Non Traditional Manufacturing Processes
MF30604
A K Nath
Lecture No.-1
Introduction to NTMP
Fabrication of large size domes Nano-Fabrication of Eiffel Tower
Fabrication of Micro-lens
3-D features inside transparent glass Exotic components of different materials
50-100 mm
60m square hole in Si Curved slot in SS
Deep penetration welding
Conventional Machining Processes
Milling
Drilling
Circular symmetry
Turning
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.
Why is the need of Modern Manufacturing Processes !
Challenges & Competition in Manufacturing Industries:
New Products - Better Performance, More Features, More Durable, Less Production
Time, Energy Efficient, Low cost,
Demand for Products with
✓ New exotic work materials: Improved mechanical, thermal, & chemical
properties
Super-alloys, toughened glass, 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; Quartz
Silicon wafer, Ceramic – Damage during machining
✓ Innovative designs, complex shapes, high precision & high surface quality
* Stringent design requirements * Micro- Nano Sizes
Micro-lenses
60m square hole in Si Curved slot in SS
Other requirements of the New Manufacturing Process
✓ Low machining cost
* Automated processing, Fast production
✓ Rapid change of Product design
* Elimination of Traditional tooling to reduce time & cost:
Rapid Manufacturing
✓ Less Temperature rise or residual stresses
Photochemical Machining Electro-Discharge Machining
Modern / Nonconventional Manufacturing processes employ
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 conventional 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----
Basic MMM / MMP Groups:
* Mechanical NTM Processes( Plastic deformation / Abrasive Erosion)
- Abrasive Jet Machining (AJM)
- Ultrasonic Machining (USM)
- Water Jet Machining (WJM)
- Abrasive Water Jet Machining (AWJM)
* Thermal NTM Processes
- Laser Beam Machining (LBM)
- Electron Beam Machining (EBM)
- Plasma Arc Machining (PAC)
- Electrical Discharge Machining (EDM)
* Kinetic Energy ( Atom by atom knocking)
- Ion beam * High Energy
Rate Forming
* Electrochemical NTM Processes
- Electrochemical Machining (ECM) * Physical &
- Electrochemical Grinding (ECG) Chemical
Vapour
* Chemical NTM Processes
Deposition for
- Chemical Machining (CHM)
thin coatings
- Thermo chemical Machining (TCM)
Course Outline by Topical Areas:
Introduction to Nontraditional Manufacturing Processes
Abrasive jet machining, Water jet machining, Abrasive Water Jet Machining,
Ultrasonic Machining: Basic process, Machine Design, Process parameters, Process
capability, Process modeling
Laser Beam Machining (LBM): Fundamentals of Materials Processing- (Laser
cutting, drilling, welding, surface modification surface hardening, cladding; marking,
micro-machining, laser forming, laser additive manufacturing)
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
High Energy Rate Forming (HERF)
Physical Vapour Deposition (PVD) & Chemical Vapour Deposition (CVD): Basic
processes, Different types of Machine Designs
Attributes of Non Traditional 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
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
