Advances in Nonconventional Machining Processes

The utilization of advanced materials like ceramics, composites etc. has increased these days and simultaneously machining of these hard, brittle and costly materials is very challenging. Industries are relying on non-conventional machining processes because conventional machining processes have many limitations to machine hard and brittle materials. The birth of modern machining processes like Ultrasonic Machining (USM) has taken place due to these limitations in conventional machining. In USM, material is removed due to action of abrasive grains and vibrations cutting tool during machining. Up to some extent, it overcomes the problems of conventional machining. Besides USM has some drawbacks e.g. low material removal rate, high wear rate of tool. As it tools continuously strikes on the workpiece, there is oversize in produced cavities and a limit of depth in drilling operation. Optimization of process parameters can improve all these problems. The literature survey study has shown, in drilling and milling operations, a hybrid machining process named Rotary Ultrasonic Machining (RUM) gives tremendous results as compared to ultrasonic machining alone. In recent years, it is gaining popularity due to its intelligent machining in industries. The present paper confers about the technique of parametric optimization of ultrasonic machining and future aspects of rotary ultrasonic machining processes.

Electrical discharge machining is an advanced machining process used in the machining of hard materials and in die manufacturing industry. The main cost component in electrical discharge machining is the cost of the tool electrode. The conventionally used electrode material like copper and graphite has very low wear resistance, hence, wear out fast. Continuous efforts are being made to find electrode materials which have optimum value of electrical conductivity, thermal conductivity and wear resistance. Composites of various combinations of material have been tried in search of alternative tool materials. The current study presents a review of different materials utilized for the manufacturing of composite electrodes for electrical discharge machining and their fabrication techniques. It has been observed that among the different electrode fabrication techniques available, powder metallurgy has shown very promising results.

The present work puts light on the non-conventional machining process in which heat energy is utilized to remove the material from the workpiece. Laser beam machining is a process in which a high-intensity beam falls on the work surface to raise the temperature so that the vaporization of material could take place. Laser beam machining process can be utilized to machine hard and brittle materials. The laser types used and laser drilling processes are reviewed. The complex profiles cutting and microdrilling can be achieved which is not possible by other conventional and nonconventional machining processes. Many researchers have studied that a hybrid process can improve the process parameters of laser beam machining. This paper reviews its need, hybrid process and latest developments in the field of machining of different materials like ceramics, composites, etc. The last section of the paper discusses the area of future research in this field.

Abrasive water jet machining (AWJM), non-conventional machining (NCM), has been improved radically, in terms of quality and reliability. AWJM is a widely used NCM process broadly established in technical application areas of machining tools, parts, microstructures or intricate products like Titanium Alloy, Alloy steel etc. It has become entrenched in every single significant region of theoretical researches and across the broad spectrum of applications. Applications include medical apparatuses, precision parts, efficient material, smart automotive manufacturing, aerospace equipment, renewable energy science etc. This paper audits the verifiable, most recent research improvements, incorporated uses of AWJM system and execution. The examination encourages the high assembling accuracy and balanced out execution quality with more noteworthy productivity. The benefits of AWJM incorporates the capacity to cut convoluted materials, difficult to cut surfaces, high flexibility, little cutting powers and ecologically safe. Additionally,the AWJM system’s limitations are highlighted too. AWJM is one of the exceptionally advanced system that have significant potential for micromachining.

Abrasive Machining has been seen making a significant advancement in recent years. Localized erosion with intensification-based technology used in manufacturing is known as Abrasive jet machining. This paper emphasizes on the recent advances being done in the various parameters and innovative techniques like thermal assistance, completely or intermediate submerge conditions on jet used for machining etc. Advancement in AJM is also seen in certain areas like tribology. There are certain areas like micro machining and polishing of small micro channels which also harness its advantages. It is also found that a new way of machining has been developed using elastic erosion. Other than this, certain parameters like material of jet nozzle, its design criteria, particle size, and flow rate of jet used are reviewed too. large amount of micro machining and Composite material machining advancements has been witnessed using the Abrasive jet machining.

