, electrically
ionized gas.
• -PAC uses a plasma stream operating at
temperatures in the range 10,000oC to
14,000oC to cut metal by melting.
• ~operates by directing the high-velocity
plasma stream at the work
• ~thus melting it and blowing the molten
through the kerf
• -The arc is generated between an electrode
and the anode workpiece. • Operation :
• -The plasma flows through a water-cooled - manually by hand-held torch.
nozzle. • - by the torch under numerical
control
29
Advantages Disadvantages
- Can be used to nearly - The cut surface is
any electrically rough.
conductive metal. - Metallurgical damage
at the surface is the
most severe among
-Cutting of flat
the nontraditional
metal sheets and
metalworking
plates.
processes.
ADD A FOOTER 30
1. http://www.custompartnet.com/wu/machining
2.http://www.me.nchu.edu.tw/lab/CIM/www/courses/Manufacturing%20Processes/C
h26-NontraditionalMachining-Wiley.pdf
3. file:///C:/Users/User/Downloads/unit2ucm-150104224317-conversion-gate02.pdf
4. file:///C:/Users/User/Downloads/unit4-
chemicalandelectrochemicalenergybasedprocesses-180430090927.pdf
5. https://me-mechanicalengineering.com/electrochemical-deburring-and-grinding/
6. https://www.slideshare.net/NarayananSamy/unit-4-chemical-and-electrochemical-
energy-based-processes
7. https://slideplayer.com/slide/4900337/
31
BIG IMAGE
ADD A FOOTER
Lorem ipsum dolor sit amet, consectetuer adipiscing elit. 32
Maecenas porttitor congue massa
ANY QUESTIONS?
