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HYBRID NON-TRADITIONAL MACHINING PROCESSES - Coggle Diagram
HYBRID NON-TRADITIONAL MACHINING PROCESSES
Electron Chemical Spark Machining
It also known as Electrochemical Discharge Machining (ECDM) — is a hybrid non-traditional machining process that combines principles of Electrochemical Machining (ECM) and Electrical Discharge Machining (EDM), and is especially effective for micromachining of non-conductive, brittle materials like glass, ceramics, and quartz.
Applications
Lab-on-chip device fabrication
Drilling microholes in non-conductive hard materials
MEMS applications
Micromachining of glass, ceramics, quartz, sapphire
Advantages
Produces complex microfeatures
Low tool wear
No direct contact → less mechanical stress
Can machine non-conductive materials
Limitations
Only suitable for small-depth and small-diameter holes
Limited to brittle, non-conductive materials
Surface finish is not very high
mechanical advanced micromachining process
Abrasive Water Jet Micromachining (AWJM)
Principle
Pressure: Up to 4000 bar.
Nozzle diameter: As small as 100 µm.
Abrasive: Garnet, alumina
Applications
Precision cutting of metals, polymers, and composites.
Micro-cutting in biomedical implants.
Advantages
Minimal heat-affected zone.
Environmentally friendly (uses water)
Ultrasonic Micromachining (USM)
Principle: Material is removed by high-frequency (typically 20–40 kHz) vibrations of a tool against the workpiece in the presence of an abrasive slurry.
Tool: Vibrating tool made of materials like stainless steel, tungsten carbide.
Abrasive: Silicon carbide, boron carbide, diamond particles.
Slurry: Water-based or oil-based carrier fluid.
Applications
:
Micro-drilling of ceramics and glass.
Machining of brittle materials.
MEMS component fabrication.
Advantages
No thermal damage.
Suitable for hard and brittle materials.
Electron Beam Micromachining (EBMM)
Principle
Focused beam of high-velocity electrons generates heat upon impact with the workpiece, melting and evaporating material.
Features
:
Extremely high precision (nanometer-scale)
High aspect ratio features
Applications
Semiconductor patterning
Micro-holes in metal foils
Laser Beam Micromachining (LBMM)
Laser Beam Micromachining is the process of removing material using a high-energy, focused laser beam to create micro-scale features such as holes, grooves, or patterns.
Advantages
No tool wear
Extremely high precision and repeatability
Capable of machining hard and brittle materials
No mechanical force on the workpiece
Suitable for complex shapes
Limitations
High equipment cost
Heat-affected zone (HAZ) in some laser types
Requires careful control of parameters
Low material removal rate (for deep features)
Applications
Micro-holes in fuel injectors
Stent manufacturing in biomedical field
Micro-drilling of PCBs
MEMS device fabrication
Surface texturing for friction control