UNIT-5

INTRODUCTION
Modern machining methods are also named as non-conventional machining methods. These
methods form a group of processes which removes excess material by various techniques involving
mechanical, thermal, electrical chemical energy or combination of these energies. There is no cutting
of metal with the help of metallic tool having sharp cutting edge. The major reasons of development
and popularity of modern machining methods are listed below.
a) Need have machine newly developed metals and non-metals having some special properties
like high strength, high hardness and high toughness. A material possing the above mentioned
properties are difficult to be machined by the conventional machining methods.
b) Sometimes it is required to produce complex part geometries that cannot be produced by
following conventional machining techniques. Non-conventional machining methods also
provide very good quality of surface finish which may also be an encouragement to these
methods.
There can be a very long list of non-conventional machining methods. These methods can be
classified as the basis of their base principle of working.
PRINCIPLE OF WORKING OF ENERGY
The principle of working is the base of type of energy used to remove the material.
Classification along with the principle of working is described below.
Use of Mechanical Energy
Mechanical energy is used for removing material from workpiece. In this process, cutting tool
with sharp edge is not used but material is removed by the abrasive action of high velocity of
stream of hard, tiny abrasive particles. The particles are kept vibrating with very high velocity
and ultra high frequency to remove the material.
Electrical Energy
In this category of non-traditional machining electrical energy is used in the form of
electrochemical energy or electro-heat energy to erode the material or to melt and vaporized it
respectively. Electrochemical machining, electroplating or electro discharge machining are
the examples work on this principle.
Use of Thermal Energy
According to this principle heat is generated by electrical energy. The generated thermal
energy is focused to a very small portion of workpiece. This heat is utilized in melting and
evaporating of metal. The example based o this principle is electric discharge machining.
Use of Chemical Energy
According to this principle of working chemicals are used to erode material from the
workpiece. Selection of a chemical depends upon the workpiece material. Example of this
type of machining is electrochemical machining. The dame principle can also be applied in
reversed way in the process of electrochemical plating.
NON-CONVENTIONAL MACHINING PROCESSES
There can be one more way of classification of the non-conventional machining processes
which is mechanisms of metal removal.
Abrasion and Shear
When small and hard metallic particles are made vibrating against the workpiece to be
machined, the material is removed by shear action and abrasion. These phenomenon take place in case
of ultrasonic machining.
Chemical Ablation and Ionic Dissolution
This is the dissolution of workpiece material into electrolyte solution (chemical) which takes
place atom by atom. This happens in case electrochemical machining.
Vapourization by Spark Erosion
Concentrated heat is focused at a point of the workpiece by electric spark which melts and
evaporates the workpiece material like electric discharge machining and LBM.
Different processes used in non-conventional machining are described below.
ELECTRIC DISCHARGE MACHINING (EDM)
It is also known as spark erosion machining or sparks machining. Material of workpiece
removed due to erosion caused by electric spark. Working principle is described below.
Working Principle of Electric Discharge Machining
Electric discharge machining process is carried out in presence of dielectric fluid which
creates path for discharge. When potential difference is created across the two surfaces of die electric
fluid, it gets ionized. An electric spark/discharge is generated across the two terminals. The potential
difference is developed by a pulsating direct current power supply connected across the two terminals.
One of the terminals is positive terminal given to workpiece and tool is made negative terminal. Two
third of the total heat generated is generated at positive terminal so workpiece is generally given
positive polarity. The discharge develops at the location where two terminals are very close. So tool
helps in focusing the discharge or intensity of generated heat at the point of metal removal.
Application of focused heat raises the temperature of workpiece locally at a point, this way
two metals is melted and evaporated.

