non traditional manufacturing process

1. Nontraditional Manufacturing Processes:Nontraditional Manufacturing Processes:
MF30604MF30604
Lecture No.-1Lecture No.-1
Introduction to NTMPsIntroduction to NTMPs

2. Fabrication of largeFabrication of large
size domessize domes
FabricationFabrication ofof
Micro-lensMicro-lens
6060µµm square hole Curved slot in SSm square hole Curved slot in SS
in Siin Si

3. 3-D features inside transparent glass3-D features inside transparent glass
Drilling hole and creating interconnect inDrilling hole and creating interconnect in
integrated circuitsintegrated circuits
Exotic components of different materialsExotic components of different materials
Deep penetration weldingDeep penetration welding
50-100 mm

4. Conventional Machining ProcessesConventional Machining Processes
DrillingDrilling
TurningTurning
MillingMilling
Circular symmetryCircular symmetry

5. Conventional Machining Processes (Material Removal):
Primarily rely on electrical motors and hard tool materials to perform tasks e.g.
Turning, Drilling, Boring, Milling, Shaping, Sawing, Slotting, & Grinding etc.
Main Characteristics of Conventional Machining:
* Material removal by chip formation
* Material removal by mechanical force
* Cutting tool – harder than work piece under machining condition
* Direct mechanical contact - residual mechanical & thermal stress.

6. Demand for Products with
 New exotic work materials: Improved mechanical, thermal, & chemical
properties
Super-alloys, ceramics and composites
* Too hard / brittle to machine with traditional process
* Materials too flexible / slender to cut or clamp
Ex: Machining Polycrystalline diamond
- fast wear of grinding wheel;
Silicon wafer, Ceramic – Damage during machining
60µm square hole in Si Curved slot in SS
Micro-lenses
Quartz
Need of Nontraditional / Modern Manufacturing Processes !
Challenges & Competition in Manufacturing IndustriesChallenges & Competition in Manufacturing Industries:
New Products - Better Performance, More Features, More Durable, Less
Production Time, Energy Efficient, Low cost,
 Innovative designs, complex shapes, high precision & high surface quality
* Stringent design requirements * Micro- Nano Sizes

7. Other requirements of the New Manufacturing Process
 Low machining cost
* Automated processing, Fast production
Photochemical Machining Electro-Discharge Machining
 Rapid change of Product design
* Elimination of Traditional tooling to reduce time & cost:
Rapid Manufacturing
 Less Temperature rise or residual stresses

8. Modern / Nontraditional Manufacturing processes employing
New tools and
New forms of energy
Developed as
Efficient and economic alternatives to conventional ones
Often the first choice for certain technical requirements.
Modern / Nontraditional Manufacturing Processes differ to Traditional Mfg.
Processes in following aspects ⇒
 Unconventional Energy Sources : Thermal, Chemical, Electrochemical, Kinetic
Energy ---
 Nontraditional media to transfer energy from tool to work piece :
Photons, E-beam, Dielectric media, Electrolytic media, Water,
Abrasive slurry.
 Processing usually not by direct MECHANICAL contact:
Nontraditional mechanism of interaction between tool and work piece:
Evaporation, Ablation, Melt Ejection, Dissolution, Erosion----

9. Basic NTM Process Groups:
* Thermal NTM Processes
- Laser Beam Machining (LBM)
- Electron Beam Machining (EBM)
- Plasma Arc Machining (PAC)
- Electrical Discharge Machining (EDM)
* Mechanical NTM Processes( Plastic deformation / Abrasive Erosion)
- Abrasive Jet Machining (AJM)
- Ultrasonic Machining (USM)
- Water Jet Machining (WJM)
- Abrasive Water Jet Machining (AWJM)
* Electrochemical NTM Processes
- Electrochemical Machining (ECM)
- Electrochemical Grinding (ECG)
* Chemical NTM Processes
- Chemical Machining (CHM)
- Thermo chemical Machining (TCM)
* Kinetic Energy ( Atom by atom knocking)
- Ion beam

