MECH 3503 - Nontraditional Machining Processes

• ultrasonic machining
• water jet cutting
• abrasive water jet cutting
• abrasive jet machining
• abrasive flow machining

a tool has a high frequency oscilliation. an abrasive slurry is added



good for hard. brittle work materials such as ceramics, glass, and carbides

mechanical - mechanical erosion

electrical - electrochemical energy to remove material (electroplating ADDS material)

thermal - thermal energy applied to surface to be fused or vaporized

chemical - chemical etchants selectively remove material from portions

high pressure, high-velocity stream of water 

often automated by CNC 

not suitable for brittle materials (e.g. glass)

good bc minimum material loss, no environmental pollution, ease of automation

same as water jet cutting except adding abrasive particles to jet stream

aluminum oxide, silicon dioxide, garnet (silicate material)

grit sizes range between 60 and 120

high velocity stream of GAS containing small abrasive particles 

electrical energy is used with chemical reactions to REMOVE material (OPPOSITE of electro plating)

THE WORK MATERIAL MUST!!!! BE CONDUCTOR!!!

• - electrochemical machining
• - electrochemical deburring
• - electrochemical grinding

removal of material by ANODIC DISSOLUTION

materla goes from anode workpiece to cathode tool in an electrolyte bath 

based on FARADAY'S law 

abrasive particles mixed in viscoelastic polymer flowing through and around part surfaces and edges 

the polymer has a consistency of putty 

used to debur and polish difficult to reach areas of parts

removes burrs or sharp corners on holes in metal parts 

• grinding wheel is cathode
• work is anode
• electrolyte in between 
• = anodic dissolution

applications: sharpening cemented carbide tools, grinding surgical needs and other thin wall tubes

very high local temperatures; material is removed by FUSION OR VAPORIZATION

resulting finish is often poor af - need subsequent processing

• - electric discharge machining
• - electric discharge wire cutting
• - electron beam machining
• - laser beam machining

shape is of electrode tool

sparks occur accross a small gap between tool and work 

required dielectric fluid creating a path for each discharge as fluid becomes ionized in the gap 

• 
• applications: molds for plastic injection molding, extrustion dies, wire drawing dies, forging dies

wire is electrode to cut



work is fed slowly past wire along desired path 



applications: stamping die components (punch and die), irregular outline cuts

• 
• high velocity stream of electrons focused on workpiece surface to rmove material by melting and vaporizing 

an electron beam gun shoots electrons, which are then focused through an electromagnetic lens. kinetic energy of electrons converted to thermal energy of high density, melting or vaporizing material

application: on any material, good for micromachining (drilling small diameter holes or holes with high depth-to-diameter ratio, 100:1)

light energy from a laser to remove material by vaporization and ablation



similar to EBM except mirrors shoot lasers thru a lens. laser converts electrical to light beam 

light beam is monochromatic (single wave length) and collimated (light rays are almost parallel), making a focused laser

applications: drilling, slitting, slotting, scribing, and marking operations. drilling small diameter holes. used on thin stock. 

work materials: metals with high hardness and strenth, soft metals, ceramics, glass, plastic,rubber, cloth, wood

• electrochemical machining
• electric discharge machining + wire EDM

dont use a sharp cutting tool conventionally

• - can machien new metals and nonmetals 
• - can go more complex geometries 
• - avoids some surface damage