Non traditional technologies

BACHELOR OF ENGINEERING
MANUFACTURING TECHNOLOGIES
NON-TRADITIONAL
TECHNOLOGIES
by Endika Gandarias

2by Endika Gandarias
Dr. ENDIKA GANDARIAS MINTEGI
Mechanical and Manufacturing department
Mondragon Unibertsitatea - www.mondragon.edu
(Basque Country)
www.linkedin.com/in/endika-gandarias-mintegi-91174653
Further presentations: www.symbaloo.com/mix/manufacturingtechnology

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CONTENTS
 BIBLIOGRAPHY
 INTRODUCTION
 NON-TRADITIONAL TECHNOLOGIES:
 Ultrasonic Machining (USM)
 Jet Machining (AJM / WJM / AWJM)
 Chemical Machining (CM)
 Electro-Chemical Machining (ECM)
 Plasma Arc Machining (PAM)
 Laser Beam Machining (LBM)
 Electro Discharge Machining (EDM)
 Ion Beam Machining (IBM)
 Electron Beam Machining (EBM)
 SUMMARY
 GLOSSARY
by Endika Gandarias

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BIBLIOGRAPHY
BIBLIOGRAPHY
by Endika Gandarias

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The author would like to thank all the bibliographic references and videos that
have contributed to the elaboration of these presentations.
For bibliographic references, please refer to:
• http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)
• http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)
For videos, please refer to:
• www.symbaloo.com/mix/manufacturingtechnology
BIBLIOGRAPHY
by Endika Gandarias

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INTRODUCTION
INTRODUCTION
by Endika Gandarias

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INTRODUCTION
• Non-traditional technologies refer to a group of processes that remove material NOT using a sharp
cutting tool like in conventional machining. In contrast, non-traditional technologies use other type of
energies to remove material:
IMPORTANCE OF NON-TRADITIONAL TECHNOLOGIES
• To machine newly developed difficult to cut materials: high strength, high hardness and high toughness.
• When workpiece is too flexible or slender to support conventional cutting/grinding forces.
• To machine complex part geometries which are difficult or impossible to machine by traditional methods.
• To avoid surface damage, such as stresses, created in conventional processes.
MECHANICAL
ELECTRO-CHEMICAL
THERMO-ELECTRICAL
CHEMICAL
by Endika Gandarias

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INTRODUCTION
by Endika Gandarias
Low
HAZ
No
HAZ
HAZ
HAZ: Heat Affected Zone

9by Endika Gandarias
1980, Machining data Handbook
INTRODUCTION

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NON-TRADITIONAL
TECHNOLOGIES
NON-TRADITIONAL TECHNOLOGIES
by Endika Gandarias

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ULTRASONIC MACHINING
(USM)
Dimensional tolerance: ± 0,0025mm
Surface finish: Ra ~ 0,1-0,8µm
by Endika Gandarias
THERMO-ELECTRICALMECHANICAL CHEMICAL ELECTRO-CHEMICAL
ULTRASONIC MACHINING (USM)

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 A vibrating tool oscillates at ultrasonic frequencies (f=20-30kHz & A=15-50µm).
 The tool never contacts the workpiece, and the abrasive slurry flows freely between the tool and
the workpiece (20-50 µm gap).
 Abrasive grains (100-800 grit size) – SiC, Al2O3, CBN, diamond
 Abrasive slurry – abrasive grains (20-60%) + usually water
 PRO:
 Low HAZ.
 Suitable for hard and brittle non-conductive materials: ceramics, glass or carbides
(otherwise EDM or ECM is used).
 Holes and cavities with various shapes can be produced.
 Excellent surface finish.
 CON:
 Low MRR (Material Removal Rate).
 Small depth of holes and cavities can be produced.
 Tool wear rate is fast (tool is usually softer than the
workpiece as it needs to be tough: soft steel or
stainless steel).
by Endika Gandarias
VIDEOVIDEOVIDEO

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Types of parts made by this process
by Endika Gandarias