Line Diagram Indicating Working Principle and Process Details of EDM

Electric Discharge Machining Process Details
The working principle and process of EDM is explained with the help of line diagram in
Figure. The process details and components are explained below serially.
Base and Container
A container of non-conducting, transparent material is used for carrying out EDM. The
container is filled with dielectric solution. A base to keep workpiece is installed at the bottom
of container. The base is made of conducting material and given positive polarity.
Tool
Tool is given negative polarity. It is made of electrically conducting material line brass,
copper or tungsten. The tool material selected should be easy to machine, high wear resistant.
Tool is made slightly under size for inside machining and over sized for cut side machining.
Tool is designed and manufactured according to the geometry to be machined.
Dielectric Solution
 Dielectric solution is a liquid which should be electrically conductive. This solution provides
two main functions, firstly it drive away the chips and prevents their sticking to workpiece
and tool. It enhances the intensity of discharge after getting ionized and so accelerates metal
removal rate.
Power Supply
A DC power supply is used, 50 V to 450 V is applied. Due to ionization of dielectric solution
an electrical breakdown occurs. The electric discharge so caused directly impinges on the
surface of workpiece. It takes only a few micro seconds to complete the cycle and remove the
material. The circuit cam is adjusted for auto off after pre-decided time interval.
In case of EDM, feeding the tool means controlling gap between workpiece and the tool. This
gap is maintained and controlled with the help of servo mechanism. To maintain a constant
gap throughout the operation tool is moved towards the machining zone very slowly. The
movement speed is towards the machining zone very slowly. The movement speed is
maintained by the help of gear and rack and pinion arrangement. The servo system senses the
change in gap due to metal removal and immediately corrects it by moving the tool
accordingly. The spark gap normally varies from 0.005 mm to 0.50 mm.
Workpiece and Machined Geometry
The important point for workpiece is that any material which is electrical conductor can be
machined through this process, whatever be the hardness of the same. The geometry which is
to be machined into the workpiece decides the shape and size of the tool.
Application of Electric Discharge Machining
This process is highly economical for machining of very hard material as tool wear is
independent of hardness of workpiece material. It is very useful in tool manufacturing. It is also used
for broach making, making holes with straight or curved axes, and for making complicated cavities
which cannot be produced by conventional machining operations. EDM is widely used for die making
as complex cavities are to be made in the die making. However, it is capable to do all operations that
can be done by conventional machining.
Advantages of EDM
a. This process is very much economical for machining very hard material.
b. Maintains high degree of dimensional accuracy so it is recommended for tool and die making.
c. Complicated geometries can be produced which are very difficult otherwise.
d. Highly delicate sections and weak materials can also be processed without nay risk of their
distortion, because in this process tool never applies direct pressure on the workpiece.
e. Fine holes can be drilled easily and accurately.
f. Appreciably high value of MRRR can be achieved as compared to other non-conventional
machining processes.
Disadvantages and Limitations of EDM Process
There are some limitations of EDM process as listed below :
a. This process cannot be applied on very large sized workpieces as size of workpiece is
constrained by the size of set up.
b. Electrically non-conducting materials cannot be processed by EDM.
c. Due to the application of very high temperature at the machining zone, there are chances of
distortion of workpiece in case of these sections.
d. EDM process is not capable to produce sharp corners.
e. MRR achieved in EDM process is considerably lower than the MRR in case of conventional
machining process so it cannot be taken as an alternative to conventional machining processes
at all.
WIRE CUT ELECTRIC DISCHARGE MACHINING (WCEDM)
This is a special type of electric discharge machining that uses a small diameter wire as a
cutting tool on the work. Working a principle of wire cut electric discharge machining is same as that
of electric discharge machining.
Process Details of WCEDM
Process details of WCEDM are almost similar to EDM with slight difference. The details of
the process are indicated in the line diagram shown in Figure. Its major difference of process details
with EDM process details are described below.
Tool Details
The tool used in WCEDM process is a small diameter wire as the electrode to cut narrow kerf
in the workpiece. During the process of cutting the wire is continuously advanced between a
supply spoil and wire collector. This continuous feeding of wire makes the machined
geometry insensitive to distortion of tool due to its erosion. Material of wire can be brass,
copper, tungsten or any other suitable material to make EDM tool. Normally, wire diameter
ranges from 0.076 to 0.30 mm depending upon the width of kerf.

