Comprehensive Report: Non-Mechanical Machining Technologies

This report explores various non-mechanical machining technologies, essential for precision manufacturing. It details the principles of operation for Electrical Discharge Machining (EDM), Electrochemical Machining (ECM), Electrochemical Grinding (ECG), and Radiant Energy Machining, explaining their advantages and disadvantages. The report also covers Water Jet Cutting and Abrasive Jet Cutting. Furthermore, it emphasizes health and safety considerations associated with these methods, highlighting potential risks from laser beams and ionizing radiation, and suggesting mitigation strategies. The report concludes by emphasizing the promising future of non-mechanical material removal techniques in the production of microscopic work-pieces, making it a valuable resource for understanding the evolution and implications of these technologies.

1.0 INTRODUCTION
The continued proliferation of miniature and the different micro products components had steadily
increased the demand for their production to rise exponentially. Most manufacturers today are
investing heavily in the micromachining technique in the production of precision wise equipment.
With the ever decreasing feature size required from the conventional millimeters to tens of
micrometers, the conventional mechanical machining technology cannot be trusted to handle such
high precision. It is therefore imperative to switch to more non-mechanical means of material
removal to be adopted by the company. This report describes briefly, the operations of the non-
mechanical material removal tools(Kussul et al., 1996).
2.0 BODY
This section outlines the basic principles behind the operations of the non-traditional machining
tools for deeper understanding, the industry specification for the different level of precision
required. A comparison is done on the different tools used by the manufacturing industry and the
sharp contrast between them, this will be vital in making the best decision on the way forward for
the company in embracing the new technology.
2.1 PRINCIPLES OF OPERATION
Removal of materials from the work-piece using the non-mechanical approach generally are
grouped into four principles primarily based on the source of energy used in the removal process of
the material at the work-piece. These principles are hereinafter discussed in details. This will enable
deeper comprehension of their modus operanda, which is vital is ensuring safety and health
requirements are adhered to. The four basic principles are
i. Electrochemical grinding (ECG)
ii. electrochemical machining (ECM)
iii. electrical discharge machining(EDM)
iv. Radiant Energy Material Removal Method.

The discussion below details their mode of operation and basic principle they use to achieve their
desired efficiency and effectiveness.
2.1.1 Electrical Discharge (EDM)
This technique is the widely used non-mechanically machining technology to remove materials
from the work-piece .it involves passing a low voltage but of high-frequency direct current which
aims at removing the covering layers of the metallic material. This is done using an electrode which
in most case is the brass. Care is taken such that the cross-sectional part of the container technically
is supposed to be identical to the cavity to be machined. The dielectric fluid is used which provides
the medium where the electrode and the part to undergo machining is immersed(Goswami, Mitra
and Sarkar, 2009). For a medium to act as a dielectric in this method, it must meet the following
minimums.
i. The dielectric must have the ability to prevent the electric current from flowing in a centric
manner.
ii. Ability to flash away the would be remains of the work-piece part.
iii. Ability to act as a coolant.
The figure below illustrates the principle behind its working,
Advantages
Illustration 1: Electrical Discharge (EDM)

i. The ability to apply machining has no independent of the strength of the mechanical
components.
ii. It is possible to produce irregular shapes whose contours are intricate. This is achievable
since the shape of the machined part entirely depends on the electrical configuration. This
makes it easier to come up with accurate dimensions with a lot of ease(Curtis et al., 2009).
Despite the enormous advantages, this method display some disadvantage. This is explained below,
Disadvantage
i. Their is chances the machined part will crack along the boundaries due to relatively low
fatigue strength compared to the parts machined
2.1.2 Electrochemical (ECM)
This method consist of passing through a direct current through an electrolyte which separates the
surface of the would be machined parts from an electrode. In this arrangement, the part will be used
as an anode whereas the electrode takes the role of cathode. The chemical reaction caused by the
electric current lead to the dissolution of the anode which is the part to be machined(Kozak,
Budzynski and Domanowski, 1998).
2.1.3 Electrochemical Grinding (ECG)
This method looks similar to the ECM in principle, however, in this method, electrode I made from
a grinding wheel whose role is twofold. The electrode does two roles, first by virtue of being a
cathode, it causes anodic dissolution of surface layers of the part to be removed. Second, being a
grinding wheel, it further enhances metal removal through grinding (Levinger and Malkin, 1979).
2.1.4 Radiant-energy machining
It uses the principle of high energy which can be in form of a laser or an electron beam which is
focused on the surface of the would be removed surface of the metals, a process called vaporization.
This method is ideal for those work-piece with high melting points. Its ability to focus the laser on a
particular part makes it possible to reach the area which would otherwise be inaccessible
(Steigerwald and Meyer, 1969).

2.2 SPECIFICATIONS
Various tools can be used in cutting and removal of parts of the work-piece. This section highlight
some of the known non-mechanical machining tools.
2.2.1 Water Jet Cutting
It uses use the high velocity of water focused on the work surface hence causing cutting
2.2.2 Abrasive Jet Cutting
Removal of materials is due to the impingement of some fine abrasive particles onto the surface part
of the work-piece. The typical
abrasive material is 0.025mm in
the diameter.
2.3 HEALTH AND
SAFETY REQUIREMENTS
Despite their continued adoption, the non-mechanical methods of machining pose serious health
and safety issues to the human operating them. This section highlights some of this safety threat and
how much can be mitigated by providing requirements for the non-mechanical machining tools to
fulfill. The first obvious safety concern is the high light intensity from the laser beam which if get in

contact with skin can be cancerous. Ionizing radiations in form of X-rays and microwave are
equally very dangerous to human. They cause skin rashes. To mitigate some of this risks, the
organization shall enforce access controls policy to monitor who uses what. Regular maintenance is
also vital for their continued work delivery(Hutter, 2001).
3.0 CONCLUSION
The non-traditional machining technology requires a non-mechanical machining technology to
speed up the manufacturing process of microscopic work-pieces. The various principles the
technology are discussed. Despite their promising usage, the above tools have serious health and
safety implications on the operator and various ways to mitigate the risk are outlined. The future
seems bright for non-mechanical removal of work-piece parts.
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Goswami, R.N., Mitra, S. and Sarkar, S., 2009. Experimental investigation on electrochemical
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