PES INSTITUTE OF TECHNOLOGY, BANGALORE SOUTH CAMPUS DEPARTMENT OF MECHANICAL ENGINEERING LESSON PLAN NON-TRADITIONAL MACHINING Faculty name : JAGADEESH BAGALI Subject code : 10ME665 Total No. of Lecture hrs: 52 No. of Lecture hrs/week: 04 Class No Text/ Reference page Topics to be covered 1 Introduction: Unit 1 History 2 T 1 Page.No.1-6 Classification 3 R 3 Page.No.1-7 Conventional and Non-conventional machining process 4 Comparison between conventional and Non-conventional. 5 Conventional and Non-conventional machining process selection. Ultrasonic Machining (USM): 6 Introduction 7 Unit 2 Equipment, tool materials & tool size. 8 T 1 Page.No.36-112 abrasive slurry, cutting tool system design 9 R 3 Page.No. 73-93 Effect of parameter: Effect of amplitude and frequency and vibration. 10 Effect of abrasive grain diameter, effect of applied static load, effect of slurry, tool & work material 11 USM process characteristics: Material removal rate, tool wear, 12 USM process characteristics Accuracy, surface finish, applications 13 Advantages & Disadvantages of USM 14 Abrasive Jet Machining (AJM) Introduction, Equipment 15 Variables in AJM: Carrier Gas, Type of abrasive, size of abrasive 16 Unit 3 T 1 Page.No.39-45 R 3 Page.No. 12-22 grain, velocity of the abrasive jet, mean number Abrasive particles per unit volume of the carrier gas, work material, standoff distance (SOD) nozzle design and shape of cut. 17 Process characteristics-material removal rate, Nozzle wear, Accuracy R 3 Page.No.45-52 & surface finish. 18 Applications, advantages & Disadvantages of AJM 19 Water Jet Machining, Principal, 20 Equipment, Operation. 21 Application, Advantages and limitations of water Jet machinery 22 23 24 25 Unit 4 T 1 Page.No. 52-83 R 3 Page.No. 59-80 Electrochemical Machining (ECM): Introduction, study of ECM machine Elements of ECM process: Cathode tool, Anode work piece, source of DC power, Electrolyte, chemistry of the process. ECM Process characteristics Material removal rate, Accuracy, surface finish ECM Tooling: ECM tooling technique & example, Tool & insulation materials,. 26 Electrolyte flow arrangement, Handling of slug, Economics of ECM 27 Unit 5 T 1 Page.No. 80-83 28 R 3 Page.No.53-58 Chemical Machining (CHM) Introduction, elements of process, chemical blanking process : Preparation of work piece and masters Masking with photo resists preparation, etching for blanking, % of syllabus covered Chap Cumul 9.61 9.61 15.3 25 13.5 38.5 11.5 50 11.5 62
accuracy of chemical blanking 29 chemical milling (contour machining): process steps masking, Etching, process 30 Characteristics of CHM: material removal rate, accuracy, surface finish, 31 Hydrogen Embrittlement 32 Advantages & application of CHM. 33 Electrical Discharge Machining (EDM): Introduction, mechanism of metal removal, 34 Dielectric fluid, spark generator, EDM tools (electrodes) Electrode feed control, Electrode manufacture, Electrode wear,. EDM tool design, choice of machining operation, electrode material 35 selection, Unit 6 T 1 Page.No. 84-114 Under sizing and length of electrode, machining time. Flushing; 36 R 1 Page.No. 86-145 pressure flushing Suction flushing, side flushing, pulsed flushing synchronized with 37 electrode movement, 38 EDM process characteristics: metal removal rate, accuracy, surface finish, 39 Heat Affected Zone. Machine tool selection, Application, EDM accessories 40 Applications, electrical discharge grinding, traveling wire EDM. 41 Plasma Arc Machining (PAM): Introduction, equipment. non-thermal generation of plasma, selection of gas, Mechanism of 42 Unit 7 metal removal T 1 Page.No.114-133 43 R 3 Page.No. 168-177 PAM parameters. 