Non Conventional Machining Process Ppt: Updated [best]

| Process | Material Removal Rate (mm³/min) | Surface Finish (Ra, µm) | Tool Wear Ratio | Typical Tolerance (mm) | "Updated" Note | | :--- | :--- | :--- | :--- | :--- | :--- | | | 300 - 600 | 0.1 - 5.0 | 0.1 - 5% (Electrode) | ±0.005 | Dry EDM reduces environmental cost by 90% | | LBM (Femtosecond) | 10 - 100 | 0.05 - 1.0 | Zero contact (No tool) | ±0.002 | Zero HAZ – critical for medical implants | | ECM | 500 - 1500 | 0.05 - 0.8 | 0% (Cathode lasts) | ±0.01 | Pulsed ECM doubles MRR | | USM | 50 - 200 | 0.1 - 0.5 | High (Abrasive slurry) | ±0.02 | RUM reduces cracking in glass | | AJM | 10 - 50 | 0.5 - 1.5 | High (Nozzle wear) | ±0.05 | Nano-abrasives enable die cutting |

: As modern engineering materials become harder, tougher, and more brittle (e.g., ceramics, superalloys), traditional machining methods often fail due to excessive tool wear, high heat generation, and inability to produce complex micro-features.

Uses strong chemical etchants to selectively dissolve material through a mask.

Reverse electroplating. Material is removed atom-by-atom via anodic dissolution into a fast-flowing electrolyte solution (like NaCl in water).

High-speed stream of abrasive particles. non conventional machining process ppt updated

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Traditional machining relies on plastic deformation to create chips. Non-conventional machining uses thermal, chemical, electrical, or mechanical energy to erode, melt, vaporize, or chemically dissolve material. NCM processes eliminate the requirement that the cutting tool must be harder than the workpiece. Slide 2: Why Do We Need Non-Conventional Machining? Limitations of Conventional Machining

Modern Manufacturing Methods for High-Strength Materials

A laser source (such as CO2, Nd:YAG, or fiber lasers) emits a highly concentrated beam of light. Optical lenses focus this beam onto a minuscule spot on the workpiece. The extreme energy density instantly melts, burns, or vaporizes the target area. | Process | Material Removal Rate (mm³/min) |

Wire spool, wire guidance system, CNC controller, and deionized water flushing.

Mass production of turbine blades, complex internal profiles, and burr-free deburring. Laser Beam Machining (LBM)

Schematic diagram showing the ultrasonic transducer and horn focusing energy onto a workpiece. Ultrasonic Machining (USM)

Real-time monitoring using machine learning to dynamically adjust pulse frequencies, dielectric flow rates, and feed speeds to prevent wire breakage and micro-cracking. Material is removed atom-by-atom via anodic dissolution into

Uses ultrasonic vibrations and abrasive slurry; perfect for brittle materials like glass.

Why it matters: Environmental regulations (e.g., EU REACH, OSHA) are banning toxic dielectrics.

Conventional cutting creates high residual stresses, micro-cracks, and thermal damage due to friction. NCM provides stress-free machining.

: Easily cuts materials like tungsten carbide, polycrystalline diamond, and titanium.

However, modern engineering demands the use of high-strength, temperature-resistant materials like titanium, ceramics, nimonics, and carbon composites. These materials are incredibly difficult to machine using traditional mechanical forces.