processes, designed to be easily adaptable for a professional or academic presentation.
| Energy Source | How It Works | Key Processes (Presented in PPTs) | | :--- | :--- | :--- | | | Erosion : A high-velocity stream of abrasives or fluid bombards the workpiece. | USM (Ultrasonic Machining) : Uses a vibrating tool with an abrasive slurry. AJM (Abrasive Jet Machining) : Uses a high-velocity gas mixed with abrasives. WJM (Water Jet Machining) : Cuts soft materials with a high-pressure water stream. | | Electrical Energy | Spark Erosion : A controlled, high-frequency electrical spark erodes material from the workpiece. | EDM (Electrical Discharge Machining) : Material is removed by sparking between an electrode and the workpiece in a dielectric fluid. WEDM (Wire EDM) : Uses a continuously moving wire as the electrode to cut complex profiles. | | Chemical & Electrochemical Energy | Ion Displacement / Dissolution : Material is removed at an atomic level through a chemical reaction or controlled anodic dissolution. | ECM (Electrochemical Machining) : The reverse of electroplating, where the workpiece acts as an anode and material is removed by ions. CM (Chemical Machining) : Uses chemical etchants to selectively remove material, often for shallow cavities or weight reduction. | | Thermal Energy | Melting / Vaporization : A highly concentrated beam of heat energy melts or vaporizes the material. | LBM (Laser Beam Machining) : Uses a high-energy laser beam for cutting, drilling, and welding. EBM (Electron Beam Machining) : Uses a focused beam of high-velocity electrons, ideal for high-precision micro-machining. |
: Employs an ultrasonic transducer and abrasive slurry to achieve intricate shapes. Applications
Ideal for removing shallow layers from massive, weight-sensitive aerospace panels. Slide 8: Comparative Evaluation Matrix
Die and mould making, aerospace component manufacturing, and drilling deep micro-holes. Electrochemical Machining (ECM) Non Conventional Machining Process Ppt
Conventional cutting creates residual stress, burrs, and thermal distortion.
Present a summary table to give your audience a quick reference guide. Energy Source Material Removal Action Suitable Workpiece Surface Finish Mechanical Erosion by abrasive grains Brittle (Glass, Ceramics) EDM Melting and vaporization Conductive metals Good to Fair LBM Melting and vaporization Any material ECM Electrochemical Ion displacement Conductive metals Slide 9: Industry Applications
High temperatures melt or vaporise the workpiece material locally.
Brittle materials handle USM or AJM exceptionally well. processes, designed to be easily adaptable for a
Understanding the operational differences between these two methodologies is critical for process selection. Conventional Machining Non-Conventional Machining Physical contact occurs. No physical contact. Tool Hardness Tool must be harder than the workpiece. Tool hardness is irrelevant. Energy Source Mechanical energy (shear force). Thermal, chemical, electrical, or fluid energy. Material Removal Mechanism Plastic deformation and chip formation. Melting, vaporisation, ionic dissolution, or erosion. Tool Wear High tool wear due to friction. Minimal to no tool wear. Waste Production Large, macroscopic chips. Microscopic particles or chemical ions. Classification of Non-Conventional Machining Processes
For those seeking ready-to-use presentations, several online platforms offer high-quality slides. Many university resources, like those from institutions such as Muthayammal Engineering College and the Institute of Aeronautical Engineering, provide structured PowerPoint files covering entire syllabi on this topic.
The tool and workpiece rarely make physical contact, eliminating tool wear from friction.
Traditional machining (like turning or milling) relies on physical contact and tool hardness exceeding workpiece hardness. NCM is used when: AJM (Abrasive Jet Machining) : Uses a high-velocity
Slicing weight-reduction pockets into large aerospace wing panels (Chemical Milling).
EDM uses rapidly recurring electrical discharges (sparks) between an electrode (the "tool") and the conductive workpiece to remove material. The intense heat from the sparks melts and vaporizes a tiny amount of material from the workpiece. A dielectric fluid (like oil) is used to control the sparks and flush away debris, allowing for the precise creation of intricate shapes and deep holes in extremely hard materials.
Introduces abrasive particles into a high-pressure water stream to cut hard materials like metals and stone. 2. Electrochemical Energy Processes