44 process characteristics 45 Safety precautions, Applications, Advantages and limitations 46 Laser Beam Machining (LBM): Introduction, equipment of LBM 47 Unit 8 mechanism of metal removal, LBM parameters 48 T 1 Page.No.143-147 Process characteristics, Applications, Advantages & limitations. T 1 Page.No.134-141 Electron Beam Machining (EBM): 49 R 3 Page.No. 160-166 Principles, equipment. R 3 Page.No.147-157 50 Operations. 51 Applications. 52 Advantages and limitation of EBM. 15.3 77.3 9.61 86.5 13.5 100 TEXT BOOKS: 1. Modern machining process, Pandey and Shan, Tata McGraw Hill 2000 REFERENCE BOOKS: 1. Non-Conventional Machining, P.K.Mishra, The Institution of Engineers (India) Test book series, Narosa Publishing House 2005. production engineering by HMT -2005
DEPARTMENT OF MECHANICAL ENGINEERING NON-TRADITIONAL MACHINING QUESTION BANK Subject code: 10ME665 Faculty name: JAGADEESH BAGALI UNIT-1: INTRODUCTION 1. Why are nontraditional machining methods required as compared to conventional machining methods? Discuss the history and development of nontraditional machining process. 3. How NTM differs from conventional machining? 4. Classify the NTM operations, giving an example for each. Briefly discuss the context under which these NTM operations were developed. 5. Comment on the process selection for NTM processes. 6. What do you understand by the term Unconventional or nontraditional machining process? What is its importance? 7. Compare various Nontraditional Machining methods regarding process economy. UNIT-2: Ultrasonic Machining (USM): 1. Sketch and explain USM. Discuss the effect of process parameters of USM on metal removal rate (MRR). 3. What do you mean by the term ultrasonic? Explain the principle process with a neat sketch. 4. Briefly discuss how MRR is influenced by the following parameters in USM i) Frequency ii) Grain size iii) Applied static load iv) slurry concentration 5. 6. UNIT 3: Abrasive Jet Machining (AJM): 1.
i) Abrasive flow rate ii) Mixing ratio iii) Gas pressure iv) Nozzle distance 3. Write a note on AJM process, with a neat sketch. State the process parameters. 4. What is the fundamental principle between AJM? 5. How does the operating parameter affect the machining process in AJM? 6. Why different abrasives produce different MRR? 7. i) What is the principle of water jet machining? ii) Write a note on the special features of the equipment used in this method of machining. iii) Give the practical applications of WJM. UNIT 4: Electrochemical Machining (ECM): 1. Discuss Faraday s laws with respect to ECM Discuss electrochemical grinding 3. Discuss the effect of process parameters of ECM on MRR 4. Define electrochemical machining process and explain the elements of the ECM process. 5. Write and explain chemistry of electro chemical process 6. Explain electrochemical grinding with a schematic diagram. 7. 8. UNIT 5: Chemical Machining (CHM): 1. With a block diagram, describe chemical blanking 3. 4.Discuss the masking techniques for different production level. 5. What are the factors on which the selection of a resist for use in chemical machining depend? 6. Distinguish between cut and peel resists and photographic resists. 7. Explain chemical milling and blanking with a suitable block diagram.
UNIT 6 Electrical Discharge Machining (EDM): 1. 3. 4. 5. 6. Draw a neat sketch and explain wire cut EDM and electro discharge grinding. 7.Explain the principle and mechanism of metal removal in electro discharge machining Process UNIT 7: Plasma Arc Machining (PAM): 1. Write and explain metal removal mechanism in plasma arc machining. 3. 4. 5. 6. 8. What are the safety precautions to be followed while operating PAM? State the advantages and disadvantages for the same. UNIT 8: Laser Beam Machining (LBM) and Electron Beam Machining (EBM 1.
3. Sketch and explain laser Beam machining. 4. Explain the mechanism of material removal in EBM 5. Explain the limitations of LBM 6. Write a note on a. Electron beam machining. b. Laser beam machining. 7. 8. 9. 10. 11..