Unconventional Machining Processes Premium Lecture Notes - Damodhiran Edition

Unconventional Machining Processes Premium Lecture Notes. Specially for Mechanical Engineering Candidates. Syllabus Covered based on Anna University B.E Mechanical Engineering Sixth Semester.

Syllabus :

UNIT I INTRODUCTION

UNIT II MECHANICAL ENERGY BASED PROCESSES

UNIT III ELECTRICAL ENERGY BASED PROCESSES

UNIT IV CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES

UNIT V THERMAL ENERGY BASED PROCESSES

Content :

UNIT I INTRODUCTION

Conventional machining Process

Disadvantage of Conventional machining Process

Unconventional manufacturing Process

Unconventional machining Process

Need for Unconventional machining Process

Classification of Unconventional machining Process

1. Thermal Energy Methods
2. Electrical Energy Methods
3. Electro Chemical Energy Methods
4. Chemical Energy Methods
5. Mechanical Energy Methods

Process Selection

1. Physical Parameter
2. Shapes to be machined
3. Materials to be machined
4. Process Capability
5. Economic Considerations

Advantage of Unconventional machining Process

Disadvantage of Unconventional machining Process

UNIT II MECHANICAL ENERGY BASED PROCESSES

Introduction

Abrasive Jet Machining

• Principle – Description – Working

 Process parameter – Metal removal rate

Carrier Gas

Type of Abrasive

• Size of Abrasive Grain
• Gas Pressure
• Velocity of Abrasive Particle
• Mixing Ratio
• Mass Flow Rate
• Nozzle Tip Clearance / Stand off distance (SOD)
• Work Material
• Shape of Cut

Advantage of AJM

Disadvantage of AJM

Application of AJM

Water Jet Machining

Principle – Description – Working

Process Parameter

Material Removal Rate (MRR)

Geometry and Surface Finish of Work Material

Wear Rate of the Nozzle

• Advantage – Disadvantage  - Application

Abrasive Water Jet Machining

• Principle – Description – Working

Abrasive Type

Abrasive Size

Abrasive Flow Rate

Process Parameter

Water Flow Rate

Water Pressure

Traverse Speed

Number of Passes

Stand off Distance (SOD)

Material Removal Rate (MRR)

• Advantage – Disadvantage – Application

Ultrasonic Machining (USM)

• Principle – Description

Process Parameters

1. Material Removal Rate

• Grain size of Abrasive
• Frequency
• Concentration of sherry
• Amplitude of Vibration
• Abrasive Materials
• Feed Force
• Hardness Ratio
• Viscosity of Slurry

1. Tool Material
2. Wear Rate
3. Abrasive Materials and Abrasive Slurry
4. Surface Finish

Work Material

Advantage of USM

Disadvantage of USM

Application of USM

UNIT III ELECTRICAL ENERGY BASED PROCESSES

Electric Discharge Machining (EDM)

• Principle – Description

Dielectric Flusing

Power Circuit used in EDM

Resistance – Capacitance Circuit

Resistance – Capacitor – Inductance Circuit

Rotary Pulse Generator

Controlled Pulse Circuit

Process Parameter

Metal Removal Rate

Frequency of Discharge

Overcut

Dielectric Pollution

• Advantage – Disadvantage – Applications

Wire Cut EDM

• Construction and Working
• Process Parameter
• Advantage
• Disadvantage
• Applications

UNIT IV CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES

Introduction

Chemical Machining

• Principle – Working

Etchants

Maskant

Methods / Techniques of Applying Maskant

1. Cut and Peel
2. Screen Printing
3. Photoresist Maskant

Surface Finish

Classification of Chemical Machining Process

1. Chemical Milling
2. Chemical Blanking

Advantage of CHM

Disadvantage of CHM

Application of CHM

Electrochemical Machining

• Principle – Working

Cathode Tool

Anode Workplace

D.C Power and Control System

Electrolyte

Surface Roughness

Material Removal Rate

Solved Problems

Tool Design

Factors of Tool

Advantage

UNIT V THERMAL ENERGY BASED PROCESSES

Thermal Energy based processes

Electron Beam Machining (EBM)

Construction and Working of EMB

Electron Beam Gun

Power Supply

Vacuum System and Machining Chamber

Mechanics of EBM

Process Parameters

Effect of Thermal velocities

Spherical deviation of focusing lens

Space charge sprcading of target

Advantage of EBM Process

Disadvantage of EBM Process

Applications

Solved Problems

Laser Beam Machining

Principle of Laser beam production

Principle of Laser Beam Machining

Working of LBM

Solid State Laser Resonator Construction

Gas (Carbon dioxide) laser resonator construction

Machining Application of LASER

LASER Drilling

Advantages of Laser Drilling

Disadvantages of Laser Drilling
Application of Laser Drilling

Plasma arc Machining

Working

Process Parameters

Advantages – Disadvantages - Applications