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JET MACHINING
(AJM / WJM / AWJM)
AJM:
Surface finish: Ra ~ 0,15-1,5 µm
WJM / AWJM:
Surface finish: Ra ~ 1,6-6.3 µm
by Endika Gandarias
JET MACHINING (AJM / WJM / AWJM)

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Abrasive Jet Machining (AJM)
 It is an abrasive blasting machining process that uses abrasives (SiC, Al2O3 or glass bead of
Ø15-40µm) propelled by a high velocity (150-300m/s) gas (air or inert gas) to erode material from the
workpiece.
 It is mainly used for finishing operations: deburring, cleaning and polishing (cutting thin plates too).
 PRO:
 Low HAZ.
 It can be easily automated for high production volumes.
 Ability to machine hard and brittle materials.
 Good surface finish.
 CON:
 Low MRR.
 Tends to round off sharp edges
and it produces tapered cut.
by Endika Gandarias
BLASTING
VIDEO

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Water Jet Machining (WJM)
 It uses a fine, high pressure, high velocity (540-1400m/s) stream of water (~ Ø0.1-0.4mm) directed at
the work surface to cause cutting of the workpiece.
 Cutting of all non-metallic materials (food, composites, plastics, fabrics, rubber, wood, paper,…).
 PRO:
 Low HAZ.
 It can be easily automated.
 Ability to machine flexible materials.
 Burr produced is minimum.
 CON:
 Limited number of materials can be cut economically.
 It produces tapered cut.
 Noisy.
by Endika Gandarias
VIDEOVIDEO

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Abrasive Water Jet Machining (AWJM)
 The water jet contains abrasive particles (quartz sand, SiC or Al2O3 at 60-120 grit size, up to 900
m/s) to increase the material removal rate and enable cutting of thick and hard materials.
 Cutting of metallic and non-metallic materials (marble, granite, stone, composites, wood, titanium
alloys,…).
 Same PROs and CONs as WJM.
by Endika Gandarias
VIDEO

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Various non-metallic parts (WJM) 5-axis waterjet cutting head (WJM)
Cutting food (WJM) Marble waterjet cutting
(AWJM)
by Endika Gandarias
VIDEO

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CHEMICAL MACHINING
(CM)
CHEMICAL
by Endika Gandarias
THERMO-ELECTRICALMECHANICAL ELECTRO-CHEMICAL
CHEMICAL MACHINING (CM)

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 This process is also called etching.
 The metal is removed by the chemical attack of an acidic or alkaline etchant (FeCl3, H2SO4,
HNO3). The portion of workpiece where no material is to be removed is masked (maskant: polymer
or rubber) before chemical etching. The process is usually carried out at high temperature.
 Steps: Cleaning  masking  etching  demasking
 PRO:
 No HAZ and no forces.
 It is not workpiece hardness dependent.
 Complicated shapes can be produced.
 Good surface quality.
 Simple to implement, low tooling and equipment cost.
 Suitable for low production runs.
 No burr formation.
 CON:
 Very low MRR, limited to thin layers.
 Difficult to get sharp corners.
 Low dimensional accuracy.
by Endika Gandarias
CHEMICAL THERMO-ELECTRICALMECHANICAL ELECTRO-CHEMICAL
VIDEOVIDEOVIDEO

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Missile skin-panel section contoured by
chemical milling to improve the stiffness-to-
weight ratio of the part.
Weight reduction of space-launch vehicles
by the chemical milling of aluminum-alloy
plates.
by Endika Gandarias
CHEMICAL THERMO-ELECTRICALMECHANICAL ELECTRO-CHEMICAL

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ELECTRO-CHEMICAL
MACHINING
(ECM)
ELECTRO-CHEMICAL
by Endika Gandarias
THERMO-ELECTRICALCHEMICALMECHANICAL
ELECTRO-CHEMICAL MACHINING (ECM)

