Non Conventional Machining Process Ppt Updated !!top!! <RECOMMENDED · 2025>

Presentation Title: Non-Conventional Machining Processes (Updated)

Advantages:
- Can machine any conductive material regardless of hardness.
- No mechanical forces (good for slender workpieces).
- Complex shapes are easy to machine.
Limitations:
- Only for electrically conductive materials.
- Slow MRR compared to conventional machining.
- Surface finish can be damaged by thermal stress (recast layer).
- Electrode wear.

What is Machining? The process of removing excess material from a workpiece to achieve the desired shape and finish.
The Limitation of Conventional Machining:
- Requires a tool harder than the workpiece.
- Generates significant heat and noise.
- Inefficient for very hard or brittle materials (e.g., Titanium, Ceramics, Composites).
The Solution: Non-Conventional Machining.
- Defined as material removal processes that do not rely on direct contact between a cutting tool and the workpiece.
- Utilizes energy forms: Mechanical, Thermal, Chemical, and Electrochemical.

Principle: A high-velocity jet of pure water (up to 4000 bar) cuts soft materials.
Abrasive Water Jet (AWJM): Water mixed with abrasives for cutting harder materials (steel, stone).
Applications: Cutting foils, plastics, paper, leather, food products, and metals (AWJM).
Advantages: No heat affected zone (HAZ), no dust, high cutting speed for soft materials.
Limitations: High initial cost, requires high-pressure sealing maintenance.

Hybrid Machining: Combining two processes to overcome limitations.
- EDG (Electro-chemical Discharge Grinding): Combines ECM and EDM.
- Ultrasonic Assisted EDM: Improves flushing and MRR.
Automation & Industry 4.0:
- Integration of AI for predicting tool wear in EDM.
- Adaptive control systems for Wire EDM.
Green Machining:
- Dry EDM (using gas as dielectric) to reduce waste.
- Bio-degradable electrolytes in ECM.