Non Conventional Machining Process Ppt · Real

Title Slide (Topic Name, Presenter Name, Institution)

Components for electronics and medical implants require micro-machining capabilities that traditional tools cannot physically scale down to achieve. Key Differences: Conventional vs. Non-Conventional Conventional Machining Non-Conventional Machining Tool Material Must be harder than the workpiece Hardness is irrelevant; relies on energy forms Tool-Workpiece Contact Direct physical contact No direct physical contact (gap maintained) Mechanism of Removal Plastic deformation / Shear chip formation Melting, vaporization, ionic dissolution, erosion Material Waste High (large chips produced) Low (microscopic debris or sludge) Surface Finish Limited by tool geometry and vibration Extremely high precision and surface finish Noise & Pollution High noise and physical scrap Silent operations; handles chemical/sludge waste 2. Classification of Non-Conventional Machining Processes

: Uses a focused, high-intensity laser beam .

One of the most common slides in any "Non Conventional Machining Process PPT" is the classification chart. These processes are broadly categorized by the primary source of energy used for material removal.

Visual: A broken high-speed steel drill bit snapped inside a metal block, with sparks flying (or an image of a worn-out tool). Story: "Your first instinct is to use traditional methods—a lathe or a milling machine. You clamp the titanium block and bring the tool closer. The spindle spins at thousands of RPM. But the moment the tool touches the metal, disaster strikes. Because Titanium is so tough, the tool generates immense heat. It dulls instantly. The vibrations tear the surface apart. You try to drill a simple hole, and the drill bit snaps. You realize the fundamental limitation: Conventional machining relies on physical contact and mechanical force. The tool must be harder than the workpiece. But what happens when the workpiece is the hardest thing on earth? You are stuck. You cannot build the engine." Non Conventional Machining Process Ppt

DC power supply, dielectric system, servo control mechanism (to maintain spark gap), tool electrode, and workpiece.

– Micro-machining and hybrid manufacturing setups. 8. Summary of Advantages and Disadvantages Advantages

A highly concentrated, monochromatic laser beam focuses onto the workpiece. The intense energy density instantly melts and vaporizes the material.

EBM uses a highly focused stream of high-velocity electrons in a vacuum chamber to heat and vaporize material. The kinetic energy of the electrons is converted into intense heat upon impact. EBM is capable of extremely fine cuts and is often used in aerospace and electronics for high-precision machining and drilling of tiny holes, though its requirement for a vacuum is a significant limitation. Visual: A broken high-speed steel drill bit snapped

Machines high-strength alloys and fragile parts without damage. High accuracy and surface integrity. Enables micro-machining. Limitations Higher initial equipment cost.

Micro-hole drilling, sheet metal cutting, engraving across metals, polymers, and ceramics.

: Uses high-pressure water streams to cut .

To help tailor this presentation or article for your specific project, tell me: tell me: Extreme precision

Extreme precision, but leaves a small heat-affected zone (HAZ) on the edges. Electron Beam Machining (EBM)

Uses electrical sparks between an electrode and the workpiece submerged in a dielectric fluid.

A nickel-based superalloy turbine blade requires 50-80 angled cooling holes (<0.5 mm diameter). Conventional drilling fails due to tool breakage. Laser Beam Machining (LBM) drills holes in 0.2 seconds per hole but leaves a recast layer requiring secondary polishing. EDM provides a cleaner hole but takes 15 seconds per hole. The industry trend is "Laser roughing + ECM finishing."