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 Electrochemical machining removes material from an electrically conductive workpiece by anodic
dissolution. Workpiece geometry is obtained by a formed electrode tool which is in close proximity
but separate.
 An electrolyte acts as a current carrier, and high electrolyte movement in the tool-workpiece gap
washes metal ions away from the workpiece (anode) before they are deposited on the tool (cathode).
 Tool – generally made of bronze, copper, brass or stainless steel.
 Electrolyte – salt solutions in water.
 Power – DC supply 5-25V & 1000A.
 PRO:
 High MRR
 No HAZ & no mechanical distortion.
 There is almost no tool wear.
 Complex shapes with deep cavities.
 Burr free surface.
 CON:
 Workpiece electrically conductive.
 Expensive tooling and equipment.
 High power consumption.
by Endika Gandarias
ELECTRO-CHEMICAL THERMO-ELECTRICALCHEMICALMECHANICAL
VIDEOVIDEOVIDEO

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by Endika Gandarias
ELECTRO-CHEMICAL THERMO-ELECTRICALCHEMICALMECHANICAL
Its industrial application has been extended to:
• ECM machining
• ECM drilling
• ECM deburring
• ECM grinding
• ECM polishing
VIDEO
VIDEO

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PLASMA ARC MACHINING
(PAM)
Dimensional tolerance: ± 1.3mm
by Endika Gandarias
THERMO-ELECTRICALMECHANICAL ELECTRO-CHEMICALCHEMICAL
PLASMA ARC MACHINING (PAM)

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 A plasma is a ionized gas typically formed when heating the gas at high temperatures (>5000ºC).
Plasma state: Molecules are separated into atoms, and atoms are disaggregated into free electrons
and positive atom nucleus.
 It uses a high velocity jet of high temperature gas (Ar, N, H, He or mixtures of them) called
plasma that melts the metal and then removes the molten material to form a kerf.
 The electrode (W) and nozzle of the gun create a strong electric arc  gases collide the arc and
become into plasma.
 It is used to cut flat metal sheets and plates and it can
be used manually or by CNC.
 PRO:
 Highest MRR among non-traditional processes.
 Very hard and brittle metals can be machined.
 CON:
 Relatively large HAZ.
 Generally used for conductive materials (Plasma is
highly conductive).
 High cost equipment.
 Safety precautions are needed.
 Rough surface finish.
by Endika Gandarias
VIDEO

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by Endika Gandarias
VIDEO

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LASER BEAM MACHINING
(LBM)
by Endika Gandarias
LASER BEAM MACHINING (LBM)

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 LASER stands for Light Amplification by Stimulated Emission of Radiation.
 It uses the light energy from a laser to remove material by vaporization and ablation. Laser
beam melts the material by focusing a coherent beam of monochromatic light on the workpiece.
 Energy of the coherent light is concentrated not only optically, but also in terms of time.
The type of laser used in LBM is typically the CO2 gas laser.
 It is used to perform cutting, drilling, slotting or scribing.
 PRO:
 Unlimited range of materials: high hardness metals,
ceramics, glass, rubber, wood, cloth, food,…
 Does not require a vacuum.
 No tool wear.
 Easy to be automatized.
 CON:
 Low MRR.
 HAZ exists.
 High reflectivity materials (mirror) may be a problem.
 Expensive equipment.
 High energy consumption.
 It produces tapered cut.
by Endika Gandarias
VIDEOVIDEO

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Sheet metal cutting
by Endika Gandarias
PHB stent
Coronary Stent
Tube cutting VIDEO
VIDEO

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ELECTRICAL DISCHARGE
MACHINING
(EDM)
Dimensional tolerance: ± 0.025mm
by Endika Gandarias
ELECTRICAL DISCHARGE MACHINING (EDM)

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 The workpiece is removed by a series of sparks that cause localized melting and
evaporation of the material in the presence of a dielectric fluid.
 The workpiece is typically submerged in a dielectric bath of deionized water or oil.
by Endika Gandarias
VIDEO

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 A formed electrode tool produces the shape of the workpiece.
 Electrode – copper, tungsten, graphite or brass.
 PRO:
 It is one of the most widely used non-traditional processes.
 Complex geometries can be produced.
 CON:
 Low MRR.
 HAZ exists.
 Workpiece needs to be electrically conductive.
 Not capable to produce sharp corners.
 Tool wear affects dimensional accuracy.
Sinking EDM
by Endika Gandarias
VIDEO

