Non Conventional Machining Process Ppt Instant

Pure WJM uses an ultra-high-pressure stream of water (up to 60,000 PSI or higher) to slice soft materials. AWJM mixes abrasive particles into the water jet to cut through dense, hard materials.

: Use chemical reactions or electrolysis.

| | Conventional | Non-Conventional | |---------------|------------------|----------------------| | Tool contact | Yes | No (or minimal) | | Material hardness limit | Soft to medium | Any hardness | | Heat generation | High | Low to none (except thermal methods) | | Surface finish | Moderate | Good to excellent | | Complexity | Simple shapes | Intricate, micro features | | Cost | Low to moderate | High equipment cost | Non Conventional Machining Process Ppt

: Employs a vibrating tool and abrasive slurry .

USM uses a magnetostrictive transducer to convert high-frequency electrical energy (20 kHz) into mechanical vibrations. An abrasive slurry (Boron Carbide or Alumina) is pumped between the vibrating tool and workpiece. The abrasive particles impact the surface, causing micro-cracking and fracture. USM is the only viable method for machining non-conductive, brittle materials like glass, ferrite, and piezo-ceramics. Key drawback: Material Removal Rate (MRR) drops below 2 mm³/min for hard materials. Pure WJM uses an ultra-high-pressure stream of water

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Non-conventional (or Unconventional) machining refers to a group of processes that remove excess material through various techniques involving mechanical, thermal, electrical, or chemical energy—or a combination of these. A plasma channel forms

EDM operates on the thermoelectric phenomenon. When a voltage (50-400 V) is applied across a small gap (0.01-0.5 mm) between an electrode (copper/graphite) and a conductive workpiece in a dielectric fluid, the dielectric breaks down. A plasma channel forms, reaching 8000-12000°C, melting and vaporizing material. The dielectric flushes away debris. EDM is specifically suited for mold and die making. However, the rapid heating/cooling creates a "recast layer" (2-10 µm thick) containing micro-cracks and tensile residual stresses, reducing fatigue life by up to 40% in critical components.

They can create intricate shapes, deep holes, and delicate parts that would snap under the pressure of a traditional drill bit. 2. The Big Four Categories

Examples of these innovative hybrid processes include: