Introduction to Non-traditional machining: Need for Non-traditional machining process, Comparison between traditional and non-traditional machining, general classification Non-traditional machining processes, classification based on nature of energy employed in machining, selection of nontraditional machining processes, Specific advantages, limitations and applications of non-traditional machining processes.

Ultrasonic Machining (USM) & Abrasive Jet Machining (AJM): USM: Introduction, Equipment and material process, Effect of process parameters: Effect of amplitude and frequency, Effect of abrasive grain diameter, effect of slurry, tool & work material. Process characteristics: Material removal rate, tool wear, accuracy, surface finish, applications, advantages & limitations of USM.

AJM: Introduction, Equipment and process of material removal, process variables: carrier gas, type of abrasive, work material, stand-off distance (SOD). Process characteristics: Material removal rate, Nozzle wear, accuracy & surface finish. Applications, advantages & limitations of AJM.

Electrochemical Machining (ECM) & Chemical Machining (CHM): ECM: Introduction, Principle of electro chemical machining, ECM equipment, elements of ECM operation, Chemistry of ECM. ECM Process characteristics: Material removal rate, accuracy, surface finish. Process parameters: Current density, Tool feed rate, Gap between tool & work piece, velocity of electrolyte flow, type of electrolyte, its concentration temperature, and choice of electrolytes. ECM Tooling: ECM tooling technique & example, Tool & insulation materials. Applications ECM: Electrochemical grinding and electrochemical honing process. Advantages, disadvantages and application of ECG, ECH.

CHM: Elements of the process, Resists (maskants), Etchants. Types of chemical machining process: chemical blanking process, chemical milling process. Process characteristics of CHM: material removal rate, accuracy, surface finish, advantages, limitations and applications of chemical machining process.

Electrical Discharge Machining (EDM) & Plasma Arc Machining (PAM): EDM: Introduction, mechanism of metal removal, EDM equipment: spark erosion generator (relaxation type), dielectric medium: its functions & desirable properties, electrode feed control system. Flushing types: pressure flushing, suction flushing, side flushing, pulsed flushing. EDM process parameters: Spark frequency, current & spark gap, surface finish, Heat Affected Zone. Advantages, limitations & applications of EDM, Electrical discharge grinding, Traveling wire EDM.

PAM: Introduction, non-thermal generation of plasma, equipment mechanism of metal removal, Plasma torch, process parameters, process characteristics. Safety precautions, applications, advantages and limitations.

Laser Beam Machining (LBM) & Electron Beam Machining (EBM): LBM: Introduction, generation of LASER, Equipment and mechanism of metal removal, LBM parameters and characteristics, Applications, Advantages & limitations.

EBM: Introduction, Principle, equipment and mechanism of metal removal, applications, advantages and limitations.