ML8001 Modern Manufacturing Process Notes

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UNIT I INTRODUCTION

Need of Non-Traditional Machining Processes
Classification Based on Energy, Mechanism,
source of energy, transfer media and process
Process selection-Based on Physical Parameters,
shapes to be machined,
process capability and economics
Overview of all processes.

UNIT II MECHANICAL PROCESS

Ultrasonic Machining: Principle
Transducer types
Concentrators
Abrasive Slurry
Process Parameters
Tool Feed Mechanism
Advantages and Limitations
Applications.
Abrasive Jet Machining: Process
Principle
Process Variables
Material Removal Rate
Advantages and Limitations
Applications. Water Jet Machining: Principle
Process Variables
Advantages and Limitations
Practical Applications
Abrasive water jet machining process.

UNIT III ELECTRICAL DISCHARGE MACHINING

Electrical Discharge Machining: Mechanism of metal removal
Dielectric Fluid
Flushing methods
Electrode Materials
Spark Erosion Generators
Electrode Feed System
Material Removal Rate
Process Parameters
Tool Electrode Design
Tool wear Characteristics of Spark Eroded Surfaces
Advantages and Limitations
Practical Applications.
Electrical Discharge Wire Cut and Grinding: Principle
Wire Feed System
Advantages and Limitations
Practical Applications

UNIT IV CHEMICAL AND ELECTRO CHEMICAL MACHINING

Chemical Machining: fundamentals,
Principle –classification and selection of Etchant
chemical milling, Engraving, Blanking
Advantages and limitations
Applications.
Electro Chemical Machining: Electro-chemistry of the process
Electrolytes
Electrolyte and their Properties
Material Removal Rate
Tool Material
Tool Feed System
Design For Electrolyte Flow
Process Variables
Advantages and Limitations
Applications
Electro Chemical Grinding: Honing, cutting off,
Deburring and turning.

UNIT V HIGH ENERGY MACHINING PROCESS

Electron Beam Machining: Principle
Generation and control of electron beam
Advantages and Limitations
Applications.
Laser Beam Machining: Principle
Solid and Gas Laser Application
Thermal Features of LBM
Advantages and Limitations
Applications.
Ion Beam Machining: Equipment
process characteristics
Advantages and Limitations
Applications.
Plasma Arc Machining: Principle
Gas mixture
Types of Torches
Process Parameters
Advantages and Limitations
Applications.
Ion Beam Machining
Principle
MRR
advantages, limitation, applications.

OUTCOMES

  • Describe the modern manufacturing process with respect to productivity economic
  • Explain the trends in development of manufacturing process selection of suitable process for metal cutting and non-traditional manufacturing.

TEXT BOOKS

  1. P.C Pandey And H.S. Shan, “Modern Machining Process”, Tata Mc Graw – Hill Publishing Company Limited, New Delhi, 2007
  2. V.K. Jain, “Advanced Machining Process”, Allied Publishers Pvt Limited 2007

REFERENCES

  1. Amithaba Bhattacharyya, “New Technology”, The Institution Of Engineers, India
  2. HMT Bangalore, "Production Technology”, Tata Mc Graw–Hill Publishing Company Limited, New Delhi, 2006.
  3. Hassan El – Hofy “Advanced machining Processes” MC Graw-Hill, 2005.