18ME641 Non-Traditional Machining syllabus for ME

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.

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.

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 process-chemical 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.

Course Outcomes:

At the end of the course, the student will be able to:

CO1: Understand the compare traditional and non-traditional machining process and recognize the need for Non- traditional machining process.

CO2: Understand the constructional features, performance parameters, process characteristics, applications, advantages and limitations of USM, AJM and WJM.

CO3: Identify the need of Chemical and electro-chemical machining process along with the constructional features, process parameters, process characteristics, applications, advantages and limitations.

CO4: Understand the constructional feature of the equipment, process parameters, process characteristics, applications, advantages and limitations EDM & PAM. CO5: Understand the LBM equipment, LBM parameters, and characteristics. EBM equipment and mechanism of metal removal, applications, advantages and limitations LBM & EBM.

Question paper pattern:

• The question paper will have ten full questions carrying equal marks.
• Each full question will be for 20 marks.
• There will be two full questions (with a maximum of four sub- questions) from each module.
• Each full question will have sub- question covering all the topics under a module.
• The students will have to answer five full questions, selecting one full question from each module.

Textbook/s

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. Amitabha Bhattacharyya The Institute of Engineers (India) 2000

2 Modern Machining process Aditya 2002