Non-Traditional Machining

This article will be the first in a series of TMA News Bulletin articles attempting to provide a detailed look into the many technologies utilized by TMA members that manufacture in Illinois.

Non-traditional machining can be defined as modifying material into a specific shape without using milling, turning or drilling. These newer technologies have increased production and efficiency as manufacturers seek ways to increase speed & accuracy and decrease costs.

Sinker & Wire EDM (Electrical Discharge Machining)
Thermal Machining: The use of an electrode or brass wire to erode/burn the material (1950’s)
Ample precision and favorable appearance of the final surface
MUST be a conductive material
Ideal for lower volumes as the technology is slower
Heat Affected Zone: the heat in the process can alter the properties of the material
~$20/hr operating cost

Laser Cutting
Thermal Machining: The use of laser technology to cut material (1960’s)
Ample precision
Great for higher production volumes
Can cut, drill, mark, weld
Difficulties with reflective materials (copper/silver/nickel/aluminum)
Need some mass of material as heat must be absorbed
As the laser progresses though thicker material, a burr is created at the bottom (called DROSS) which must be removed, adding a step
Heat Affected Zone: the heat in the process can alter the properties of the material
~$20/hr operating cost

Waterjet
The use of high pressure water plus abrasive to cut material (1970’s)
Great for thicker material (+1/2”)
Less accuracy
No limitations such as conductivity or reflection
~$20/hr operating cost

A special thanks to Tim Doran of Tristate Machinery for this article.

Kent Gladish
Senior Marketing & Sales Director
kgladish@tmanet.com 847-825-1120 x1339