Line Diagram for Process Details of Working of Wire Cut Electric Discharge Machining
Tool Feed Mechanism
Two type of movements are generally given to the total (wire). One is continuous feed from
wire supply spoal to wire collector. Other is movement of the whole wire feeding system, and
wire along the kerf to be cut into the workpiece. Both movements are accomplished with ultra
accuracy and pre-determined speed with the help of numerical control mechanism.
Dielectric Fluid and Spray Mechanism
Like EDM process dielectric fluid is continuously sprayed to the machining zone. This fluid
is applied by nozzles directed at the tool work interface or workpiece is submerged in the
dielectric fluid container.
Rest of the process details in case of WCEDM process are same as that in case of EDM
process.
Application of WCEDM
WCEDM is similar to hand saw operation in applications with good precision. It is used to
make narrow kerf with sharp corners. It does not impose any force to workpiece so used for very
delicate and thin workpieces. It is considered ideal for making components for stamping dies. It is
also used to make intricate shapes in punch, dies and other tools.
Advantages of WCEDM
a. Accuracy and precision of dimensions are of very good quality.
b. No force is experienced by the workpiece.
c. Hardness and toughness of workpiece do not create problems in machining operation.
Disadvantages and Limitations of WCEDM
The major disadvantages of this process are that only electrically conducting materials can be
machined. This process is costly so recommended for use specifically at limited operations.
ULTRASONIC MACHINING (USM)
Ultrasonic machining (USM) is one of the non-traditional machining processes. Working
principle of this process resembles with conventional and metal cutting as in this process abrasives
contained in a slurry are driven at high velocity against the workpiece by a tool vibrating at low
amplitude and high frequency. Amplitude is kept of the order of 0.07 mm and frequency is maintained
at approximately 20,000 Hz. The workpiece material is removed in the form of extremely small chips.
Normally very hard particle dust is included in the slurry like, Al2O2, silicon carbide, boron carbide
or diamond dust.
Working principle of USM is same as that of conventional machining that is material of
workpiece is removed by continuous abrasive action of hard particles vibrating in the slurry. Abrasive
slurry acts as a multipoint cutting tool and does the similar action as done by a cutting edge.
Process Details
USM process is indicated in line diagram shown in Figure. Details of the process are discussed below.

Details of USM Process

Abrasive Slurry
Abrasive slurry consists of dust of very hard particles. It is filled into the machining zone.
Abrasive slurry can be recycled with the help of pump.
Workpiece
Workpiece of hard and brittle material can be machined by USM. Workpiece is clamped on
the fixture I the setup.
Cutting Tool
Tool of USM does not do the cutting directly but it vibrates with small amplitude and high
frequency. So it is suitable to name the tool as vibrating tool rather than cutting tool. The tool
is made of relatively soft material and used to vibrate abrasive slurry to cut the workpiece
material. The tool is attached to the arbor (tool holder) by brazing or mechanical means.
Sometimes hollow tools are also used which feed the slurry focusing machining zone.
Ultrasonic Oscillator
This operation uses high frequency electric current which passes to an ultrasonic oscillator
and ultrasonic transducer. The function of the transducer is to convert electric energy into
mechanical energy developing vibrations into the tool.
Feed Mechanism
Tool is fed to the machining zone of workpiece. The tool is shaped as same to the cavity of be
produced into the workpiece. The tool is fed to the machining area. The feed rate is
maintained equal to the rate of enlargement of the cavity to be produced.
Applications of USM
This process is generally applied for the machining of hard and brittle materials like carbides
glass, ceramics, precious stones, titanium, etc. It is used for tool making and punch and die making.
The workpiece material is normally removed in the form of very find chips so generated surface
quality is extremely good. It is widely used for several machining operations like turning, grinding,
trepanning and milling, etc. It can make hole of round shape and other shapes.
Advantages of USM
a. Its main advantage is the workpiece after machining is free from any residual stress as to
concentrated force or heat is subject to it during the machining process.
b. Extremely hard and brittle materials can be machined; their machining is very difficult by
conventional methods.
c. Very good dimensional accuracy and surface finish can be obtained.
d. Operational cost is low.
e. The process is environmental friendly as it is noiseless and no chemical and heating is used.
Disadvantages of USM
a. Its metal removal rate (MRR) is very low and it can not be used for large machining cavities.
b. Its initial setup cost and cost of tool is very high, frequency tool replacement is required as
tool wear takes place in this operation.
c. Not recommended for soft and ductile material due to their ductility.
d. Power consumption is quite high.
e. Slurry may have to be replaced frequently.
CHEMICAL MACHINING PROCESSES (CHM)
Chemical machining is one of the non-conventional machining processes where material is
removed by bringing it in contact of a strong chemical enchant. There are different chemical
machining methods base on this like chemical milling, chemical blanking, photochemical machining,
etc.
Working Principle of CHM
The main working principle of chemical machining is chemical etching. The part of the
workpiece whose material is to be removed, is brought into the contact of chemical called enchant.
The metal is removed by the chemical attack of enchant. The method of making contact of metal with
the enchant is masking. The portion of workpiece where no material is to be removed, is mashed
before chemical etching.
Process Details of CHM
Following steps are normally followed in the process of CHM:
Cleaning
The first step of the process is a cleaning of workpiece; this is required to ensure that material
will be removed uniformly from the surfaces to be processed.
Masking
Masking is similar to masking action is any machining operation. This is the action of
selecting material that is to be removed and another that is not to be removed. The material
which is not to be removed is applied with a protective coating called maskent. This is made
of a materials are neoprene, polyvinylchloride, polyethylene or any other polymer. Thinkers
 of maskent are maintained upto 0.125 mm. The portion of workpiece having no application of
maskent is etched during the process of etching.
Etching
In this step the material is finally removed. The workpiece is immersed in the enchant where
the material of workpiece having no protective coating is removed by the chemical action of
enchant. Enchant is selected depending on the workpiece material and rate of material
removal; and surface finish required. There is a necessity to ensure that maskant and enchant
should be chemically in active. Common enchants are H2SO4, FeCL3, HNO3. Selection of
enchant also affects MRR. As in CHM process, MRR is indicated as penetration rates
(mm/min).
Demasking
After the process is completed demasking is done. Demasking is an act of removing maskent
after machining.
Application of CHM
Chemical Milling
It is widely used in aircraft industry. It is the preparation of complicated geometry on the
workpiece using CHM process.

