NON TRADITIONAL MANUFACTURING PROCESSES

NEED:
1. HIGH STRENGTH MATERIALS
Development of high strength materials like high strength temperature
resistant alloys (HSTR) and Ti led to the development of nontraditional
manufacturing processes to machine these materials.

2. ACCURACY AND TOLERANCE:

They are mainly affected by the high temperature and residual
stress encountered. High temperature developed due to physical
contact between the tool and the workpiece in traditional processes
led to high heat as a result there may be a non-uniform contraction
or expansion in the part size. The residual stress developed may be
compressive or tensile. If it is compressive it is advantageous as it
will provide a better surface finish whereas if it is tensile in nature
it should be reduced. Thus w.r.t NTMP reduced residual stress
may be an advantage or a limitation.
3. REDUCED TOOL COST:
Tool cost reduces depending on the material

4. PRODUCTIVITY:
Production time = (loading + machining + unloading) time. In NTMP tool setup is
done only once and tool regrinding is totally eliminated hence time consumed is
less and so more productivity.
5. CHIP FORATION:
60% of material is wasted as chip in traditional process whereas less chip
formation is there in NTMP.
6. COMPLICATED JOBS:
Electrode materials like Cu, graphite used in NTMP are produced by
traditional manufacturing process which can be used for complicated jobs. Hence the
number of processes and tools are reduced.
7. HOLDING DIFFICULTY:
Due to reduced physical contact less forces are encountered so only less
difficulty in encountered in holding
8. MAINTANANCE:
No mechanical interaction between the components hence the wear and
tear is eliminated
9. COST:
Capital cost is high but w.r.t the number of components produced the cost
involved is justified.

10. COMPACT AND AUTOMATION

Number of mechanical parts is reduced and so it is compact. Also
automation is achieved with CNC.
 Classification:

1. Based on machining process

1) Mechanical
Abrasive jet machining (AJM)
Abrasive flow machining (AFM)
Ultrasonic machining(USM)
Water jet machining(WJM)
2) Chemical

3) Electrochemical
Electrochemical grinding(ECG)
Electrochemical discharge grinding(ECDG)
Electrochemical honing (ECH)

4) Electrothermal
Electro discharge machining (EDM)
Laser beam machining (LBM)
Electron beam machining (EBM)
Plasma arc machining (PAM)
Ion beam machining (IBM)

2. Based on forming process (HERF methods)

1) electrohydraulic forming
2) explosive forming
3) magnetic pulse

CLASSIFICATION BASED ON ENERGY SOURCE, TRANSFER

MEDIA, MECHANISM OF MATERIAL REMOVAL
Group Process Energy source Transfer Mechanism
media
Mechanical USM Electricity Abrasive Erosion,
slurry abrasion
WJM Hydraulic Water Erosion
AJM Hydraulic Abrasive Erosion,
slurry abrasion
Chemical CHM Chemical reaction Chemicals Reaction
ECM Electrical and Electrolyte Ion
Electro chemical reaction displacement
chemical
ECG Electrical ,chemical Electrolyte Ion
reaction + displacement +
mechanical abrasion
Thermal EDM Electricity Dielectric Erosion
fluid
LBM Electricity Light beam Radiation and
vaporization
EBM Electricity Electrons Vaporization
IBM Electricity Ionized gas Ionization
PAM Electricity Ionized gas Ionization

Factors governing the choice of NTMP

1. Type of material: material must be efficient and conductivity of material

determines the MRR.
2. Accuracy
3. surface finish
4. Cost effectiveness:coupled with accuracy and surface finish.
5. No of Components: determined by cost effectiveness
6. Frequency of design changes: depending on design the manufacturing process
changes and hence machine cost increases
7. Job complication: less number of variables controls the surface finish of the job.
8. Productivity
9. Noise level
10. Cleanliness

Ultrasonic machining process(USM)

Invented in 1950 by Henry Balsmouth and fully developed in 1975. suitable for brittle
materials. It is a safest process.. here erosion mechanism is used.

