Syllabus - Non Conventional Machining Processes (AB602)

Automation and Robotics

Non Conventional Machining Processes (AB602)

VI

Unit 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.

Unit 2

Ultrasonic Machining (USM) and Abrasive Jet Machining (AJM)

Ultrasonic Machining (USM) ; Introduction, Equipment and process of material removal, 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.

Unit 3

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 of ECM: Electrochemical grinding and electrochemical honing process. Advantages, disadvantages and application of ECG, ECH.

Unit 4

Electrical Discharge Machining (EDM) and Plasma Arc Machining (PAM)

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.

Unit 5

Laser Beam Machining (LBM) and Electron Beam Machining (EBM)

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 Objective

Understand and compare traditional and non-traditional machining processes and recognize the need for non-traditional machining process.

Course Outcome

["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 features, process parameters, process characteristics, applications, constructional 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"]

Practicals

  • Comparative study of unconventional Machining processes under following parameters: (i) Energy Type (ii) Mechanics of Material Removal (iii) Energy Source (iv) Process

  • Study of working principle, various parts and applications of EDM.

  • Study of working principle, various parts and applications of ECM

  • Study of working principle, various parts and applications of AJM

  • Study of working principle, various parts and applications of Laser Beam Machining Method

  • Study of working principle, various parts and applications of Electron Beam Machining (EBM)

  • Study of working principle, various parts and applications of Plasma Arc Machining (PAM)

Reference Books

  • P.C Pandey and H S Shah ; Modern Machining Process , McGraw Hill Education India Pvt. Ltd

  • V.K.Jain , Advanced Machining Processes, Allied Publishers

  • P.K.Mishra Advanced Machining Processes, Paradise Books Publisher

  • Jagdeesha T Non conventional Machining Processes, Wiley India