The main reasons for choosing nontraditional machining processes are. Materials removed from the workpiece stay in the electrolyte fluid. In unconventional machining, a form of energy is used to remove unwanted material from. This course will define the areas of application of traditional as well as nontraditional abrasive finishing processes in the manufacturing industry. Modern machining processes presents unconventional machining methods which are gradually commercial acceptance. 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. When do we need nontraditional processes very high hardness and the strength of the material. Electrochemical grinding is similar to electrochemical machining but uses a wheel instead of a tool shaped like. For example, abrasive water jet operations use mechanical energy, but material is removed by erosion. The following examples are provided where ntm processes are preferred over the conventional machining process. Chapter 2 overview of hybrid machining processes iit kanpur. Advanced nontraditional machining processes springerlink. Electrochemical machining ecm is one of the nontraditional machining ntm process belonging to electrochemical category 1, 2.
Nontraditional manufacturing processes or unconventional machining processes conventional machining processes mostly remove material in the form of chips by applying forces on the work material with a wedge shaped cutting tool that is harder than the work material under machining condition. Ashish umarkar advanced manufacturing processes amp12154 unit no. A mechanical conventional single cutting or ma action process can be combined with the respective machining phases of electrodischarge ed in electrodischarge. Advanced machining processesnontraditional and hybrid machining processes, mcgrawhill, newyork. Other machining operations shaping and planing a singlepoint tool moves linearly relative to the work part shaping a tool moves planing a workpart moves broaching performed by a multipletooth cutting tool by moving linearly relative to. The resulting hybrid machine tools combine the flexibility and unique geometries of 3d printing with the speed and precision that comes from cnc machining. The common nontraditional machining processes are described in this section. Very hard fragile materials difficult to clamp for traditional machining when the work piece is too flexible or slender when the shape of the part is too complex several types of nontraditional machining processes have been developed to. Hybrid machining processes hybrid production manufacturing means the combination of processesmachines in order to produce parts in a more efficient and productive way. This chapter has summarized some important aspects of the literature on hybrid machining processes. Conventional and non conventional machining processes.
Non traditional abrasive machining processes ultrasonic, abrasive jet and abrasive water jet. Introduction to abrasive machining and finishing processes mechanical engineering instructor name. Chapter 18 lean manufacturing pennsylvania state university. Download nontraditional manufacturing processes by gary f. Courses introduction to abrasive machining and finishing processes. Brief overview and introduction to electrochemical machining, electrode discharge machining, ultrasonic machining, abrasive jet machining, material removal r.
The course is aimed at teaching the pros and cons of different processes, so that one can apply this knowledge to the selection of a process for making a part to the required. There is no cutting of metal with the help of metallic tool having sharp cutting edge. Material is removed from the workpiece through localized melting and vaporization of material. In the above overview on hybrid processes the processes presented in this brochure are written in blue letters. This hybrid combination allows parts to be created which are lighter weight and less expensive than the parts they replace, and which have novel geometries that were previously.
Carl sommer, author of over 50 books, is uniquely qualified to author this book on nontraditional machining. There is a need for machine tools and processes which can accurately and easily. When these processes are employed properly, they offer many advantages over nontraditional machining processes. The process was first developed in 1950s and was originally used for finishing edm surfaces. In addition, non traditional manufacturing processes, like electrodischarge machining edm, laser beam machining, plasma cutting etc are also a part of this course. Unconventional machining processes introduction and. Pdf nontraditional manufacturing processes by gary f. Processes, systems sensing and control of traditional and nontraditional macro, micro and nano manufacturing processes, such as electric discharge, electrochemical machining and ultrasonic machining and their hybrid processes. Me 338 manufacturing processes ii department academic. One possibility of vibrationsuperimposed machining is the. Hence the machining process which utilizes other machining methods are termed as unconventional machining or nontraditional machining or advanced machining processes or modern machining processes.
An unconventional machining process or nontraditional machining process is a special type of machining process in which there is no direct contact between the tool and the workpiece. The basic idea behind a hybrid machining process is the synergistic combination of constituent machining processes in order to overcome their individual shortcomings and achieve effective material removal. Today we shall discuss some hybrid machining process using electrochemical machining concept. From time to time a number of definitions for hybrid machining processes have been proposed by researchers like rajurkar et al. New and novel materials because of their greatly improved chemical, mechanical and thermal properties are sometimes impossible to machine using traditional machining processes. So first we shall discuss electrochemical grinding process. The role of nonconventional machining parameters during machining helps in understanding the mechanism of hybrid machining processes. Paul,department of mechanical engineering, iit kharagpur.