Application and Working of CHM

Chemical Blanking
In this application cutting is done on sheet metal workpieces. Metal blanks can be cut from
very thin sheet metal, this cutting may not be possible by conventional methods.
Photochemical Machining
It is used in metal working when close (tight) tolerances and intricate patterns are to be made.
This is used to produce intricate circuit designs on semiconductor wafers.
Advantages of CHM
a. Low tooling cost.
b. Multiple machining can be done on a workpiece simultaneously.
c. No application of force so on risk of damage to delicate or low strength workpiece.
d. Complicated shapes/patterns can be machined.
e. Machining of hard and brittle material is possible.
Disadvantages and Limitations of CHM
a. Slower process, very low MRR so high cost of operation.
b. Small thickness of metal can be removed.
c. Sharp corners cannot be prepared.
d. Requires skilled operators.
ELECTROCHEMICAL MACHINING (ECM)
Electrochemical machining (ECM) process uses electrical energy in combination with
chemical energy to remove the material of workpiece. This works on the principle of reverse of
electroplating.
Working Principle of ECM
Electrochemical machining removes material of electrically conductor workpiece. The
workpiece is made anode of the setup and material is removed by anodic dissolution. Tool is made
cathode and kept in close proximity to the workpiece and current is passed through the circuit. Both
electrodes are immersed into the electrolyte solution. The working principle and process details are
shown in the Figure. This works on the basis of Faraday’s law of electrolysis. The cavity machined is
the mirror image of the tool. MRR in this process can easily be calculated according to Faraday’s law.

