06ME665-Non –Traditional Machining |
PART – A |
UNIT I: |
INTRODUCTION: History, Classification, comparison between
conventional and Non-conventional machining process selection |
UNIT II: |
ULTRASONIC MACHINING (USM): Introduction, equipment, tool
materials & tool size, abrasive slurry, cutting tool system design:- Effect of
parameter: Effect of amplitude and frequency and vibration, Effect of
abrasive grain diameter, effect of applied static load, effect of slurry, tool &
work material, USM process characteristics: Material removal rate, tool wear,
Accuracy, surface finish, applications, advantages & Disadvantages of USM.
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UNIT III: |
ABRASIVE JET MACHINING (AJM): Introduction, Equipment,
Variables in AJM: Carrier Gas, Type of abrasive, size of abrasive grain,
velocity of the abrasive jet, mean number. abrasive particles per unit volume
of the carrier gas, work material, stand off distance (SOD), nozzle design,
shape of cut. Process characteristics-Material removal rate, Nozzle wear,
Accuracy & surface finish. Applications, advantages & Disadvantages of
AJM. Water Jet Machining: Principal, Equipment, Operation, Application,
Advantages and limitations of water Jet machinery
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UNIT IV: |
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,
Tool size Electrolyte flow arrangement, Handling of slug, Economics of
ECM, Applications such as Electrochemical turning, Electrochemical
Grinding, Electrochemical Honing, deburring, Advantages, Limitations.
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PART – B |
UNIT V: |
CHEMICAL MACHINING (CHM): Introduction, elements of process,
chemical blanking process : Preparation of work piece, preparation of
masters, masking with photo resists, etching for blanking, accuracy of
chemical blanking, applications of chemical blanking, chemical milling
(contour machining): process steps –masking, Etching, process
characteristics of CHM: material removal rate, accuracy, surface finish,
Hydrogen embrittlement, advantages & application of CHM.
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UNIT VI: |
ELECTRICAL DISCHARGE MACHINING (EDM): Introduction,
mechanism of metal removal, dielectric fluid, spark generator, EDM tools
(electrodes) Electrode feed control, Electrode manufacture, Electrode wear,
EDM tool design, choice of machining operation, electrode material
selection, under sizing and length of electrode, machining time. Flushing;
pressure flushing, suction flushing, side flushing, pulsed flushing
synchronized with electrode movement, EDM process characteristics: metal
removal rate, accuracy, surface finish, Heat Affected Zone. Machine tool
selection, Application, EDM accessories / applications, electrical discharge
grinding, Traveling wire EDM.
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UNIT VII: |
PLASMA ARC MACHINING (PAM): Introduction, equipment, nonthermal
generation of plasma, selection of gas, Mechanism of metal removal,
PAM parameters, process characteristics. Safety precautions, Applications,
Advantages and limitations.
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UNIT VIII: |
LASER BEAM MACHINING (LBM): Introduction, equipment of LBM
mechanism of metal removal, LBM parameters, Process characteristics,
Applications, Advantages & limitations.
ELECTRON BEAM MACHINING (EBM): Principles, equipment,
operations, applications, advantages and limitation of EBM.
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REFERENCE |
TEXT BOOKS: |
1. Modern machining process, Pandey and Shan, Tata McGraw Hill
2000
2. New Technology, Bhattacharya 2000
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Reference Books |
1. Production Technology, HMT Tata McGraw Hill. 2001
2. Modern Machining Process, Aditya. 2002
3. Non-Conventional Machining, P.K.Mishra, The Institution of
Engineers (India) Test book series, Narosa Publishing House –
2005.
4. Metals Handbook: Machining Volume 16 Joseph R. Davis (Editor), American Society of Metals (ASM)
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