List down all advantages and disadvantages of non-conventional machining processes from other sources as well and discuss economic, environmental, and society benefits

List down all advantages and disadvantages of non-conventional machining processes from other sources as well and discuss economic, environmental, and society benefits.

The correct answer and explanation is:

Correct Answer:

Advantages of Non-Conventional Machining (NCM) Processes:

1. High precision and accuracy for complex geometries.
2. No mechanical contact, reducing tool wear.
3. Ability to machine hard or brittle materials (e.g., ceramics, carbides).
4. Minimal residual stresses or deformation.
5. Micromachining capability (suitable for electronics, medical devices).
6. No thermal damage (in processes like EDM with cooling or waterjet).
7. No need for costly tooling like dies or molds.
8. Flexibility in operation—suitable for small and medium batch production.
9. Capable of working with heat-sensitive and delicate materials.

Disadvantages of Non-Conventional Machining Processes:

1. High initial and operating cost.
2. Slow material removal rates compared to traditional machining.
3. Requires skilled labor and training.
4. High energy consumption (especially in EDM and laser machining).
5. Limited to specific materials (e.g., EDM only works with conductive materials).
6. Safety hazards from electrical discharges, lasers, or high-pressure water.
7. Complex setup and maintenance.
8. Environmental concerns due to dielectric fluids, abrasive waste, and energy use.

Economic, Environmental, and Societal Benefits:

Economic Benefits:

• NCM allows the production of intricate and high-value parts (e.g., in aerospace and medical sectors), improving productivity and innovation.
• Though costly upfront, reduced tool wear and longer equipment life can lower long-term costs.
• Reduces scrap and rework due to higher precision.

Environmental Benefits:

• Processes like waterjet cutting are eco-friendly, using water and natural abrasives.
• Minimal material waste, especially in additive and hybrid processes.
• Reduced lubricant and coolant use in some methods (e.g., laser machining).

Societal Benefits:

• Supports advancements in healthcare (e.g., producing implants, micro-tools).
• Enhances safety by enabling precise manufacturing of critical parts (e.g., aircraft components).
• Promotes sustainable development through cleaner technologies and precision production.

Non-conventional machining, while technologically demanding, leads to more efficient, cleaner, and more advanced production methods across industries.