The constrained applications of conventional machining processes in generating complex shape ge-ometries with the desired degree of tolerance and surface finish in various advanced engineering materials are being gradually compensated by the non-traditional machining (NTM) processes. These NTM processes usually have higher procurement, maintenance, operating and tooling cost. Hence, in order to attain their maximum machining performance, they are usually operated at their optimal or near optimal parametric settings which can easily be determined by the application of dif-ferent optimization techniques. In this paper, 133 international research papers published during 2012-16 on parametric optimization of NTM processes are extensively reviewed to have an idea on the selected process parameters, observed responses, work materials machined and optimization techniques employed in those processes while generating varying part geometries for their industrial use. It is observed that electro discharge machining is the mostly employed NTM process, applied voltage is the identified process parameter with maximum importance, surface roughness and material removal rate are the two maximally preferred responses, different steel grades are the mostly machined work materials and grey relational analysis is the most popular tool utilized for para-metric optimization of NTM processes. These observations would help the process engineers to attain the machining performance of the NTM processes at their fullest extents for different work material and shape feature combinations.

Due to various added advantages over the conventional material removal processes, non-traditional machining (NTM) processes have now been widely applied in different manufacturing industries. To achieve the desired response values, it is always recommended to operate these NTM processes at their optimal parametric settings. Various single response optimization techniques are already available to determine the optimal combinations of NTM process parameters for achieving maximum or minimum value of a single response. In this paper, a multivariate quality loss function approach is adopted for simultaneous optimization of responses for three NTM processes. It is observed that this approach outperforms the other multi-response optimization techniques, like desirability function, distance function and mean squared error methods with respect to the achieved re-sponse values. With modification of the corresponding objective function and constraints of the de-veloped non-linear programming problem, it can be effectively applied to any non-traditional as well as conventional machining process as a multi-objective optimization tool.

With ever-increasing demands for high surface finish and complex shape geometries on various difficult-to-machine materials, conventional metal removal methods are now being replaced by non-traditional machining (NTM) processes. These NTM processes use energy in its direct form to remove material from the workpiece surface. They are also cost effective for a wide range of micro- and nano-level applications. For effective utilization of different NTM processes, it is quite important to study their characteristics and material removal mechanisms in order to identify the most significant control parameters affecting the process responses. In this paper, a data mining approach using classification and regression tree algorithm is employed to identify the most important input parameters of three NTM processes, i.e. micro electro discharge milling process, wire electrical discharge machining process and laser beam machining process. The derived observations are also validated using the analysis of variance results.

Non-traditional machining (NTM) refers to a variety of thermal, chemical, electrical and mechanical material removal processes, developed to generate complex and intricate shapes in advanced engineering materials with high strength-to-weight ratio. Selection of the optimal NTM process for generating a desired feature on a given material requires the consideration of several factors among which the type of the work material and shape to be machined are the most significant ones. Presence of a large number of NTM processes along with their complex characteristics and capabilities, and lack of experts in NTM process selection domain compel for development of a structured approach for NTM process selection for a given machining application. Thus, the objective of this paper is set to develop a decision-making model in Visual BASIC 6.0 to automate the NTM process selection procedure with the help of graphical user interface and visual decision aids. It is also integrated with quality function deployment technique to correlate the customers’ requirements (product characteristics) with technical requirements (process characteristics). Four illustrative examples are also provided to demonstrate the potentiality of the developed model in solving NTM process selection problems.

With the ever-increasing demands for high surface finish and complex shape geometries, conventional metal removal methods are now being replaced by non-traditional machining (NTM) processes. These NTM processes use energy in its direct form to remove materials in the form of atoms or molecules to obtain the required accuracy and burr-free machined surface. In order to exploit the optimal capabilities of the NTM processes, it is often required to determine the best possible combinations of their controllable parameters. Different non-conventional optimization techniques have been used for dealing with these process optimization problems because of their inherent advantages and capabilities for arriving at the almost global optimal solutions. This paper reviews the applications of different non-conventional optimization techniques for parametric optimization of NTM processes. It is observed that electrical discharge machining processes have been optimized most number of times, followed by wire electrical discharge machining processes. In most of the cases, the past researchers have preferred to maximize material removal rate. Genetic algorithm has been found to be the most popular non-conventional optimization technique.

With ever increasing demand for manufactured products of hard alloys and metals with high surface finish and complex shape geometry, more interest is now being paid to non-traditional machining (NTM) processes, where energy in its direct form is used to remove material from workpiece surface. Compared to conventional machining processes, NTM processes possess almost unlimited capabilities and there is a strong believe that use of NTM processes would go on increasing in diverse range of applications. Presence of a large number of NTM processes along with complex characteristics and capabilities, and lack of experts in NTM process selection domain compel for development of a structured approach for NTM process selection for a given machining application. Past researchers have already attempted to solve NTM process selection problems using various complex mathematical approaches which often require a profound knowledge in mathematics/artificial intelligence from the part of process engineers. In this paper, four NTM process selection problems are solved using an integrated PROMETHEE (preference ranking organization method for enrichment evaluation) and GAIA (geometrical analysis for interactive aid) method which would act as a visual decision aid to the process engineers. The observed results are quite satisfactory and exactly match with the expected solutions.