Unconventional Machining Process

Course Objectives:

• The course aims in identifying the classification of unconventional machining processes.

• To understand the principle, mechanism of metal removal of various unconventional machining processes.

• To study the various process parameters and their effect on the component machined on various unconventional machining processes.

• To understand the applications of different processes.

UNIT – I

INTRODUCTION: Need for non-traditional machining methods-classification of modern machining processes – considerations in process selection, applications. Ultrasonic machining – Elements of the process, mechanics of material removal, MRR process parameters, economic considerations, applications and limitations.

UNIT – II

ELECTRO – CHEMICAL MACHINING: Fundamentals of electro chemical machining, electrochemical grinding, electro chemical honing and deburring process, metal removal rate in ECM, Tool design, Surface finish and accuracy, economic aspects of ECM – Simple problems for estimation of metal removal rate, fundamentals of chemical, machining, advantages and applications.

UNIT - III

THERMAL METAL REMOVAL PROCESSES: General principle and applications of Electric Discharge Machining, Electric Discharge Grinding and wire EDM – Power circuits for EDM, Mechanics of metal removal in EDM, Process parameters, selection of tool electrode and dielectric fluids, surface finish and machining accuracy, characteristics of spark eroded surface

UNIT – VI

Electron Beam Machining, Laser Beam Machining - Basic principle and theory, mechanics of material removal, process parameters, efficiency & accuracy, applications

UNIT-V

Plasma Machining: Application of plasma for machining, metal removal mechanism, process parameters, accuracy and surface finish and other applications of plasma in manufacturing industries.

UNIT – VI

Abrasive jet machining, Water jet machining and abrasive water jet machining: Basic principles, equipments, process variables, mechanics of material removal, MRR, application and limitations, agnetic abrasive finishing, abrasive flow finishing, Electrostream drilling, shaped tube electrolytic machining.