Non Conventional Machining Process Ppt __top__ Jun 2026

Mastering Non-Conventional Machining Processes: A Complete Guide for Engineering Presentations

USM uses a magnetostrictive transducer to convert high-frequency electrical energy (20 kHz) into mechanical vibrations. An abrasive slurry (Boron Carbide or Alumina) is pumped between the vibrating tool and workpiece. The abrasive particles impact the surface, causing micro-cracking and fracture. USM is the only viable method for machining non-conductive, brittle materials like glass, ferrite, and piezo-ceramics. Key drawback: Material Removal Rate (MRR) drops below 2 mm³/min for hard materials.

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Does not produce the residual stresses or heat-affected zones typical of heavy mechanical cutting. Non Conventional Machining Process Ppt

Setting up lasers, vacuum systems, or chemical neutralization systems requires substantial investment.

Uses high-velocity electrons to machine materials. C. Chemical Energy Processes

A high-velocity stream of gas (air or nitrogen) focused with fine abrasive particles strikes the workpiece surface. The micro-abrasive action cuts, cleans, or deburrs the material. USM is the only viable method for machining

Leaves smooth edges without structural deformation. Disadvantages

Capital costs for laser (LBM) and electron beam (EBM) systems are incredibly high compared to abrasive jet systems (AJM). 6. Slide-by-Slide Outline for a Presentation (PPT)

Extreme precision, but leaves a small heat-affected zone (HAZ) on the edges. Electron Beam Machining (EBM) Does not produce the residual stresses or heat-affected

Modern electronics and aerospace components require micro-scale features that a physical drill bit or milling cutter cannot physically replicate. Comparative Summary: Conventional vs. Non-Conventional Conventional Machining Non-Conventional Machining Material Removal Mechanism Plastic deformation / chip formation via physical contact. Erosion, dissolution, vaporization, or melting. Tool Material Requirement Tool must be harder than the workpiece. Tool hardness is irrelevant; energy transfer is key. Physical Contact Direct contact; high cutting forces and tool wear. No direct contact; negligible tool wear and physical force. Material Constraints Limited to macro-machining softer/ductile materials.

Deburring delicate parts, frosting glass, cleaning electronic components, deflashing molded plastics. Water Jet & Abrasive Water Jet Machining (WJM / AWJM)