Smart Manufacturing

(ME505)

Introduction to Advanced Machining

Processes

By
Dr Vishal Jagota
vishal.jagota@chitkara.edu.in
+91 8683038218
Definition of Machining

“Machining involves the removal of

some material from the workpiece
(machining allowance) in order to
produce a specific geometry at a
definite degree of accuracy and
surface quality”

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Nontraditional Machining

• A machining process is called non-traditional if its material removal mechanism is

basically different than those in the traditional processes

• Processes that remove excess material by various techniques involving mechanical,

thermal, electrical or chemical energy or combinations of these energies.

• These processes do not use a sharp cutting tools as those need to be used for traditional
manufacturing processes.

• Also called advanced machining processes

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Nontraditional machining processes, also called advanced manufacturing processes, are employed
where traditional machining processes are not feasible, satisfactory or economical due to special
reasons as outlined below.

➢ Very hard fragile materials difficult to clamp for traditional machining

➢ When the workpiece is too flexible or slender

➢ When the shape of the part is too complex

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Advantages of Advanced Machining Processes

• Enhanced Precision: Advanced machining processes, such as electrical discharge

machining (EDM) and laser machining, offer high precision and accuracy,
allowing for the production of intricate and complex parts with tight tolerances.

• They can achieve dimensional accuracy in the sub-micron range, making them
suitable for applications that demand extreme precision.

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Advantages of Advanced Machining Processes

• Versatility in Material Selection: Advanced machining processes can effectively

machine a wide range of materials, including hard and difficult-to-machine
materials. Materials such as hardened steels, titanium alloys, ceramics,
composites, and heat-resistant alloys can be machined using processes like
abrasive water jet cutting, laser machining, and electrical discharge machining.

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Advantages of Advanced Machining Processes

• Improved Surface Finish: These processes can achieve superior surface finishes
compared to conventional machining. They can eliminate or minimize the
occurrence of burrs, tool marks, and surface imperfections, resulting in smoother
and more polished surfaces.

• This is particularly important in industries like aerospace, medical, and optics,

where high-quality surface finishes are critical.

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Advantages of Advanced Machining Processes

• Minimal Thermal Damage: Traditional machining methods often generate heat

during the cutting process, which can lead to thermal damage in the workpiece,
such as material distortion, residual stresses, and surface hardening.

• Advanced machining processes, like laser machining and water jet cutting, are
non-contact methods that generate minimal heat, reducing the risk of thermal
damage.

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Disadvantages of Advanced Machining Processes

• Cost: Advanced machining processes require specialized equipment, tooling, and

technologies, which are expensive to acquire, operate, and maintain.

• The initial investment and ongoing costs associated with advanced machining
processes is higher compared to traditional machining methods.

• Additionally, the need for skilled operators proficient in handling the advanced
equipment may also add to the overall cost.

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Disadvantages of Advanced Machining Processes

• Complex Setup and Programming: Advanced machining processes typically

involve complex setup procedures and programming requirements.

• The preparation and programming of the equipment requires specialized

knowledge and expertise.

• This can result in longer setup times and increased complexity in process planning
and optimization.

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Disadvantages of Advanced Machining Processes

• Limited Material Removal Rates: In some cases, advanced machining processes

may have relatively lower material removal rates compared to traditional
machining methods. Processes such as electrical discharge machining (EDM) and
laser machining can be slower in terms of material removal, which can impact
productivity in certain applications where high material removal rates are
essential.

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Disadvantages of Advanced Machining Processes

• Surface Integrity and Heat Affected Zone (HAZ): Certain advanced machining
processes, such as laser machining and electrical discharge machining, generate
heat during the machining process. This heat can lead to changes in the material's
microstructure, residual stresses, and potential heat-affected zones (HAZ) near the
machined surfaces.

• These effects can negatively impact the material's mechanical properties,

dimensional stability, and surface integrity.

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Disadvantages of Advanced Machining Processes

• Process-specific Requirements: Different advanced machining processes may

have specific requirements and limitations. For example, for electrical discharge
machining (EDM) dielectric fluids and electrode materials are required.