EDM is the non-conventional process that has used, extensively, for cutting harder like nickel and its alloys, titanium and complex shape materials which are difficult to machine by other conventional processes. EDM utilizes, electrical and heat, energy to machine the workpiece by removing the undesirable material. This process use two electrodes, anode and cathode out of which tool act as cathode and the workpiece on which the job is being performed act as anode. Various factors like current, pulse on and off time, voltage applied can be used to optimize the major machining parameters of EDM like MRR, rate of tool wear, surface roughness etc. the main focus of this study these parameters on composite materials made of CMs, tungsten and cobalt carbides etc. In the end future prospective of the areas which require further improvements and investigations has also been discussed.

Demand for advanced materials, possessing, and better properties is always there in the multi-disciplinary fields of automotive, aerospace and medical applications requires advanced machining processes. Wire electric discharge machining (WEDM) is a promising non-traditional machining method utilized extensively to machine materials with varying hardness and intricate shapes with great accuracy and precision. A WEDM is a non-contact process, involves the removal of material in the form of spark erosions. DC electrical sparks are constantly generated between the wire electrode and the workpiece to achieve desired shape on the component. The input variable such as pulse-on-time, pulse-off-time, wire speed, servo voltage and flushing pressure can be tuned and controlled in order to optimize the machining process responses. The aim of this study is to identify the significant effects of process parameters on MRR, TWR, SR and surface morphology of titanium nickel memory alloys. Additionally, areas have been recognized that require intense research considerations. Future aspects of WEDM are also presented.

Electric discharge machining has been the one of the advanced machining processes that deals with the machining of intricate and complex shapes on a workpiece considering various parameters like surface roughness and higher accuracy. A lot of research has been carried out in the EDM area for developing various models and selecting the best optimum condition for machining using conventional or wire EDM. Some results regarding submerged and dry EDM processing have also been discussed. Along with this, a recent development of smart EDM is also discussed for predicting the future capabilities of an EDM machine. In this article a light has being thrown on all the recent developments being done on the basis of machining capabilities, parameter, along with the characteristics of machining surface and various wire materials and the effect on the EDM wire during machining and the overall performance.

Whatever is being done by humans today, will be done by Artificial Intelligence (AI) based systems, but at computer speed, scale and scope. AI is making its path towards the transformation of the manufacturing industry and improving the manufacturing processes. According to the panel of Forbes technology council members, 13 different sectors, including the manufacturing industry will be revolutionized by artificial intelligence. AI and robotics can transform the complicated task into consistent along with precise solutions. With the increasing operation of the industrial robot have drastically marked an increased deployment of AI in manufacturing processes. Artificial Intelligence (AI) is widely applied and is gradually approaching in the manufacturing segment, easing the automation with learning and error-free decision-making using learning algorithms. AI-driven systems are placing a simpler route to the future manufacturing industry by producing a lot of benefits by presenting innovative prospects, boosting production of goods with improving efficiencies, by implementing general AI to make machine interaction closer to human interaction. This technology enables the manufacturer to overcome various challenges that have remained in the manufacturing sector such as expertise shortage, poor decision making, problems associated with integration, and overloaded data. Hence, the implementation of AI in the manufacturing sector allows companies to fully renovate their procedures. It allows smart AI-robots/machines to collect and extract data, acknowledge various patterns, learn from that patterns and adapt to new environments through a machine or deep learning based on the complexity of tasks assigned to them. Therefore, the deployment of AI and robots in the industry will transform the massproduction along with the error-free decision-making capability. AI-based Robots in Industry 4.0 can do persistent actions such as from designing the manufacturing model, developing expertise, developing new automation solutions, eliminating human error along with providing exceptional quality in products. With the implementation of AI, robots will replace manpower and carry out hazardous activities. As a result, the number of accidents will drop across all sections in the manufacturing sector. AI & robotics technology will free the manufacturer issues related to untrained workers. Hence, entrepreneurs can concentrate on further modernization of industries and scaling their industry to greater heights. Apart from the numerous opportunities in adopting emerging technologies like AI, there are some challenges too for industrialists.The AI and robotics technology into the manufacturing industry would necessitate a huge capital investment for startups and existing manufacturers. But the return on investment will be high because smart machines will begin to take care of daily activities, companies will incur a considerably lower operating cost. AI’s proponents claim that technology is only an evolutionary form of automation, a predictable result of the Fourth Industrial Revolution. AI may be efficient at creating things, improving them, and making them cheaper. But there is no replacement for human ingenuity in dealing with the unanticipated changes in tastes and demands.