PART - A

UNIT - 1

Introduction: History, Classification, Comparison between conventional and non-conventional machining process selection.

Mechanical Process: Ultrasonic machining (USM) :  Introduction, Equipment, tool materials & tool Size, Abrasive slurry, Cutting tool system design : Magnetostriction assembly, Tool cone (Concentrator), Exponential concentrator of circular cross section & rectangular cross section Hallow cylindrical concentrator. Mechanics of cutting : Theory of Miller & Shaw Effect of parameter : Effect of amplitude and frequency and vibration, Effect of grain diameter , Effect of applied static load, Effect of slurry, Tool and work material, USM process Characteristics ; Material removal rate, tool wears, Accuracy, surface finish., Applications, Advantages & Disadvantages of USM.         

8 Hours

UNIT - 2

Abrasive Jet Machining (AJM): Introduction, Equipment, Variables in AJM: carrier Gas Type of abrasive, Size of abrasive grain, velocity of the abrasive jet, Mean No. 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.

6 Hours

UNIT - 3

Electrochemical and Chemical Metal Removal Process: 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.

6 Hours

UNIT - 4

ECM Tooling: ECM tooling technique 7 example, Tool &insulation materials, Tool size Electrolyte flow arrangement, Handling of slug., Economics of ECM, Applications such as Electrochemical turning, Electrochemical Grinding, Electrochemical Horning, deburing, Advantages, Limitations.

6 Hours

PART - B

UNIT - 5

Chemical Machining (CHM): Introduction, Elements of process Chemical blanking process :- Preparation of work piece.  Preparation of masters, masking with photo resists, etching for 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.

8 Hours

UNIT - 6

EDM Process: Introduction, machine, mechanism of metal removal, dielectric fluid, spark generator, EDM tools (electrodes) Electrode feed control, Electrode manufacture, Electrode wear, EDM tool design : Choice of matching operation, electrode material selection, under sizing and length of electrode Machining time.

6 Hours

UNIT - 7

EDM Process Characteristics: Flushing – Pressure flushing synchronized with electrode movement, EDM process characteristic: Metal removal rate, Accuracy surface finish, Heat affected Zone. Machine tool selection, Application: EDM accessories / applications, electrical discharge grinding, Travelling wire EDM.

6 Hours

UNIT - 8

Plasma Arc Machining (PAM): Introduction, equipment non-thermal generation of plasma, selection of gas, Mechanism of Metal removal, PAM parameters, Process characteristics. Safety precautions, Applications, Advantages and limitations.

6 Hours

TEXT BOOKS:

1.      Modern machining process - PANDEY AND SHAH, TATA Mc Graw Hill 2000.

2.      New technology - BHATTACHARAYA 2000

REFERENCE BOOKS:

1.      Production Technology, by HMT TATA McGraw Hill 2001.

2.      Modern Machining Process - ADITYAN 2002.

3.      Thermal Metal cutting processes - B G Ranganath - I K International Publishing house Pvt. Ltd,

4.      Fundamentals of Machining and Machine Tools - R.K.Singal - I K International Publishing house Pvt. Ltd,