Non Conventional Machining Process Ppt Updated Link Jun 2026

Oscillator, Transducer (Magnetostrictive or Piezoelectric), Concentrator/Horn, Abrasive Slurry system.

A transducer converts electrical energy into mechanical vibrations at ultrasonic frequencies (typically 20 kHz to 40 kHz). This drives a tool tip against an abrasive slurry (such as boron carbide or silicon carbide) pumped into the machining gap. The microscopic hammering of the abrasive grains fractures and erodes brittle workpieces.

| Process | Material Removal Mechanism | Key Applications | Key Advantages | Key Limitations | Typical MRR | | :--- | :--- | :--- | :--- | :--- | :--- | | | Thermal (spark erosion) | Die/mold making, complex cavities, small holes, aerospace components | High accuracy, complex shapes, machines any conductive material regardless of hardness | Low MRR, tool wear, heat-affected zone (recast layer), high energy consumption | 2–400 mm³/min | | ECM | Electrochemical (anodic dissolution) | Turbine blades, surgical implants, deburring, large cavities | No tool wear, stress-free, high surface finish, machines hard conductive alloys | High tooling cost, difficult to control stray cutting, electrolyte disposal issues | 1500–10,000 mm³/min | | USM | Mechanical (abrasive erosion) | Machining hard, brittle materials like glass, ceramics, and carbides | No thermal damage, non-thermal, machines non-conductive materials, good hole quality | Low MRR, high tool wear, limited to small features, abrasive slurry disposal | 0.05–120 mm³/min | | LBM | Thermal (melting/vaporization) | High-precision cutting, micro-drilling, marking, welding | High speed, high precision, non-contact, extreme flexibility (various materials) | High equipment cost, heat-affected zone (HAZ), thermal process, limited thickness for quality cuts | 10–5000 mm³/min | | AWJM | Mechanical (abrasive erosion) | Cutting thick composites, metals, stone, heat-sensitive materials | No thermal damage (no HAZ), no tool wear, very versatile, environmentally friendly | Nozzle wear, lower precision than EDM/laser, noisy operation, issues with depth regulation | 20–7000 mm³/min | | EBM | Thermal (vaporization) | High-precision micro-drilling, welding aerospace alloys, semiconductor manufacturing | Extremely high power density (10⁹ W/cm²), capable of very fine features, high welding depth-to-width ratio (50:1) | Requires high vacuum (costly), X-ray emission risk, limited to conductive materials | 0.1–400 mm³/min | | PAM | Thermal (melting) | High-speed cutting of thick plates (steel, aluminum), weld preparation, bevel cutting | Very high cutting speed for thick sections, low equipment cost compared to lasers | Significant HAZ and thermal distortion, limited to conductive materials, poor edge quality | 1000–30,000 mm³/min | | CHM | Chemical (dissolution) | Photochemical milling of thin sheets, production of shallow cavities, etching for electronics | Low equipment and tooling cost, no thermal/mechanical stress, good for low production runs | Slow process, limited to shallow removal (0.0025–0.1 mm/min), hazardous chemical handling | Low (area-dependent) |

Employs a high-velocity jet of ionized gas (plasma) to cut thick metal plates. C. Chemical and Electrochemical Processes non conventional machining process ppt updated

If conductive, choose EDM, WEDM, or ECM. If non-conductive, choose USM, LBM, or AJM.

Selecting the correct process depends on specific design and material requirements. Use this matrix to guide presentation slides on process selection.

Unlike traditional methods (turning, drilling, milling) that rely on mechanical energy and direct physical contact with a harder cutting tool, NCM uses thermal, chemical, electrical, or light energy to remove material. The microscopic hammering of the abrasive grains fractures

[Non-Conventional Machining] | +------------------------+------------------------+ | | | [Mechanical] [Thermal/Thermoelectric] [Chemical & Electrochemical] |- USM (Ultrasonic) |- EDM (Spark Erosion) |- CHM (Chemical) |- AJM (Abrasive Jet) |- LBM (Laser Beam) |- ECM (Electrochemical) |- WJM (Water Jet) |- EBM (Electron Beam) |- ECG (ECG Grinding) |- AWJM (Abrasive Water) |- PAM (Plasma Arc) A. Mechanical Energy Processes

Updated color scheme (blue/gray with orange highlights) is professional.

– Graphical breakdown of Mechanical, Thermal, and Chemical categories. or complex materials used in aerospace

Non-conventional processes are classified based on the primary source of energy used for material removal. Mechanical Energy Processes

Traditional methods struggle with intricate shapes, micro-holes, or very thin/fragile components. Precision:

The Ultimate Guide to Non-Conventional Machining Processes (Updated PPT Download)

Sheet metal cutting, micro-drilling cooling holes in turbine blades, and engraving. 4. Process Selection Criteria

. These processes have become essential in 2025–2026 for handling extremely hard, brittle, or complex materials used in aerospace, medical, and nuclear industries. Classification of NCM Processes