INTRODUCTION
Introduction to Non-traditional machining, Need for Non-traditional machining process, Comparison between traditional and non-traditional machining, general classification Nontraditional 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.
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.
Water Jet Machining (WJM): Equipment & process, Operation, applications, advantages and limitations of WJM.
ELECTROCHEMICAL MACHINING (ECM)
Introduction, Principle of electro chemical machining: ECM equipment, 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 processchemical blanking process, chemical milling process. Process characteristics of CHM: material removal rate, accuracy, surface finish, advantages, limitations and applications of chemical machining process.
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.
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.