INTRODUCTION - Unconventional Manufacturing Processes

Unconventional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be used for traditional manufacturing processes.

Extremely hard and brittle materials are difficult to machine by traditional mach ining processes such as turning, drilling, shaping and milling. 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 work piece is too flexible or slender

•    When the shape of the part is too complex

Several types of non-traditional machining processes have been developed to meet extra required machining conditions. When these processes are employed properly, they offer many advantages over non-traditional machining processes. The common non- traditional machining processes are described in this section.

Manufacturing processes can be broadly divided into two groups)

a) Primary manufacturing processes: Provide basic shape and size

b) Secondary manufacturing processes: Provide final shape and size with tighter control on dimension, surface characteristics

Material Removal Processes Once Again Can Be Divided Into  Two Groups

1. Conventional Machining Processes

 2. Non-Traditional Manufacturing Processes or Unconventional Machining processes

Conventional Machining Processes mostly remove material in the form of chips by applying forces on the work material with a wedge shaped cutting tool that is harder than the work material under machining condition.