I high surface nish nanolevel ra value i miniaturization of products examples. Manufacturing process technology part i 28,171 views. Book download link provided by engineering study material esm. Conventional machining methods hacettepe universitesi. Limitations out of all the unconventional machining methods, electro chemical machining. The advent of hard materials for aerospace applications have made the machining process by conventional methods very difficult and time consuming.
Pdf nonconventional machining processes selection using. This process may be used for machining any material, irrespective of its hardness. Introduction as a result of the advances in machine tools and cutting tool technology in recent decades, many of the conventional machining processes such as turning, milling and drilling have become costeffective, flexible and highthroughput manufacturing processes for producing high precision and high. Machining centers machining center highly automated machine tool capable of performing multiple machining operations under cnc control. Basic concept of electrochemical machining process with its. Machining process flow chart is an important document to guide machining, while also ensuring the quality of processing, based on the machining process allows higher productivity and lower cost. Machining is a processes in which a piece of raw material is cut into a desired final shape and size by a controlled materialremoval process. Unconventional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be used for.
Nontraditional manufacturing processes or unconventional machining processes conventional machining processes mostly remove material in the form of chips by applying forces on the work material with a wedge shaped cutting tool that is harder than the work material under machining condition. This channel is formed by faculty from bit to enhance the knowledge of students towards technical and fundamentals. The removal of material can be achieved by cutting, abrasion, and erosion. Manufacturing processes i nptel online videos, courses. Non traditional machining process mechenchy modern machining processes by p. Conventional machining processes and machine tools module.
So, due to this, edm is particularly useful in machining of small holes, orifices, slots in diesel fuel injection nozzles, airbrake valves and aircraft engines etc. Jain department of mechanical engineering, indian institute of technology kanpur, kanpur208016, india. While making a part from raw material, one may require bulk removal of material, forming cavitiesholes and finally finishing as per the parts requirements. Ultrasonic machining feed mechanism, head design and other aspects. After achieving the merits of nonconventional machining methods, efforts are being made for cross process innovations to improve the machining characteristics.
The unconventional machining is also called as nontraditional machining the unconventional machining use for the machine the hard and brittle materials such as carbides, stainless steel, hastelloy, nitralloy, waspalloy, and any other that cannot be machined by a conventional process using the conventional machines such as lathe, milling, shaper, planer etc. The former onesprovide basic shape and size to the material as per designers requirement. Ultrasonic machining is a mechanical type nontraditional machining process. Hence the machining process which utilizes other machining methods are termed as unconventional. Senthil kumar, ars publications the book unconventional machining processes for engineering and technology studies. It is employed to machine hard and brittle materials both electrically conductive and non conductive material having hardness usually greater than 40 hrc. In addition, non traditional manufacturing processes, like electrodischarge machining edm, laser beam machining, plasma cutting etc are also a part of this course. There are 10 steps to draw up machining process flow chart.
Automatic tool changer pallet shuttles automatic workpart positioning cnc turning center. The following list of questions is to get you thinking about some important concepts during the design process. After achieving the merits of nonconventional machining methods, efforts are being made for crossprocess innovations to improve the machining characteristics. If you cannot answer all of these questions, do not get frustrated since some of them are open ended. Electrochemical machining is one of the most unconventional machining processes. Basic working principle, configuration, specification. In order to make the concepts easier to understand, a variety of applications are discussed as well as several numerical problems are worked out. Manufacturing processes can be broadly divided into two groups and they are primarymanufacturing processes and secondary manufacturing processes. The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process.
This is due to material removal rate mrr decreases with increased hardness of the work material. The process was first developed in 1950s and was originally used for finishing edm surfaces. A new nontraditional machining method using cavitation. Material al2o3 sic glass beads shape irregular spherical size 10 50. The metal removal takes place due to the erosion caused by the electric spark. Process details of wcedm are almost similar to edm with slight difference. The details of the process are indicated in the line diagram shown in figure 5. The answers will fall into place as experience is gained. Process parameters and machining characteristics abrasive. Tools that belongs to reaming and tapping processes are tend to breakage so machinists should behave carefully not to break tapers and reamers pieces in the hole. Pdf unconventional machining processes local author by. Examples of conventional machining processes are turning, boring, milling, shaping, broaching, slotting, grinding etc.
Jan, 2016 manufacturing process technology part i 28,171 views. Me 206 manufacturing processes 1 department academic. Removal of unwanted material in the form of chips in order to create a geometric shape market. In unconventional machining, a form of energy is used to remove unwanted material from a given workpiece. The two most extensively used unconventional machining processes are. To learn about various unconventional machining processes, the various process parameters and their influence on performance and their applications. Introduction to nontraditional machining iit kanpur. A new nontraditional machining method using cavitation process. Unconventional machining processes introduction and. Nonconventional machining processes selection using multiobjective 1449 journal of engineering science and technology november 2015, vol. Selectthe best process from the remaining processes under consideration by optimizing process performance criteria.
