MEC466

NONTRADITIONAL AND
COMPUTER AIDED
MANUFACTURING

Syllabus

Unit 4
Introduction to Non-Traditional Machining : Classifications of
material removal
processes, Need for non-conventional or nontraditional processes,
Characteristics of non-traditional material removal (machining)
processes, Ultrasonic machining,
Chemical and Photo-chemical machining
Unit 5
Process Description, Modelling, Application and Product Quality
Related
Issues : Abrasive Jet Machining, Water Jet Machining, Abrasive Water Jet
Machining, Electro Discharge Machining, Electro-Chemical Machining
Unit 6
Advanced Topics : Laser Beam Machining, Electron Beam Machining,
Thermal
spraying processes, Electrochemical grinding
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Syllabus

Text Books:
1. Automation, Production system and computer integrated
manufacturing by Mikell P. Groover, Pearson, 2nd Edition,
2. Modern Machining Processes by Pandey and Shan, Mc graw Hill,
1st Edition, (1980)
References:
1. Non Conventional Machining by Mishra, P. K., Narosa, 1st
Edition, (2006)
2. CAD/CAM by Mikell P. Groover, Emory W. Zimmers, Pearson, 2nd
Edition, (1984)
3. Advanced Machining Processes by jain V.K., Allied Publishers,
2nd Edition, (2007)

Introduction to Non-Traditional
Machining

Machining
Machining involves the removal of some material from
the work piece (machining allowance) in order to
produce a specific geometry at a definite degree of
accuracy and surface quality.
It covers several processes, which we usually divide
into the following categories:
i. Cutting, generally involving single-point or multipoint
cutting tools, each with a clearly defined geometry.
ii. Abrasive processes, such as grinding.
iii.Nontraditional machining processes, utilizing
electrical, chemical, and optimal sources of energy.
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History of Machining
From the earliest of times methods of cutting materials have
been adopted using hand tools made from bone, stick, or stone

Later, hand tools made of elementary metals such as bronze

and iron were employed.
Up to the seventeenth century, tools continued to be either
hand operated or mechanically driven.
The introduction of water, steam, and, later, electricity as useful
sources of energy led to the production of power-driven machine
tools.
John Wilkinson in 1774 constructed a precision machine for
boring engine cylinders.
Twenty-three years later, Henry Maudslay devised a screwcutting engine lathe.

History of Machining

James Nasmyth invented the second basic machine tool for

shaping and planing; The familiar drilling machine is the
third category of machine tools.
The first universal milling machine, is constructed in 1862
by J. R. Brown.
In the late nineteenth century, the grinding machine was
introduced.
A notable development includes the turret lathe made in
the middle of the nineteenth century for the automatic
production of screws.

Need For NCM Methods

During machining by these conventional methods the

operator is given a drawing of the finished part.
He or she determines the machining strategy, sets up the
machine, and selects tooling, speeds, and feeds.
Under such circumstances, the product accuracy and
surface quality are not satisfactory.
In this regard, the nonconventional machining techniques
came into practice as a possible alternative concerning
machinability, shape complexity, surface integrity, and
miniaturization requirements.

Traditional Machining
Methods
Machining removes certain parts of the work pieces to change
them to final parts.
Traditional, also termed conventional, machining requires the
presence of a tool that is harder than the work piece to be
machined.
This tool should be penetrated in the work piece to a certain
depth. Moreover, a relative motion between the tool and work
piece is responsible for forming or generating the required
shape.
The absence of any of these elements in any machining
process such as the absence of tool-work piece contact or
relative motion, makes the process a nontraditional one.
Traditional machining can be classified according to the
machining action of cutting (C) and mechanical abrasion (MA).
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Material Removal Processes

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Machining by Cutting

During machining by cutting, the tool is penetrated in the

work material to the depth of the cut. A relative motion
determines the work piece geometry required.

The cutting action removes the machining allowance in the form of chips,
which are visible to the naked eye.

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Machining by Mechanical Abrasion

The term abrasion machining usually describes processes

whereby the machining allowance is removed by hard,
angular abrasive particles or grains (also called grits), which
may or may not be bonded to form a tool of definite
geometry.

The material is removed in the form of minute chips, which are

invisible in most cases
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Classification of Advanced Machining

Processes

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Mechanical machining

Ultrasonic machining (USM) and water jet machining (WJM)

are typical examples of mechanical, nontraditional
machining processes.

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Thermal machining

Thermal machining removes the machining allowance by

melting or vaporizing the work piece material.

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Chemical and electrochemical machining

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Hybrid Processes

To enhance the capabilities of machining processes, two or

more than two machining processes can be combined to
take the advantage of the worthiness of the constituent
processes.

Example: ECG, ECSM, ECAM, EDAG ECDM etc.

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Factors for selection of a process

Physical Parameters
Properties of work material and shape to be machined
Process capability
Economic Considerations

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Physical Parameters

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Power Consumption vs. Metal Removal Rate

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Shape to be machined

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Material Application

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Process Capabilities

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Economy

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