Working Principle and Process Details of ECM

Workpiece
Workpiece is made anode, electrolyte is pumped between workpiece and the tool. Material of
workpiece is removed by anodic dissolution. Only electrically conducting materials can be
processed by ECM.
Tool
A specially designed and shaped tool is used for ECM, which forms cathode in the ECM
setup. The tool is usually made of copper, brass, stainless steel, and it is a mirror image of the
desired machined cavity. Proper allowances are given in the tool size to get the dimensional
accuracy of the machined surface.
Power Supply
DC power source should be used to supply the current. Tool is connected with the negative
terminal and workpiece with the positive terminal of the power source. Power supply supplies
low voltage (3 to 4 volts) and high current to the circuit.
Electrolyte
Water is used as base of electrolyte in ECM. Normally water soluble NaCl and NaNO3 are
used as electrolyte. Electrolyte facilitates are carrier of dissolved workpiece material. It is
recycled by a pump after filtration.
Tool Feed Mechanism
Servo motor is used to feed the tool to the machining zone. It is necessary to maintain a
constant gap between the workpiece and tool so tool feed rate is kept accordingly while
machining.
In addition to the above whole process is carried out in a tank filled with electrolyte. The tank
is made of transparent plastic which should be non-reactive to the electrolyte. Connecting
wires are required to connect electrodes to the power supply.
Applications of ECM Process
a. Electrochemical Grinding: This can also be named as electrochemical debrruing. This is used
for anodic dissolution of burrs or roughness a surface to make it smooth. Any conducting
material can be machined by this process. The quality of finish largely depends on the quality
of finish of the tool.
b. This is applied in internal finishing of surgical needles and also for their sharpening.
c. Machining of hard, brittle, heat resistant materials without any problem.
 d. Drilling of small and deeper holes with very good quality of internal surface finish.
e. Machining of cavities and holes of complicated and irregular shapes.
f. It is used for making inclined and blind holes and finishing of conventionally machined
surfaces.
Advantages of ECM Process
a. Machining of hard and brittle material is possible with good quality of surface finish and
dimensional accuracy.
b. Complex shapes can also be easily machined.
c. There is almost negligible tool wear so cost of tool making is only one time investment for
mass production.
d. There is no application of force, no direct contact between tool and work and no application
of heat so there is no scope of mechanical and thermal residual stresses in the workpiece.
e. Very close tolerances can be obtained.
Disadvantages and Limitations of ECM
a. All electricity non-conducting materials cannot be machined.
b. Total material and workpiece material should be chemically stable with the electrolyte
solution.
c. Designing and making tool is difficult but its life is long so recommended only for mass
production.
d. Accurate feed rate of tool is required to be maintained.
LASER BEAM MACHINING (LBM)
Laser beam have wide industrial applications including some of the machining processes. A
laser is an optical transducer that converts electrical energy into a highly coherent light beak. One
must know the full name of laser, it stands for “light amplification of stimulated emission of
radiation”. Laser being coherent in nature has a specific property, if it is focused by conventional
optical lenses can generate high power density.
Working Principle of LBM
LBM uses the light energy of a laser beam to remove material by vaporization and ablation.
The working principle and the process details (setup) are indicated in Figure. In this process the
energy of coherent light beam is focused optically for predecided longer period of time. The beam is
pulsed so that the released energy results in an impulse against the work surface that does melting and
evaporation. Here the way of metal removing is same as that of EDM process but method of
generation of heat is different. The application of heat is very finely focused in case of LBM as
compared to EDM.
Laser Tube and Lamp Assembly
This is the main part of LBM setup. It consists of a laser tube, a pair of reflectors, one at each
end of the tube, a flash tube or lamp, an amplification source, a power supply unit and a
cooling system. This whole setup is fitted inside a enclosure, which carries good quality
reflecting surfaces inside. In this setup the flash lamp goes to laser tube, that excites the atoms
of the inside media, which absorb the radiation of incoming light energy. This enables the
light to travel to and fro between two reflecting mirrors. The partial reflecting mirror does not
reflect the total light back and apart of it goes out in the form of a coherent stream of
monochromatic light. This highly amplified stream of light is focused on the workpiece with
the help of converging lense. The converging lense is also the part of this assembly.
Workpiece
The range of workpiece material that can be machined by LBM includes high hardness and
strength materials like ceramics, glass to softer materials like plastics, rubber wood, etc. A
 good workpiece material high light energy absorption power, poor reflectivity, poor thermal
conductivity, low specific heat, low melting point and low lotent heat.

Working Principle and Process Details of LBM

Cooling Mechanism
A cooling mechanism circulates coolant in the laser tube assembly to avoid its overheating in
long continuous operation.
Tool Feed Mechanism
There is no tool used in the LBM process. Focusing laser beam at a pre-decided point in the
workpiece serve the purpose of tool. As the requirement of being focused shifts during the
operation, its focus point can also be shifted gradually and accordingly by moving the
converging lense in a controlled manner. This movement of the converging lense is the tool
feed mechanism in LBM process.
Applications of LBM
LBM is used to perform different machining operations like drilling, slitting, slotting, scribing
operations. It is used for drilling holes of small diameter of the order of 0.025 mm. It is used for
very thin stocks. Other applications are listed below:
a. Making complex profiles in thin and hard materials like integrated circuits and printed
circuit boards (PCBS).
b. Machining of mechanical components of watches.
c. Smaller machining of very hard material parts.
Advantages of LBM
a. Materials which cannot be machined by conventional methods are machined by LBM.
b. There is no tool so no tool wear.
c. Application of heat is very much focused so rest of the workpiece is least affected by
the heat.
d. Drills very find and precise holes and cavities.
Disadvantages of LBM
a. High capital investment is involved. Operating cost is also high.
b. Recommended for some specific operations only as production rate is very slow.
c. Cannot be used comfortably for high heat conductivity materials light reflecting
materials.
d. Skilled operators are required.