21ME751 Non-Traditional Machining
Course Learning Objectives
• To learn various concepts related to modern machining processes & their applications.
• To appreciate the differences between conventional and non-conventional machining processes.
• To acquire a functional understanding of non-traditional manufacturing equipment.
• To know about various process parameters and their influence on performance and their applications.• To impart knowledge on various types of energy involved in non-traditional machining processes.
SYLLABUS COPY
MODEL QUESTION PAPER
MODEL QUESTION PAPER SOLUTION
MODULE - 1
Introduction to Non-traditional machining, Need for Non-traditional machining process, Comparison between traditional and non-traditional machining, general classification Non-traditional machining processes, classification based on nature of energy employed in machining, selection of non-traditional machining processes, Specific advantages, limitations and applications of non-traditional machining processes.
MODULE - 2
Ultrasonic Machining (USM) Introduction, Equipment and material process, Effect of process parameters: Effect of amplitude and frequency, Effect of abrasive grain diameter , effect of slurry, tool & work material. Process characteristics: Material removal rate, tool wear, accuracy, surface finish, applications, advantages & limitations of USM. Abrasive Jet Machining (AJM) Introduction, Equipment and process of material removal, process variables: carrier gas, type of abrasive, work material, stand-off distance (SOD). Process characteristics-Material removal rate, Nozzle wear, accuracy & surface finish. Applications, advantages & limitations of AJM.
MODULE - 3
ELECTROCHEMICAL MACHINING (ECM) Introduction, Principle of electro chemical machining, ECM, elements of ECM operation, Chemistry of ECM. ECM Process characteristics: Material removal rate, accuracy, surface finish. Process parameters: Current density, Tool feed rate, Gap between tool & work piece, velocity of electrolyte flow, type of electrolyte, its concentration temperature, and choice of electrolytes. ECM Tooling: ECM tooling technique & example, Tool & insulation materials. Applications ECM:Electrochemical grinding and electrochemical honing process. Advantages, disadvantages and application of ECG, ECH. CHEMICAL MACHINING (CHM) Elements of the process, Resists (maskants), Etchants. Types of chemical machining process-chemical blanking process, chemical milling process. Process characteristics of CHM: material removal rate, accur acy, surface finish, advantages, limitations and applications of chemical machining process
MODULE - 4
ELECTRICAL DISCHARGE MACHINING (EDM)Introduction, mechanism of metal removal, EDM equipment: spark erosion generator (relaxation type), dielectric medium-its functions & desirable properties, electrode feed control system. Flushing types; pressure flushing, suction flushing, side flushing, pulsed flushing. EDM process parameters: Spark frequency, current & spark gap, surface finish, Heat Affected Zone. Advantages, limitations & applications of EDM, Electrical discharge grinding, Traveling wire EDM. PLASMA ARC MACHINING (PAM)Introduction, non-thermal generation of plasma, equipment mechanism of metal removal, Plasma torch, process parameters, process characteristics. Safety precautions. Safety precautions, applications, advantages and limitations
MODULE - 5
LASER BEAM MACHINING (LBM) Introduction, generation of LASER, Equipment and mechanism of metal removal, LBM parameters and characteristics, Applications, Advantages & limitations. ELECTRON BEAM MACHINING (EBM) Introduction, Principle, equipment and mechanism of metal removal, applications, advantages and limitations.
Course outcome
• Understand the comp are traditional and non-traditional machining process and recognize the need for Non- traditional machining process.
• Understand the constructional features, performance parameters, process characteristics, applications, advantages and limitations of USM, AJM and WJM.
• Identify the need of Chemical and electro-chemical machining process along with the constructional features, process parameters, process characteristics, applications, advantages and limitations.
• Understand the constructional feature of the equipment, process parameters, process characteristics, applications, advantages and limitations EDM & PAM.
• Understand the LBM equipment, LBM parameters, and characteristics. EBM equipment and mechanism of metal removal, applications, advantages and limitations LBM & EBM.
Suggested Learning Resources
Books 1 Modern Machining Process by P.C Pandey and H S Shah McGraw Hill Education India Pvt. Ltd. 2000 2 Production technology HMT McGraw Hill Education India Pvt. Ltd 2001
Reference Books 1 New Technology Dr. Amitab h Bhattacharyya The Institute of Engineers (India) 2000