Electric discharge machining is a thermoelectric nontraditional machining process. Processes likeabrasive jet machining water jet machininglaser beam machininghot machiningplasma arc machininghave also been included. For the love of physics walter lewin may 16, 2011 duration. Nontraditional machining can be thought of as operations that do not use shear as their primary source of energy. Hybrid machining made in taiwan ian wright posted on.
Difference between conventional machining and nontraditional machining ntm pintu 27042019 ntm by definition, machining is one of the secondary manufacturing processes by which excess material is gradually removed by shearing from a preformed blank in the form of solid chips using a wedge shaped cutting tool in order to get desired shape. Electrochemical machining ecm is a nontraditional machining process uses the principle of faraday to remove metal from the workpiece. Non traditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be. A new nontraditional machining method using cavitation. Lecture on non conventional machining process by mech zone. Intended as a guide for working with some of the most difficulttomachine materials such as superalloys, ceramics, and composites, advanced machining is a definitive reference for both nontraditional and hybrid machining processes. Non traditional machining traditional machining is mostly based on removal of materials using tools that are harder than the materials themselves. Nontraditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be. A mechanical conventional single cutting or ma action process can be combined with the respective machining phases of electrodischarge. There is no exact description for hybrid machining processes. Within the covers of this book, you will find expert coverage of both electrical discharge machining as well as. Ultrasonic machining is a mechanical type nontraditional machining process. Amps and their combination with conventional or unconventional machining processes can be used for process improvement.
Nontraditional machining traditional machining is mostly based on removal of materials using tools that are harder than the materials themselves. It is employed to machine hard and brittle materials both electrically conductive and non conductive material having hardness usually greater than 40 hrc. Many advanced finishing processes have been employed to make circular andor noncircular cavities and holes in difficulttomachine materials. Manufacturing process is basically a complex activity, concerned with people whove a broad number of disciplines and expertise and a wide range of machinery, tools, and equipment with numerous levels of automation, such as computers, robots, and other equipment. Hybrid machining processes in cutting technology fraunhofer iwu. Electrolysis is based on faraday laws of electrolysis which is stated as. Modern machining methods are also named as nonconventional machining methods.
The machining medium is solid grains suspended in an abrasive slurry in the former, while a fluid is employed in the wjm process. Course curriculum mtech in manufacturing technology 2016 department of mechanical engineering. It includes detailed information to gain insight into the manufacturing processes which are new, unconventional and list out the the. So already we have discussed that hybrid process means here we shall combine one nontraditional machining process and one conventional machining process. In addition, low applied forces can prevent damage to the. Feed marks are not present in which of the following machiningfinishing process. Deformation machining a new hybrid process pdf free. Electrochemical grinding is a process that removes electrically conductive material by grinding with a negatively charged abrasive grinding wheel, an electrolyte fluid, and a positively charged workpiece. Advanced nontraditional machining processes 315 this equation can be used to calculate the linear material removal rate mrr l by dividing it by cross sectional a rea a r of the tool or. Several types of nontraditional machining processes have been developed to meet extra required machining conditions. Lecture series on manufacturing processes ii by prof. What is hybrid manufacturing and classification of hybrid. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses.
Electrochemical machining ecm is one of the non traditional machining ntm process belonging to electrochemical category 1, 2. Its a safe bet that the number of available hybrid machines will continue to increase as they. Non traditional manufacturing processes an overview. Ecm is widely used in machining jobs involving intricate shapes. Nonconventional machining iit notes machining composite. Advanced machining processes nontraditional and hybrid.
Manufacturing pursuits must be receptive to several needs and developments. Nonconventional machining iit notes free download as pdf file. In ntm processes the material is removed in the form of atoms or molecules, individually or in groups. Fraunhofer iwu hybrid machining processes in cutting. Course curriculum jaypee university of engineering and. Applications of a hybrid manufacturing process for fabrication and repair of metallic. Rajurkar has more than 120 refereed publications and nearly 120 technically edited papers which. Some of the processes employed for hole making are electrodischarge machining, laser beam machining, electron beam machining, shaped tube electrochemical machining and electrochemical spark machining. Manufacturing processes i nptel online videos, courses. Electric sparks are generated between two electrodes when the electrodes are held at a small distance from each other. What is hybrid manufacturing and classification of hybrid machining process technological improvement of machining processes can be achieved by combining different machining actions or phases to be used on the material being removed. All aspects of mechanical, electrochemical and thermal processes are comprehensively covered.
It also includes chapters on outsourcing, purchasing equipment, building a successful business, and closes with a chapter on the future revolutionary nontraditional machine. Applications of a hybrid manufacturing process for. Introduction to nontraditional machining iit kanpur. Non traditional machining processes linkedin slideshare. Using hybrid processes, existing technological process limits can be extended by combining additional sources of energy and conventional existing machining processes.
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