Principle:
High frequency electrical signals are applied to the transducer which converts it into
vibrations which is transferred to the tool holder which amplifies it and the tool attached
to the tool holder transfer the mechanical motion to the abrasive particles in the abrasive
slurry which results in impact force on the workpiece and the workpiece material gets
detached. Vibrations are created above 20 khz.

Set up:
1. power source:40 to 2400 W
2. transducer:
1) magnetostrictive transducer:
*Conversion efficiency is less (20-30 %)
*Electrical energy is converted into magnetic and then into another form of energy
*can be used above 900 W
*Materials: Nickel, Alfer
2) Piezoelectric:
*Conversion efficiency is more (96%)
*electrical energy converted into another form
*used with higher power machines but only upto 900 W
*materials: quartz, lead zirconate titanate
3. tool holder
*for holding tool and amplifying the vibrations
*amplification can be done by varying the cross section of input and output
*outer dimension is constant and inner dimension is varied else the cross section
is varied
Types:1)Non amplifying tool holder
2)Amplifying tool holder – exponential type, tapered type, stepped type
Design of tool holder:
*Frequency is high which is a cyclic load and so may result in fatigue which
necessitates the roper design of tool holder
*Materials: Titanium, monel, stainless steel
(best acoustic properties)
Ti- best material but high cost also fabrication and machining is difficult
Monel-next best material , best acoustic property than Ti, easily brazed, less cost
Stainless steel-for low power machines and poor elastic properties
*tool holder shouldn’t be permanently fastened to other components because
ultrasonic welding may occur between fastened components.so tool holder is fastened
with tool or amplifier using loose screws and copper wash to get cushioning and
damping effect and avoid ultrasonic welding.
4. tool:
• replica of tool is produced in the workpiece. So high surface finish of tool
equivalent to that of workpiece is necessary.
• Materilas : Ductile- Stainless steel, mild steel and brass

5. tool feed arrangement:

Types:1)Mechanical
2)Pneumatic

Other arrangements:
1) Counter weight with rope and pulley
2) Counter weight with lever and fulcrum
3) Electric solenoid control
4) Spring control
5) Hydraulic/pneumatic control
6) Control with stalled motor
6. abrasive slurry
* Abrassives are used with fluid medium
* Abrasives: boron carbide, silicon carbide, borosilicon carbide, alumina, lass dust,
diamond dust
* Fluid medium: water/kerosene
* fluid medium – 30-40% upto 60% but theoretically 50 %
* pumping system with nozzle arrangement is employed with some electrical
arrangement. Mixing chamber may be used in bigger machines for uniform mixing of
abrasives and fluid.
 * number of abrasives in the tool determines the MRR

• abrasive fluid should be of high wetting nature, non toxic, non corrosive (water
used only if corrosion resistant ) , act as coolant, should be thermally conductive.

Process Parameters:
1. Power: Achieved by combination of tool and tool holder at its natural frequency.
Maximum power is limited by natural frequency.
2. Amplitude:
As per Miller and Rosenberg’s statement the MRR increases with amplitude
as the force applied increases with amplitude
3. Frequency:
As frequency increases force applied on the particles increases hence MRR
increases
4. Grain size:
If gap between tool and workpiece s minimum the grainsize is more and
MRR is more but surface finish is less
5. Particle velocity:
Particle velocity and hence MRR increases with increase in amplitude and frequency.
6. Fluid medium viscosity:
As viscosity decreases the flow of abrasive particle between tool and workpiece is
poor and the new particles entering the region is less and so MRR increases
7. Abrasive slurry concentration:
Theoretically 50% but generally 30-40 upto 60% is used.
8. Static load or feed force:
It is the Force given by tool on workpiece. It Supports the action on the particle.
Force applied on the particle cannot increase beyond a point. Governed by
hydraulic/pneumatic/hand
Given to counteract the force of abrasive particles i.e. all the forces are applied to
workpiece and thus increasing the efficiency.
As static load increases the gap between tool and workpiece decreases and so
crushing occurs and MRR decreases.static load maintains the MRR obtained from
other parameters. When increased beyond appoint only it reduces the MRR.
9. tool work hardness ratio
10. surface area of tool