Short Answer:

Conventional manufacturing processes are traditional methods that use mechanical tools to remove or shape material. These processes depend on physical contact between tool and workpiece, such as turning, drilling, and milling.

Non-conventional manufacturing processes are modern methods that use energy forms like electrical, thermal, or chemical energy to shape materials without direct contact. Examples include laser cutting, electrical discharge machining, and ultrasonic machining.

Detailed Explanation:

Conventional manufacturing processes

Definition and basic idea:

Conventional manufacturing processes are traditional methods used for shaping and finishing materials by using cutting tools and machines. These processes involve direct contact between the tool and the workpiece. Material is usually removed in the form of chips to get the required shape and size. These methods have been used for a long time in industries and are widely accepted.

Working principle:
In conventional processes, a harder cutting tool is used to remove material from a softer workpiece. The tool moves against the material with force, and this action removes unwanted parts. The process depends on mechanical energy and cutting forces. Friction and heat are also generated during the operation.

Examples of conventional processes:
Common examples include turning, drilling, milling, shaping, and grinding. In turning, the workpiece rotates while the tool cuts it. In drilling, holes are made using a rotating drill bit. Milling uses rotating cutters to remove material from the surface.

Advantages:
Conventional processes are simple, economical, and easy to use. Machines and tools are easily available, and operators are familiar with these processes. They are suitable for most common materials like metals and plastics.

Limitations:
These processes are not suitable for very hard, brittle, or heat-resistant materials. Also, tool wear occurs due to direct contact, and it may be difficult to produce very complex or micro-sized shapes.

Non-conventional manufacturing processes

Definition and basic idea:
Non-conventional manufacturing processes are advanced methods that remove or shape material using different forms of energy instead of mechanical cutting. These processes do not require direct contact between tool and workpiece in most cases. They are used when conventional methods are not effective.

Working principle:
These processes use energy such as electrical, thermal, chemical, or ultrasonic energy to remove material. For example, in electrical discharge machining, sparks are used to erode the material. In laser machining, a high-energy laser beam melts or vaporizes the material.

Examples of non-conventional processes:
Examples include electrical discharge machining (EDM), laser beam machining (LBM), ultrasonic machining (USM), electrochemical machining (ECM), and plasma arc machining. These processes are useful for machining very hard materials and producing complex shapes.

Advantages:
Non-conventional processes can machine hard, brittle, and heat-resistant materials easily. They can produce very fine and complex shapes with high accuracy. Tool wear is less because there is little or no physical contact.

Limitations:
These processes are expensive and require skilled operators. Equipment cost is high, and some processes may be slower than conventional methods. Also, special safety precautions are required.

Conclusion:

Conventional and non-conventional manufacturing processes are both important in modern industries. Conventional processes are simple and economical for common applications, while non-conventional processes are useful for complex shapes and hard materials. The choice of process depends on the material, shape, and accuracy required.