The wire edm process can cut intricate components for the electric and aerospace industries. Conventional machining uses tools, such as lathes, milling machines, boring machines, drill presses, or. Fundamentals of machining processes by hassan abdel contains total 16 chapters, such as cutting tools, maintainability, micromachining, high speed machining, abrasives etc. Modern machining processes tata mcgrawhill, new delhi, 2007. Please switch to hard cover of fundamentals of machining process. Each week you should save the documents matching the lecture topic listed on the course syllabus and either bring them with you to class on a working laptop or bring a printed copy on which highlights can be made.
This book is written to serve the needs of under graduate students embarking introductory course in unconventional machining processes. All questions carry equal marks 1 a classify unconventional machining processes based on basic mehanism involved in the process and medium for tranfer of enrgies and type of energy. Ultrasonic machining effects of various inputs on the output. Materials are removed by traversing in a direction parallel to the axis of rotation of axis or along a specified path to form a complex rotational shape.
The aim of the mtcs nonconventional machining ncm theme is to provide efficient, costeffective solutions for the manufacture of traditionally difficult to machine materials using stateoftheart spark erosion and laser technologies. Efficient material removal technologies for demanding applications. Classification of metal removal processes and machine tools. This paper presents a new method in machining of materials using cavitation process. Given this, nontraditional machining is widely utilized in responding to modern industrial problems. Edm is also known as spark erosion machining or simply spark machining.
The process is actually the reverse of electroplating with some. Download link is provided and students can download the anna university me6004 unconventional machining processes ump syllabus question bank lecture notes syllabus part a 2 marks with answers part b 16 marks question bank with answer, all the materials are listed below for the students to make use of it and score good maximum marks with our study materials. Non traditional manufacturing processes an overview. The course is aimed at teaching the pros and cons of different processes, so that one can apply this knowledge to the selection of a process for making a part to the required. Advanced machining processes nptel online videos, courses. Unconventional machining process imp qusts ump important. Principles of nontraditional machining processes machining. An introduction to machining practices cornell university. The material removal rate in mm 3 min is expressed as. Machining a material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application.
A circular hole of 25 mm diameter and depth of 20 mm is machined by edm process. Applications of electric discharge machining process. It is the material removal process where the material is removed or machined by the impact. Non traditional machining processes linkedin slideshare. Cannot be used for machining castings or hot rolled steel, since hard outer scale will damage the cutter. Me2026 unconventional machining process 10 sce department of mechanical engineering 2. Conventional machining processes and machine tools moduleiv turning turning operation is a machining process and is used to produce round parts in shape by a single point cutting tool. Dec 29, 2015 machining is a processes in which a piece of raw material is cut into a desired final shape and size by a controlled materialremoval process. The introduction of abrasives to the fluid jet enhances the machining efficiency and is known as abrasive water jet machining. Brief introduction of nonconventional machining processes. Mechanical engineering manufacturing processes ii nptel.
Grinding grinding is the most common form of abrasive machining. However, machining processes inevitably waste material in the form of chips, production rates may be low, and unless carried out properly, the processes can have detrimental effects on the surface properties and performance of parts. Read through this list and familiarize yourself with these. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. I high mrr i high production rate while processing di cult to machine. Analysis of part drawing and assembly drawing this is the basis of the machining. Lecture series on manufacturing processes i by prof. The subject includes, the study of modern machining processes like. Conventional and non conventional machining processes duration. Jun 20, 2016 the advent of hard materials for aerospace applications have made the machining process by conventional methods very difficult and time consuming. Its major difference of process details with edm process details are described below. Product requirement i complex shapes i machining in inaccessible areas i low tolerances say, 0. Unconventional machining process imp qusts pdf file ump important questions please find the attached pdf file of unconventional machining process importan.
An unconventional machining process or nontraditional machining process is a special type of machining process in which there is no direct contact between the tool and the workpiece. Conventional machining processes and machine tools pdf. Each of the modern machining processes is discussed in a separate chapter, with the most uptodate information and an emphasis on the economics of processes. Traditional machining processes consist of turning, boring, drilling. Machining cutting action involves shear deformation of work material to form a chip as chip is removed, a new surface is exposed figure 21.
Machining processes produce finished parts, ready for use or assembly, at high degree of accuracy and surface quality by removing a certain machining allowance from the workpiece material. Compare process parameters of different unconventional manufacturing processes. Reference material should only be used as a tool to strengthen concepts and not as a substitute for your class notes. An unconventional machining process or nontraditional machining process is a special type of machining process in which there is no direct. While it is a good practice to refer to textbooks or video lectures besides your class notes, it is also important to remember that these sources may not be flawless. Me 338 manufacturing processes ii department academic. In unconventional machining, a form of energy is used to remove unwanted material from a. Ashish umarkar advanced manufacturing processes amp12154 unit no. Features such as smooth shiny surfaces, smalldiameter deep holes in a part, threaded section, and threaded holes all require further manufacturing operations.