10. Characteristics of Modern / Non Traditional Machining (NTM) Processes:
 Mostly NTM processes do not use mechanical energy for material removal.
They use different forms of energy for machining.
Example, USM, AJM, WJM - Mechanical energy
ECM- Electrochemical dissolution
Laser, EDM, EB - Thermal
 Material removal with chip formation or even without chip formation
Example: AJM - Microscopic size chips
ECM - Electrochemical dissolution at atomic level
 In NTM, Physical tool may or may not be present.
Example: Laser beam machining- No tool,
Electrochemical Machining- Physical tool needed
 In NTM, Tool need not be harder than the work piece material.
Example: EDM, copper tool to machine hardened steels.
 Nontraditional media for energy transfer:
EDM: Dielectric fluid,
Laser: Coherent photon beam

11. Attributes of Nontraditional Machining Processes:
Increased Productivity: Faster operation
Reduction in the number of overall operations;
Reduced Rejection: Improved repeatability
Reduction in in-process breakage of fragile work piece.
Perform operation not feasible by traditional Manufacturing Processes,
Example drilling holes of very high depth to width aspect ratio, 100:1
Easy automation, On-line Process Monitoring & Control: Increased reliability,
repeatability; reduced human involvement
Versatile & Virtually unlimited Capability: Ex.- Laser can cut most materials of
any hardness: diamond, metals, concrete, glass, plastics, textiles, wood etc.
Drill holes of any diameter

12. Course Outline by Topical Areas:
Introduction to Nontraditional Manufacturing Processes
Thermal Processing:
Laser Beam Machining (LBM): Fundamentals of Materials Processing- (Laser
cutting, drilling, welding, surface modification- hardening, alloying, cladding;
marking, micro-machining, laser rapid prototyping & manufacturing) Equipment
for Laser Beam Processing
Electron Beam Machining (EBM): Fundamentals of Materials Processing (E-beam
machining, welding, lithography)
Plasma Arc Machining (PAM): Cutting, Welding & Plasma Spraying
Ion-Beam Machining (IBM): Ion Beam removal, deposition, surface treatment
Mechanical NTM Processes( Plastic deformation / Abrasive Erosion)
- Abrasive Jet Machining (AJM)
- Ultrasonic Machining (USM)
- Water Jet Machining (WJM)
- Abrasive Water Jet Machining (AWJM)

13. Objective of this course:
Learn about the basic theory, working principle, and characteristics of
different nontraditional manufacturing processes.
Identify critical process variables and their effect on process performance and
product quality
Develop mathematical model relating MRR with machining parameters
Develop understanding to properly assess the capabilities, limitations, and
potentials of nontraditional manufacturing processes

14. Examples where NTM processes is the first choice
 Intricate shaped blind holes- e.g. square holes of say 10x10mm with a depth of
20mm ⇒ EDM / ECM
 Machining hard materials- e.g. Diamond, Inconel, Ti-Alloys, Composites,
Ceramics or Carbides ⇒ EDM, ECM, LBM
 Small diameter holes with large aspect ratio (0.5mm φ, 10mm l)
⇒LBM, EBM, EDM
 Flexible , Brittle materials ⇒ WJ, AWJ, EDM, PCM, LBM, EBM
Laser Cutting
Abrasive Machining

15. Course Materials : Lecture Notes
Reference Books :
1. Nontraditional Manufacturing Processes
Gary F. Benedict, Marcel Dekker,Inc
2. Modern Machining Processes
P C Pandey & H S Shan, Tata McGraw-Hill
3. Nonconventional Machining
P K Mishra, Narosa Publishing House
4. Manufacturing Science
Amitabha Ghosh & A K Mallik, Affiliated East-West Press
5. www.nptel.iitm.ac.in
National Programme on Technology Enhanced Learning (NPTEL)
Course- IIT Kharagpur- Manufacturing-Module 9 (on NTM)
Lessons 35-40.
6. Laser Material Processing, by W M Steen