Introduction to Non-Traditional machining (BME755A)

Introduction to Non-Traditional machining

Course Code BME755A 
CIE Marks 50
Teaching Hours/Week (L: T:P: S) 3:0:0:0 
SEE Marks 50
Total Hours of Pedagogy 40 hrs 
Total Marks 100
Credits 03 
Exam Hours 3
Examination type (SEE) Theory

Module­1

Introduction to Non­traditional machining, Need for Non­traditional machining process, Comparison

between traditional and non­traditional machining, general classification Non­traditional machining

processes, classification based on nature of energy employed in machining, selection of nontraditional machining processes, Specific advantages, limitations and applications of non­traditional

machining processes.

Module­2

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, stand­off distance (SOD). Process characteristics­Material 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 process­chemical 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 medium­its 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, non­thermal generation of plasma, equipment

mechanism of metal removal, Plasma torch, process parameters, process characteristics. Safety

precautions. Safety precautions, applications, advantages and limitations

Module­5

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.

Suggested Learning Resources:

Text Books:

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