1 Teaching Innovation - Entrepreneurial - Global The Centre for Technology enabled Teaching & Learning, N Y S S, India DTEL DTEL (Department for Technology Enhanced Learning)

DEPARTMENT OF MECHANICAL ENGINEERING V-SEMESTER A DVANCED PRODUCTION PROCESSES. 2 COURSE CODE BEME503T CHAPTER NO.1 INTRODUCTION TO NON CONVENTIONAL MACHINING PROCESS

CHAPTER 1:- SYLLABUSDTEL. Intoduction & classification to Non-Conventional M/C Processes. 1 Electrochemical, Electrical Discharge Machining. 2 Ultrasonic, Laser Beam Machining. 3 Electron Beam Machining. 4 3 Water and Abrasive Jet Machining. 5

CHAPTER-1 SPECIFIC OBJECTIVE / COURSE OUTCOMEDTEL Understand the concept of Non-Conventional M/C Process. 1 Classification,Advantages,Disadvantages & Application The student will be able to:

LECTURE 1DTEL Introduction 5 5 Modern machining methods are also named as non conventional machining methods. These methods form a group of processes which removes excess material b y various techniques involving mechanical, thermal, electrical chemical energy or combination of these energies. There is no cutting of metal with the help of metallic tool having sharp cutting edge. Need of machine newly developed metals and non metals having some special properties like high strength, high hardness and high toughness. A material possing the above mentioned properties are difficult to be machined by the conventional machining methods. Sometimes it is required to produce complex part geometries that cannot be produced by following conventional machining techniques.Non conventional machining method also provide very good quality of surface finish which may also be an encouragement to these methods

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LECTURE 2:-DTEL E.C.M. PROCESS. 7 7

DTEL 8 LECTURE 2:- Electrochemical Machining (ECM) Electrochemical machining is one of the most unconventional machining processes. The process is actually the reverse of electroplating with some modifications. It is based on the principle of electrolysis. In a metal, electricity is conducted by free electrons but in a solution the conduction of electricity is achieved through the movement of ions. Thus the flow of current through an electrolyte is always accompanied by the movement of matter. In the ECM process the work-piece is connected to a positive electrode and the tool to the negative terminal for metal removal.

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DTEL E.D.M. PROCESS. 10 LECTURE 3:-

DTEL E.D.M. Process. 11 LECTURE 3 Electrical D ischarge Machining (EDM) EDM is the process of material removal by a controlled erosion through a series of electric sparks. It was developed in USSR around When a discharge takes place between two points of the anode and cathode the intense heat generated near the zone melts and evaporates the materials in the sparking zone. For improving the effectiveness the work-piece and the tool are submerged in a dielectric fluid. (Mineral oils or hydrocarbons)

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DTEL U.S.M. 13 LECTURE 4 Ultrasonic Machining Process.

DTEL U.S.M. 14 LECTURE 4:- Ultrasonic Machining (USM) USM is mechanical material removal process or an abrasive process used to erode holes or cavities on hard or brittle workpiece by using shaped tools, high frequency mechanical motion and an abrasive slurry. USM offers a solution to the expanding need for machining brittle materials such as single crystals, glasses and polycrystalline ceramics, and increasing complex operations to provide intricate shapes and workpiece profiles. It is therefore used extensively in machining hard and brittle materials that are difficult to machine by traditional manufacturing processes. The hard particles in slurry are accelerated toward the surface of the workpiece by a tool oscillating at a frequency up to 100 KHz - through repeated abrasions, the tool machines a cavity of a cross section identical to its own.

DTEL U.S.M. 15 LECTURE 4 Ultrasonic Machining (USM) USM is primarily targeted for the machining of hard and brittle materials (dielectric or conductive) such as boron carbide, ceramics, titanium carbides, rubies, quartz etc. USM is a versatile machining process as far as properties of materials are concerned. This process is able to effectively machine all materials whether they are electrically conductive or insulator.

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DTEL L.B.M. 17 LECTURE 5:-

DTEL L.B.M. 18 LECTURE 5:- Laser–Beam Machining (LBM) Laser-beam machining is a thermal material-removal process that utilizes a high-energy,coherent light beam to melt and vaporize particles on the surface of metallic and non-metallic workpieces. Lasers can be used to cut, drill, weld and mark. LBM is particularly suitable for making accurately placed holes.

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DTEL E.B.M. 20 LECTURE 6:- Electron beam is generated in an electron beam gun. Electron beam gun provides high velocity electrons over a very small spot size Electron Beam Machining Electron Beam Machining is required to be carriedout in vacuum.

DTEL E.B.M. 21 LECTURE 6:- Electron Beam Machining

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DTEL W.J.M. 23 LECTURE 7:- The water jet machining involves directing a high pressure ( MPa) high velocity ( m/s) water jet(faster than the speed of sound) to the surface to be machined. The fluid flow rate is typically from 0.5 to 2.5 l/min The kinetic energy of water jet after striking the work surface is reduced to zero. Water Jet Machining.

DTEL W.J.M 24 LECTURE 7:- Water Jet Machining.

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DTEL A.J.M. 26 LECTURE 8:- Abrasive Jet Machining Abrasive jet machining is machining process in which the operation is carriedout by continuous bombarding of abrasive particles (grains) on the surface of metal to be machining, with the help of (mixing with) pressurizes air.

DTEL A.J.M. 27 LECTURE 8:- Abrasive Jet Machining

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