Non Traditional Machining

Some past engineering industries have witnessed a rapid growth in the development of harder and difficult to machine material such as Hastelloy, Nitralloy, Waspalloy, Nimonics, stainless steel and much other high strength temperature resisting alloys.

This material widely used in various industries like aerospace, nuclear engineering and other industries. for such materials the conventional edged tool machining, in spite of recent technological advancement, is highly uneconomical and the degree of accuracy and surface finish are poor. and machining of these materials are complex shapes is difficult and sometimes impossible.

In 1960 merchant emphasized the need for the development of newer concepts in metal machining these processes are non-conventional or unconventional in the sense that they do not employ a conventional tool for metal removal. they directly utilize some form of energy for metal machining.  

Classification of non-conventional machining process :

They are classified in the various groups according to the type of fundamental machining they employ named mechanical, electrical, chemical, electro-chemical, thermo-electric etc.

They are classified according to energy used, the mechanism of metal removal in the process and the medium for transfer of those energies etc.

Type of energy	The basic mechanism of metal removal	Transfer media	Energy source	Process
Mechanical	Erosion shear	High velocity particles, physical contact	Pneumatic/hydraulic pressure cutting tool	AJM USM Conventional machining
Chemical	Chemical ablation	Reactive environment	Corrosive agent	CHM
Electro-chemical	Ion displacement	Electrolyte	High current	ECM ECG
Thermo-electric	Fusion vaporization	Hot gases electron radiation	Ionized material high voltage amplified light	IBM PAM EBM EDM LBM

  Mechanical :

• Abrasive Jet Machining ( AJM )
• Ultrasonic Machining ( USM )

Chemical :

• Chemical Machining ( CHM )

 Electro-Chemical :

• Electro-Chemical Machining ( ECM )
• Electro-Chemical Grinding ( ECG )

Thermo-electric : 

• Ion-Beam Machining ( IBM )
• Plasma Arc Machining ( PAM )
• Electrical Discharge Machining ( EDM )
• Electron-Beam Machining ( EBM )
• Laser-Beam Machining ( LBM )

Process Selection :

The points which should be looked before the selection of these process are as below : 

1. Physical parameters.
2. Properties of the work material and shape to be machined.
3. Process capability or machining characteristics.
4. Economic survey. 

Materials application of the various methods are given in the table below :
  

Process	Aluminium	Steel	Super alloy	Titanium	Refractories	Ceramics	Plastic	Glass
USM	G	F	P	F	G	G	F	G
AJM	F	F	G	F	G	G	F	G
ECM	F	G	G	F	F	N	N	N
CHM	G	G	F	F	P	P	P	F
EDM	F	G	G	G	G	N	N	N
EBM	F	F	F	F	G	G	F	F
LBM	F	F	F	F	P	G	F	F
PAM	G	G	G	F	P	N	P	N

Where

G = Good

F = Fair

P = Poor

N = Not applicable

The processing capability or machining characteristics can be analyzed with respect to :

1. Metal removal rate obtained.
2. Tolerance maintained.
3. The surface finish obtained.
4. Depth of surface damage.
5. Power requires machining.

The economics of the various process is analyzed by considering :

1. Capital cost.
2. Tooling cost.
3. Consumed power cost.
4. Metal removal rate efficiency.
5. Wear of tooling.  

Difference between G code and M code

G code is used for the machine tool what type of action to perform, such as 

• Rapid movement
• Controlled feed in a straight line or arc
• Set tool information such as offset 
• Dwell
• Plain Selection

M code is used for machine function, such as 

• Spindle ON/OFF
• Coolant ON/OFF
• Open workstation door
• Tool changing
• Other machine-related terms 

G code is used for the Preparatory function whereas the M code is used for the Miscellaneous function.

Difference between PSLV and GSLV

What is PSLV?

PSLV  is used to deliver various Low Earth Orbits satellites designed primarily to deliver the 600-900 km altitude "earth-observation" or "remote-sensing" satellites with a lift-off mass of up to approximately 1750 kg to Sun-Synchronous circular polar orbits.

What is GSLV?

The primary payloads of GSLV are INSAT-class communication satellites (about 2,500 kg mass) operating from geostationary orbits (about 36,000 km) and are thus placed in GSLV's Geosynchronous Transfer Orbits.

Let us have a deep insight into the difference between comparison between them and a certain difference between them. 

Difference : 

• An advanced version of the GSLV, called Mk-III, that will be capable of putting very heavy satellites up to about 4,000 kg into space is still under development while the PSLV can carry satellites weighing up to approximately 1,500 kg.
• PSLV is used for research purposes like agriculture, weather forecasting etc and GSLV is used for domestic purposes like communication, telecasting etc.
• PSLV's average building cost is about Rs 120 crore. The heaviest version of PSLV, the XL, cost Rs 145 crore while according to information provided by the Space Department, GSLV costs Rs 173 crore.
• The PSLV is older than the GSLV.
• The PSLV is more reliable than the GSLV.
• The GSLV has three phases, whereas the PSLV has four phases.
• The GSLV uses cryogenic fuel while the PSLV doesn’t use cryogenic fuel.
• Polar Satellite Launch Vehicle is used to place the satellite perpendicular to the direction of rotation of earth inclined to 90 degrees or some another angle depends on the purpose but GSLV-Geosynchronous A satellite Launch Vehicle is used to place the satellite in the equator to rotate along the direction of rotation of the earth.

