Non Conventional Machining Process Ppt Updated

The reverse of electroplating. The workpiece acts as an anode, and the tool acts as a cathode in an electrolyte solution. Current flows through the electrolyte, dissolving material from the workpiece with zero tool wear. 3. Thermo-Electrical Energy Processes

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Non-conventional processes are classified by the type of energy used to erode material: non conventional machining process ppt updated

– Faradaic atomic dissolution, electrolyte dynamics, and stress-free machining.

| Process | Material Removal Mechanism | Key Applications | Key Advantages | Key Limitations | Typical MRR | | :--- | :--- | :--- | :--- | :--- | :--- | | | Thermal (spark erosion) | Die/mold making, complex cavities, small holes, aerospace components | High accuracy, complex shapes, machines any conductive material regardless of hardness | Low MRR, tool wear, heat-affected zone (recast layer), high energy consumption | 2–400 mm³/min | | ECM | Electrochemical (anodic dissolution) | Turbine blades, surgical implants, deburring, large cavities | No tool wear, stress-free, high surface finish, machines hard conductive alloys | High tooling cost, difficult to control stray cutting, electrolyte disposal issues | 1500–10,000 mm³/min | | USM | Mechanical (abrasive erosion) | Machining hard, brittle materials like glass, ceramics, and carbides | No thermal damage, non-thermal, machines non-conductive materials, good hole quality | Low MRR, high tool wear, limited to small features, abrasive slurry disposal | 0.05–120 mm³/min | | LBM | Thermal (melting/vaporization) | High-precision cutting, micro-drilling, marking, welding | High speed, high precision, non-contact, extreme flexibility (various materials) | High equipment cost, heat-affected zone (HAZ), thermal process, limited thickness for quality cuts | 10–5000 mm³/min | | AWJM | Mechanical (abrasive erosion) | Cutting thick composites, metals, stone, heat-sensitive materials | No thermal damage (no HAZ), no tool wear, very versatile, environmentally friendly | Nozzle wear, lower precision than EDM/laser, noisy operation, issues with depth regulation | 20–7000 mm³/min | | EBM | Thermal (vaporization) | High-precision micro-drilling, welding aerospace alloys, semiconductor manufacturing | Extremely high power density (10⁹ W/cm²), capable of very fine features, high welding depth-to-width ratio (50:1) | Requires high vacuum (costly), X-ray emission risk, limited to conductive materials | 0.1–400 mm³/min | | PAM | Thermal (melting) | High-speed cutting of thick plates (steel, aluminum), weld preparation, bevel cutting | Very high cutting speed for thick sections, low equipment cost compared to lasers | Significant HAZ and thermal distortion, limited to conductive materials, poor edge quality | 1000–30,000 mm³/min | | CHM | Chemical (dissolution) | Photochemical milling of thin sheets, production of shallow cavities, etching for electronics | Low equipment and tooling cost, no thermal/mechanical stress, good for low production runs | Slow process, limited to shallow removal (0.0025–0.1 mm/min), hazardous chemical handling | Low (area-dependent) | The reverse of electroplating

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: Uses electrical sparks to erode material from a conductive workpiece submerged in a dielectric fluid. Ultrasonic Machining (USM) | Process | Material Removal Mechanism | Key

Uses ionized gas at extremely high temperatures to cut through thick plates. 3. Comparative Analysis: Conventional vs. Non-Conventional Conventional Non-Conventional Tool Material Must be harder than workpiece Tool hardness is irrelevant Tool Contact Physical contact required Often no physical contact Material Removal Macroscopic chips Atoms or molecules Accuracy Limited by tool vibration Extremely high (micron level) Cost Lower initial setup Higher capital investment 4. Industry Trends (The "Updated" Perspective)