Non Conventional Methods of

Manufacturing

Dr S B Patil
Associate Professor Mechanical Engineering
College of Engineering, Pune 411005
sbp.mech@coep.ac.in
 Present scenario

Nontraditional processes have been developed in

response to new and unusual machining requirements,
including
- Process capability - Tool/ Cutting tool
Complex part geometry
Surface requirements
Machining for Miniaturization
Development of newer material (High strength, high
hardness, high toughness)
High accuracy and precision requirements
 You should know
1. Non conventional manufacturing methods of machining are
gaining importance over traditional methods justify the statement
with the help of example.
2. Explain the possible criterions for classifying non conventional
methods of machining.
3. Explain the following energy type non conventional processes with
respect to basic mechanism, source of immediate energy, transfer
energy medium and examples for the same.
i. Mechanical
ii. Electro-chemical
iii. Chemical
iv. Thermo-electrical
4. How the process selection is carried out in case of non conventional
manufacturing methods?
 Classification of non conventional methods of
machining
1. According to the type of energy used
- mechanical, electro-chemical, electro-thermal,
chemical, etc
2. According to the energy source
- pneumatic or hydraulic pressure, mechanical
pressure, high current or voltage, etc
3. According to the medium of energy transfer
- high velocity particles, physical contact electrolyte, hot
gases, electrons, radiation, etc
4. According to the metal removal mechanism
- erosion, spark erosion, shear, vaporization, etc
 Non conventional processes
(Mechanical energy)

Energy type Mechanical

Basic mechanism Erosion
Source of Pneumatic or hydraulic pressure
immediate energy
Transfer energy -High velocity particles- ultrasonic machining
medium (USM), abrasive jet machining (AJM)
-High voltage liquid- Whirling jet machining
 Non conventional processes
(Mechanical energy)

Ultrasonic machining (USM)

Ultrasonic assisted machining (UAM)
Rotary ultrasonically assisted machining (RUM)
Abrasive jet machining (AJM)
Abrasive flow machining (AFM)
Orbital grinding (OG)
Water jet machining (WJM)
Non conventional processes (Electro-chemical
energy)

Energy type Electro-chemical energy

Basic mechanism Ion displacement
Source of immediate High current
energy
Transfer energy electrolyte
medium
Examples Electrochemical grinding
(ECG), electrochemical
machining (ECM)
 Non conventional processes (Electro-chemical
energy)

Electrochemical machining (ECM)

Electrochemical grinding (ECG)
Electrochemical discharge grinding (ECDG)
Electrochemical deburring (ECD)
Electrochemical honing (ECH)
Shaped tube electrolytic machining (STEM)
Electro stream drilling (ESD)
Electro jet drilling (EJD)
Non conventional processes (Chemical energy)

Energy type Chemical energy

Basic mechanism Abrasive action
Source of immediate Chemical reactive agent
energy
Transfer energy Environment
medium
Examples Chemical etching, chemical machining, hot
chlorine machining
Non conventional processes (Chemical energy)

Chemical milling (CHM)

Chemical blanking (CHB)
Chemical engraving (CHE)
Electropolishing (ELP)
Photo chemical machining (PCM)
Thermochemical machining (TCM)
 Non conventional processes (Thermo-electrical
energy)

Energy type Thermo-electrical energy

Basic mechanism Vaporization Fusion
Source of High voltage Amplified light Ionized material
immediate energy
Transfer energy Electron Radiation Hot gases
medium
Examples EDM, EBM LBM IBM, PAM
 Non conventional processes (Thermo-electrical
energy)
Electric discharge machining (EDM)
Electron beam machining (EBM)
Laser beam machining (LBM)
Electric discharge wire cutting (EDWC)
Electric discharge grinding (EDG)
Plasma arc machining (PAM)
Plasma assisted machining (PAM)
Thermal deburring (TD)
Ion beam machining (IBM)

HYBRID PRROCESSES.
 Non conventional methods-process selection

Physical properties of work material

Type of operation to be performed like cutting, drilling,
etc
Shape and size required to be produced
Process capabilities i. e. expected tolerance, power
requirement, metal removal rate (MRR) expected,
surface finish requirements, etc
Economy of the process