Explore more information: 

1. Difference between Orbit and Orbital

Difference between Heat and Temperature

Heat and temperature are different from each other. Heat is generally the measurement of energy or thermal energy in a body while temperature refers to the measurement of heat or thermal energy of any molecules in a substance. Let us have a deep insight into the difference between heat and temperature. 

Difference : 

• Heat is the amount of energy in a body while the temperature is the measure of the intensity of heat.
• Heat is measured by total kinetic and potential energy contained by molecules in an object while the temperature is measured by the average kinetic energy of molecules in a substance.
• Heat flows from hotter object to cooler object while temperature riser when heated and falls when cooled.
• Unit of measurement for Heat - Joules and for Temperature - Kelvin but also measure in Celsius and Fahrenheit.
• Calorimeter used for measuring heat while thermometer used for temperature. 
• Heat is represented by Q while the temperature is represented by T.
• Heat is analogous to an electric current that flows and Temperature is analogous to a voltage that causes the current to flow.
• Temperature is the degree of hotness while heat is thermal energy arising due to a difference in temperature.     
• Heat is a path function and Temperature is a point function.

Difference between AC and DC motors

AC and DC motors serve the same function of converting electrical energy into mechanical energy but they are powered, constructed and controlled differently. The most fundamental difference is that power source. Let us have a deep insight into the difference between AC and DC motors. 

Difference : 

• A DC motor's speed is controlled by varying the current of the armature winding while an AC motor's speed is controlled by varying the frequency, which is usually done with adjustable control of the frequency drive.
• AC motor uses alternating current to produce power and DC motor uses direct current. 
• DC motors characterize a continuous and standard current flow while AC motors are used in different situations irrespective of the current flow quality.
• DC motors are self-starting, while AC motors require effective starting equipment.
• DC motors operate in situations where the motor speed needs to be controlled externally, while AC motors are used in a completely different process based on the type of ac motor used.
• AC motors work extremely well for hard systems as they require a lot of upstream power, while DC motors do not perform as well over extended periods of time when producing power.
• DC motors are single-phase motors, while AC motors are 1 and 3-phase motors.
• DC and AC motors work on the same principle of armature winding and magnetic field while the magnetic field remains stationary in DC motor, while in AC motors the armature remains stationary and the magnetic field continues to rotate.

Difference between SUV and MUV

What is SUV?

SUV is used to denote any vehicle that looks like a station and known for performing some off-road duties such as Mahindra Scorpio, Toyota Fortuner, Maruti Grand Vitara, Tata Safari, Ford Endeavour and Honda CRV. These vehicles are used for driving rough-textured roads. The mid-size and full size SUVs have generally three rows of seats and the cargo area is placed behind the last row of seats. For people looking for features like a spacious vehicle with a bit of off-road capability, SUV is preferred. It can be easily spotted by their appearances and looks, resembling a big station wagon.

What is MUV?

MUV is used for various purposes and the cars of this segment are known for their duty-ness, durability, stability, looks, reliability such as Toyota Innova, Mahindra Xylo, Tata Sumo and Mahindra Bolero. These type of vehicle have bigger chassis dimensions, more seating capacity and most of the models are designed with folded rear seats, and the area that is left can be used for some extra luggage space. A multi-utility car can accommodate many passengers and also carry more luggage at a time.

Let us have a deep insight into the comparison and difference between them. 

Difference :

• MUV stands for Multi Utility Vehicle and SUV stands for Sport Utility Vehicle. 
• MUV is more like van while SUV built on a light-truck chassis to enhance towing capacity.
• MUVs are more fuel-efficient than SUVs.
• SUVs are costlier than MUVs.
• SUVs fair better off-road than MUVs.
• SUVs have more ground clearance than MUVs.
• MUVs are front-wheel drive while SUVs are a rear-wheel drive or all-wheel drive.
• MUVs target customers that are looking for a spacious vehicle, which can be used for both passengers and luggage, whereas SUVs are preferred by people who are looking for vehicles that can be used in all road conditions like uneven roads and hilly areas.
• MUVs are more fuel-efficient than SUVs.

Difference between Management and Administration

• Management means an organized way of managing people and things of a business organization is called the management and the process of administering an organization by a group of people is known as administration.
• Management makes decisions while the administration carries out those decisions.
• Management is predominantly the process of making sure that an organization's employees are motivated, engaged, and trained sufficiently to do their jobs and that they work well together as a team whereas the administration is predominantly the process of making sure that an organization runs efficiently. The emphasis is on compliance, infrastructure, operations, etc.   
• Management is a strategic part, people sit together to come up with some innovative ideas and create a module whereas administration is an execution part, workers here ensure that any planning or modules are executed properly without any breakdown.
• In management group of people worked executing the function and doing the function while in administration worked for decision-making function and thinking function.
• Middle-level activity is done by management in terms of the level of authority while top-level activity in administration.
• Group of managerial staff who use their expertise to fulfil a company's goals whereas in administration consists of owners who invest capital in and receive profits from an enterprise.
•  Decisions in management are influenced by the values, opinions, beliefs and decisions of the managers and in administration decisions influenced by public opinion, government policies, customs etc.
• The main function of management is motivating and controlling and the main function of administration is Planning and organizing.
• Management have ability to handles the employees and administration have ability to handles the business aspects such as finance.