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Wire EDM
 It uses a small diameter wire (Ø0,08-0,3mm) to cut a narrow kerf in the work.
 Wire – brass, copper, tungsten or molybdenum
 PRO:
 It is one of the most widely used non-traditional processes.
 It is well-suited to produce: gears, dies, cams,…
 CON:
 HAZ exists.
 Workpiece needs to be electrically
conductive.
by Endika Gandarias
VIDEO VIDEO

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by Endika Gandarias
Sinking EDM dieWire EDM parts
Sinking EDM:
screw thread
Sinking EDM:
cavities produced by
shaped electrodes
Sinking EDM:
fuel injection nozzle

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ELECTRON BEAM
MACHINING
(EBM)
Surface finish: Ra ~ 0,2-6,3µm
by Endika Gandarias
ELECTRON BEAM MACHINING (EBM)

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 It is a metal removal process that uses a high velocity focused stream of electrons (Ø~25µm).
 Electrons are created when high voltage is applied to a Wolframium filament  Accelerated by a
strong electric field (200.000km/s)  Focused by magnetic fields  Kinetic energy of the electrons is
transformed into thermal energy which melts and vaporizes the material.
 Vacuum chamber is necessary to avoid electron-air molecules collisions.
 It is used for drilling small holes, cutting, engraving, heat treatments, and improving surface roughness.
 PRO:
 Works on any material.
 Very small holes and slots can be machined
 No tool wear.
 CON:
 Low MRR.
 HAZ exists.
 Vacuum requirements limit part size.
by Endika Gandarias
VIDEO

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EBM in a vacuum
EBM in ambient air
by Endika Gandarias
Surface roughness improvement
Material: 316L SS
Hole: Ø~0,1mm
Thickness: ~1,5mm
VIDEO
VIDEO

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ION BEAM MACHINING
(IBM)
THERMO-ELECTRICAL
Dimensional tolerance: ± ??mm
Surface finish: Ra ~ <0.0001 µm
by Endika Gandarias
MECHANICAL ELECTRO-CHEMICALCHEMICAL
ION BEAM MACHINING (IBM)

40
 This process is also called Focused Ion Beam (FIB).
 A stream of charged atoms (ions) of an inert gas (Ar, He, Ga) is accelerated in a vacuum
chamber by electrical means and directed toward the workpiece to remove (or add) atoms.
When an atom strikes a cluster of atoms on the workpiece, it dislodges between 0.1 and 10 atoms
from the workpiece material. Spot size Ø~2-20nm
 Electrons are created when high voltage is applied to a Wolframium filament (high temperature) 
 Accelerated by a strong electric field  those interact with inert gas atoms to produce ions:
Ar + e− → Ar+ + 2e-
 It is used in micro/nanofabrication for smoothing of laser mirrors, polishing optical & shaping
surfaces,…
 PRO:
 Capable of modifying any material at
micro/nano scale.
 CON:
 Low MRR.
 HAZ exists (< 1 μm).
 Vacuum chamber is required.
 High cost equipment.
by Endika Gandarias
VIDEO
VIDEO

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Photonics
by Endika Gandarias
VIDEO

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SUMMARY
SUMMARY
by Endika Gandarias

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SUMMARY
by Endika Gandarias

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SUMMARY
by Endika Gandarias

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SUMMARY
by Endika Gandarias

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GLOSSARY
GLOSSARY
by Endika Gandarias

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GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Ablation Ablación Ablazio
Bead Abalorio Beira ale
Beam Haz Sorta
Blasting Chorreado Jariaketa
Brass Latón Letoia
Breakdown Ruptura Haustura
Brittle Frágil Hauskor
Bubble Burbuja Burbuila
Burr Rebaba Bizar
Cam Leva Espeka
Cardboard Cartón Kartoi
Chamber Cámara Ganbera
Cladding Aporte Aportazio
Close Cerca Gertu
Cloth Tela Oihal
Cluster Grupo Multzo
Coating Recubrimiento Estaldura
Coil Bobina Bobina
Collide Chocar Talka egin
Conductive Conductor Eroale
Copper Cobre Kobre
Debri Desecho Hondakin
Deburring Desbarbado Bizar kentze
Die Molde Molde
Dielectric Dieléctrico / No conductor Dielektriko / Ez eroale
Disaggregated Disgregado Sakabanatuta
Dislodge Dislocar Dislokatu
Drain Desagüe Hustubide

