Non — Conventional Machining Process Ppt

Non-conventional machining processes have transitioned from niche specialized solutions to mainstream manufacturing necessities. By manipulating alternative energy sources rather than raw mechanical cutting power, these techniques allow engineers to design and manufacture components once deemed completely impossible. As aerospace, semiconductor, and medical industries push the boundaries of miniaturization and material science, NCMPs will continue to evolve as the backbone of advanced manufacturing technology.

Materials like Nimonic alloys, tungsten carbide, and stainless steel are incredibly difficult to machine conventionally.

The future of non-conventional machining is moving toward hybridization and sustainability.

Minimal or zero tool wear in processes like ECM and LBM. Non Conventional Machining Process Ppt

Non-Conventional Machining │ ┌────────────────────────┼────────────────────────┐ ▼ ▼ ▼ Mechanical Thermal Chemical & │ Electrochemical ┌────┴────┐ ┌─────────┼─────────┐ │ │ AJM │ │ EDM │ LBM │ ┌─────┴─────┐ │ USM │ │ EBM │ PAM │ │ ECM │ │ WJM │ └─────────┴─────────┘ │ CHM │ └─────────┘ └───────────┘ 1. Mechanical Processes

Material is removed via controlled chemical dissolution or electrochemical reactions at the atomic level. Electrochemical Machining (ECM) 3. Deep Dive into Core Processes (Slide Content)

EDM operates on the thermoelectric phenomenon. When a voltage (50-400 V) is applied across a small gap (0.01-0.5 mm) between an electrode (copper/graphite) and a conductive workpiece in a dielectric fluid, the dielectric breaks down. A plasma channel forms, reaching 8000-12000°C, melting and vaporizing material. The dielectric flushes away debris. EDM is specifically suited for mold and die making. However, the rapid heating/cooling creates a "recast layer" (2-10 µm thick) containing micro-cracks and tensile residual stresses, reducing fatigue life by up to 40% in critical components. dry gas dielectrics

Always dedicate a slide to the . Unlike conventional grinding (which may cause burns), EDM and Laser leave a recast layer (white layer) that may contain micro-cracks. ECM and WJM have zero thermal damage , making them superior for critical aerospace parts.

Traditional machining induces residual stresses, micro-cracks, and thermal damage due to heavy friction. NCMP minimizes or eliminates these defects.

Focuses a highly concentrated coherent laser beam to melt and vaporize material. Traditional machining induces residual stresses

– Key takeaways and textbook or paper citations. 7. Conclusion

Replacing toxic dielectrics (like hydrocarbon oils in EDM) with biodegradable options, dry gas dielectrics, or pure water to reduce environmental impact.

Requires substantial energy input per unit volume of material removed.

Utilizes a high-pressure jet of pure water to cut soft materials.

A high-velocity stream of gas carries fine abrasive particles toward the target.