UNCONVENTIONAL MACHINING PROCESS- An overview

Introduction

Unconventional Machining Process is defined as a group of

processes that remove excess (stock) material by various techniques
involving Mechanical, Thermal, Electrical and chemical energy or
combination of these energies but do not use a sharp cutting tools as it
needs to be used for traditional machining processes. Extremely hard
and brittle materials are difficult to machine by traditional machining
processes such as Turning, Drilling, Shaping and Milling.Unconventional
machining process, also called advanced manufacturing processes, are
employed where traditional machining processes are not feasible,
satisfactory or economical due to various factors as follows.
Fragile & Hard material are difficult to clamp in traditional machining
If such materials are machined with the help of conventional machining
processes, either the tool undergoes extreme wear (while machining
hard workpiece) or the workpiece material is damaged (while machining
brittle workpiece).
When the shape of the part is too complex. Large cutting forces are
involved and material is removed in the form of chips. Huge amounts
of heat is produced in the workpiece. This induces residual stresses,
which degrades the life and quality of the finished product.
When the work piece is too flexible or slender (L/D ratio) conventional
machining produces poor quality workpiece with poor surface finish
All this drawbacks were overcomed by using unconventional machining
processes to attain good dimensional accuracy,better surface finish,
optimizing the process,cost reduce and quality of the product is
maintained.
Several types of Unconventional Machining Process have been
developed to meet various required machining conditions. When these
processes are implement properly, they offer many advantages over
Traditional machining processes. The common Unconventional
machining process are described below.

1. Based on the type of energy used

1. Mechanical Energy based Unconventional Machining Processes
(e.g. Abrasive Jet Machining, Water Jet Machining)
2. Electrical Energy based Unconventional Machining Processes
(e.g. Electrical Discharge Machining)
3. Electrochemical Energy based Unconventional Machining Processes
(e.g. Electrochemical Grinding)
4. Chemical Energy based Unconventional Machining Processes
(e.g. Chemical Machining)
5. Thermo-electrical (or Electro-thermal) Energy based Unconventional
Machining Processes (e.g. Plasma Arc Machining)

2. Based on the source of energy

1. Current
2. Hydraulic Pressure
3. Ionised Particles
4. Light
5. Pneumatic Pressure
6. Voltage

3. Based on the medium of energy transfer

1. Atmosphere
2. Chemical reagent
3. Electrons
4. Electrolyte
5. Ions
6. Laser
7. Pressurized gas
8. Plasma
9. Radiation
10. Water

11. Ultrasonic waves

4. Based on the mechanism of material removal

1. Blasting
2. Chemical Etching
3. Erosion
4. Electric Discharge
5. Ion Displacement
6. Melting
7. Shear
8. Vapourisation

Electrical Discharge Machining (EDM)

EDM process is used for cutting complex and precise geometric shapes into
electrically conducting metals. The metal electrode and the part are laced very close to
each other, separated by a non-conducting liquid (called a dielectric fluid) which creates
path for discharge a commonly used dielectric fluid is kerosene. A voltage difference is
then applied to the part and tool, generating a spark; the heat from the spark melts a
tiny bit of metal from the part. The melted metal cools and solidifies as tiny particles in
the dielectric. By pumping the dielectric to flow, the metal is carried away, and the
process continues. The electrode is a conductor, usually copper, graphite, or gold (very
fine gold wire is used to cut profiles into metal parts). The tool is either a wire in which
case the EDM process will cut profiles, or a negative shape of the Geometry to be
machined, in which case the tool is copper or graphite. Application of focused heat raise
the temperature of workpiece locally at a point, this way two metal is melted and
evaporated In tooled EDM, which is useful for cutting complex dies and moulds, the tool
shape is the exact negative of the required shape of the part
Advantages of EDM

1. Highly delicate sections and weak materials can also be processed without
any risk of their distortion, because in this process tool never applies direct
pressure on the workpiece
2. Appreciably high value of Material Removal Rate(MRR) can be achieved as
compared to other non-conventional machining processes.
3. Precise dimensional fine hole can be achieved with good surface finish
4. Aspect ratio is maintained to the tolerance.
Disadvantages and Limitations of EDM Process

1.Electrically non-conducting materials cannot be processed by EDM

2.EDM process is not capable to produce sharp corners
3.This process cannot be applied on very large sized workpieces as
size of workpiece is constrained by the size of set up
4.Intercate operation cannot be performed