NON TRADITIONAL MACHINING
Course Code BME405A
CIE Marks 50
Teaching Hours/Week (L: T:P: S) 3:0:0:0
SEE Marks 50
Total Hours of Pedagogy 40
Total Marks 100
Credits 03
Exam Hours 03
Examination nature (SEE) Theory
Module-1
Introduction to Non-traditional machining
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 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.
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 (Course Skill Set)
At the end of the course, the student will be able to :
CO1: Describe non-traditional machining process and compare with Traditional machining
process. Recognize the need for Non-traditional machining process.
CO2: Describe the constructional features, performance parameters, process characteristics,
applications, advantages, and limitations of USM, AJM and WJM.
CO3: Characterize the need of Chemical and electro-chemical machining process along with the
constructional features, process parameters, process characteristics, applications,
advantages, and limitations.
CO4: Illustrate the constructional feature of the equipment, process parameters, process
characteristics, applications, advantages and limitations EDM & PAM
Suggested Learning Resources:
Books
TEXT BOOKS:
1. Modern Machining Process by P.C Pandey and H S Shah, McGraw Hill Education India Pvt. Ltd.
2000
2. Wellar, E.J. "Non-Traditional Machining Processes", Society of Manufacturing Engineers
Publications, 2nd Edition, Michigan, 1984.
3. Non Traditional Manufacturing Processes, by Gary F Benedict, Taylor & Francis
REFERENCE BOOKS:
1. Production technology, HMT, McGraw Hill Education India Pvt. Ltd. 2001
2. New Technology, Dr. Amitabha Bhattacharyya, The Institute of Engineers (India), 2000
3. Modern Machining process, Aditya, 2002.
4. Non-Conventional Machining, P.K.Mishra, The Institution of Engineers (India) Test book series,
Narosa Publishing House – 2005.
5. Metals Handbook: Machining Volume 16, Joseph R. Davis (Editor), American Society of Metals (ASM)
6. Gary F. Benedict, ―Nontraditional manufacturing processes‖, Marcel Dekker, Inc. 1987.
Web links and Video Lectures (e-Resources):
• https://nptel.ac.in/courses/112105127
0 Comments