A high-speed gas stream carries abrasive particles to erode the surface [3].
Advanced & Non-Conventional Machining Processes: An Overview
Shapes materials regardless of their hardness or brittleness.
(Hybrid processes, Micro-machining, AI-driven spark monitoring).
Integration of sensors and artificial intelligence to monitor tool wear and adjust parameters in real-time, improving efficiency and accuracy. non conventional machining process ppt updated
Process selection depends entirely on material properties (conductivity, brittleness), production volume, budget, and required surface integrity.
| Process | Material Removal Rate (mm³/min) | Surface Finish (Ra, µm) | Tool Wear Ratio | Typical Tolerance (mm) | "Updated" Note | | :--- | :--- | :--- | :--- | :--- | :--- | | | 300 - 600 | 0.1 - 5.0 | 0.1 - 5% (Electrode) | ±0.005 | Dry EDM reduces environmental cost by 90% | | LBM (Femtosecond) | 10 - 100 | 0.05 - 1.0 | Zero contact (No tool) | ±0.002 | Zero HAZ – critical for medical implants | | ECM | 500 - 1500 | 0.05 - 0.8 | 0% (Cathode lasts) | ±0.01 | Pulsed ECM doubles MRR | | USM | 50 - 200 | 0.1 - 0.5 | High (Abrasive slurry) | ±0.02 | RUM reduces cracking in glass | | AJM | 10 - 50 | 0.5 - 1.5 | High (Nozzle wear) | ±0.05 | Nano-abrasives enable die cutting |
High-velocity stream of gas (air or nitrogen) loaded with fine abrasive particles focused through a nozzle.
NCM methods are primarily classified by the type of energy used for material removal: Energy Category Common Processes Mechanism of Material Removal Mechanical AJM, USM, WJM, AWJM Erosion or abrasion using high-velocity particles/fluids. EDM, LBM, EBM, PAM Melting and vaporization through high-intensity heat. Electrochemical Controlled anodic dissolution at the atomic level. Chemical etching using a suitable etchant. Key Non-Conventional Processes 02 - Non Traditional Machining Processes.ppt - Course Hero A high-speed gas stream carries abrasive particles to
As of 2026, these are the most widely adopted NCM technologies:
| | Primary Energy Form | Key Processes | |---|---|---| | Mechanical Processes | Mechanical (kinetic) energy, high-frequency vibrations or abrasive jet impact | USM, AJM, WJM, AWJM, AFM, AWJC | | Electrochemical Processes | Electrochemical dissolution via electrolyte | ECM, ECG, ECD | | Thermal (Electro-Thermal) Processes | Thermal (localized heating, melting & evaporation) | EDM, WEDM, PAM, EBM, LBM | | Chemical Processes | Chemical reaction via etchant | CHM, PCM |
Spark erosion. The tool and workpiece never touch; a spark gap of is maintained.
Achieves micro- and nano-level surface finishes and tolerances. NCM methods are primarily classified by the type
An updated presentation must include a data-driven comparison table. Here is the 2025 benchmark data:
Soft, non-metallic materials like rubber, plastics, foam, leather, and food products. It produces zero thermal distortion. Abrasive Water Jet Machining (AWJM)
A clean layout featuring sustainability icons (recycling, eco-friendly fluids). Modern Sustainability Shift
As manufacturing moves toward smarter, stronger, and lighter materials—such as titanium alloys, superalloys, ceramics, and composites—traditional machining (turning, milling, drilling) faces significant limitations. Non-Conventional Machining (NCM) processes, often termed Advanced Manufacturing Processes (AMPs), have become essential to meet these industry demands.