• The process-specific requirements can add complexity and additional

considerations to the machining process.

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Disadvantages of Advanced Machining Processes

• Limited Geometric Complexity: While advanced machining processes excel in

producing complex shapes and intricate features, there may still be limitations in
terms of the geometries that can be achieved. Certain designs with extremely tight
tolerances, deep cavities, or intricate internal features may present challenges in
terms of accessibility and tooling limitations.

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Applications of Advanced Machining Processes

• Medical Industry: Advanced machining processes are widely used in the medical
field for the fabrication of surgical instruments, implants, and medical devices.

• They enable the production of intricate and custom-designed components with

high precision and excellent surface finishes, meeting the stringent requirements
of the medical industry.

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Applications of Advanced Machining Processes

• Aerospace Industry: The aerospace industry extensively utilizes advanced

machining processes for manufacturing components with complex shapes, critical
tolerances, and high precision.

• These processes are employed in the production of turbine blades, engine

components, aerospace structures, and composite materials.

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Applications of Advanced Machining Processes

• Electronics Industry: Advanced machining processes play a vital role in the

electronics industry for the production of printed circuit boards (PCBs),
microelectromechanical systems (MEMS), and semiconductor devices.

• They are used for precise material removal, micro-drilling, and micro-machining
of electronic components.

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Applications of Advanced Machining Processes

• Automotive Industry: Advanced machining processes find application in the

automotive sector for manufacturing engine components, transmission parts, fuel
injectors, and complex automotive body parts.

• These processes help in achieving high dimensional accuracy, improved surface

finish, and efficient material removal in the production of automotive components.

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Applications of Advanced Machining Processes

• Mold and Die Industry: Advanced machining processes are extensively

employed in the mold and die industry for the production of complex molds, dies,
and tooling.

• Processes like EDM and high-speed machining enable the creation of intricate
mold cavities with precise details, allowing for the production of high-quality
plastic and metal parts.

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Comparison with traditional manufacturing
processes
• Precision and Accuracy: Advanced machining processes offer higher precision
and accuracy compared to traditional manufacturing processes. They can achieve
finer detail, tighter tolerances, and better surface finishes. For applications that
require intricate geometries or high-precision components, advanced machining
processes provide distinct advantages. Traditional machining processes, while
reliable, may struggle to achieve the same level of precision and surface quality.

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Comparison with traditional manufacturing
processes
• Complex Geometries: Advanced machining processes excel at machining
complex shapes and intricate features. They offer greater flexibility in producing
parts with intricate internal structures, undercuts, and complex contours.

• Traditional manufacturing processes, while capable of producing complex parts to

some extent, may require multiple setups, additional operations, or specialized
tooling to achieve the same level of complexity.

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Comparison with traditional manufacturing
processes
• Heat Generation and Thermal Effects: Traditional machining processes often
generate significant heat during cutting or material removal, which can lead to
thermal damage, such as residual stresses or dimensional inaccuracies. Advanced
machining processes, by contrast, may generate less heat or localize the heat-
affected zone (HAZ), minimizing the potential negative thermal effects on the
workpiece. This can be particularly beneficial when machining heat-sensitive
materials or intricate components.

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Comparison with traditional manufacturing
processes
• Process Complexity and Setup: Advanced machining processes can be more
complex to set up and require specialized knowledge and skills.

• The programming, parameter selection, and setup procedures for advanced

processes can be more involved compared to traditional methods.

• Traditional manufacturing processes generally have a simpler setup, making them

more accessible and familiar to operators without extensive training in advanced
technologies.

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Comparison with traditional manufacturing
processes
• Cost Considerations: Traditional manufacturing processes often have lower
initial costs, as they typically involve conventional machines and tooling that are
widely available.

• Advanced machining processes may require specialized equipment, tooling, or

technologies, which can result in higher initial investment costs. However, it is
important to consider the long-term benefits and cost savings that advanced
processes can offer in terms of improved efficiency, reduced scrap rates, and
enhanced product quality.

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