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GLOSSARY
by Endika Gandarias
Drilling Taladrado Zulaketa
Electro discharge machining Mecanizado por electroerosión Elektrohigadura bidezko mekanizazio
Electron Beam Machining Mecanizado por haz de electrones Elektroi sorta bidezko mekanizazio
Engraving Grabado Grabazio
Etchant Atacante Erasotzaile
Etching Ataque químico Eraso kimiko
Exhaust Campana de humos Kanpai
Fabric Tela Ohial
Fair Justo Justu
FeCl3 Cloruro de hierro Burdin kloruro
Focal length Longitud / Distancia focal Foku distantzia
Focus Enfocar Enfokatu
Gap Hueco Hutsune
Gear Engrane Engranai
Glass Vidrio Beira
Glazing Vidriado Beiratze
Grain Grano Ale
Grid Rejilla Bursin sare / Sareta
Grit Grano abrasivo Ale urratzaile
Gun Pistola Pistola
H2SO4 Ácido sulfúrico Azido sulfuriko
Hardening Temple Tenple
Hardness Dureza Gogortasuna
Heat Calor Bero
Heating Calentador Berogailu
HNO3 Ácido nítrico Azido nitriko
Insulating Aislante Isolatzaile
Ion beam machining Mecanizado por haz de iones Ioi sorta bidezko mekanizazio

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GLOSSARY
by Endika Gandarias
Jet machining Mecanizado por chorro Zurrusta bidezko mekanizazio
Kerf Canal de corte Mozte bide
Leek Puerro Porru
Len Lente Lente
Machining Mecanizado Mekanizazio
Marble Mármol Marmol
Maskant Enmascarante Estalki / Maskaratzaile
Melt Derretir Urtze
Mirror Espejo Ispilu
Molten Derretido Urturiko
Non traditional technologies Tecnologías no tradicionales Teknologia ez ohikoak
Nozzle Boquilla Aho / Pita
Plasma arc machining Mecanizado por plasma Plasma bidezko mekanizazio
Plate Placa Plaka / Xafla
Polishing Pulido Leunketa
Powder Polvo Hauts
Propel Impulsar Bultzatu
Pump Bomba Bonba
Reel Carrete / Bobina Bobina
Removal rate Tasa de eliminación Ezabapen tasa
Rough Basto Trauskil
Rubber Goma / Caucho Goma / Kautxu
Scribing Trazado a mano Eskuz idatzia
Shaping Dar forma Forma eman
Sharp Afilado Zorrotz
Shear Cizallado Zizailaketa
Sheet Chapa Xafla
Sinking EDM Electroerosión por penetración Sartze elektrohigadura

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GLOSSARY
by Endika Gandarias
Skin Piel Azal
Slender Esbelto Lerden
Slot Ranura Arteka
Slurry Pasta / Lodo Ore / Lokatz
Spark Chispa Txinpart
Spot Punto Puntu
Sputter Escupir Jaurti
Stainless steel Acero inoxidable Altzairu erdoilgaitz
Standoff distance Distancia de alejamiento Urruntze tarte
Stands for Significa Adierazi / Esan nahi
Stiffness Rigidez Zurruntasun
Stone Piedra Harri
Stream Chorro Zurrusta
Strength Resistencia Erresistentzia
Surface roughness Rugosidad superficial Gainazal zimurtasuna
Tapered cut Corte inclinado Mozte inklinatu
Tough Resistente Iraunkor
Toughness Tenacidad Zailtasun
Transducer Transductor Transduktore
Ultrasonic machining Mecanizado ultrasónico Ultrasoinu bidezko mekanizazio
Vacuum Vacío Huts
Wash Limpiar Garbitu
Wear Desgaste Higadura
Welding Soldadura Soldadura
Wire EDM Electroerosión por hilo Harizko elektrohigadura
Workpiece Pieza Pieza

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