ME2026 Unconventional Machining Processes Handwritten Lecture Notes - Damodhiran Edition

[Srini]

   

Anna University , Chennai

Department of B.E-Mechanical Engineering

Sixth Semester

ME2026 Unconventional Machining Processes

Handwritten Scanned Lecture Notes (All Units)

(Regulation 2008) 

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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
·[font=Times New Roman]         [/font]Principle – Description – Working
 Process parameter – Metal removal rate
Carrier Gas
Type of Abrasive
·[font=Times New Roman]         [/font]Size of Abrasive Grain
·[font=Times New Roman]         [/font]Gas Pressure
·[font=Times New Roman]         [/font]Velocity of Abrasive Particle
·[font=Times New Roman]         [/font]Mixing Ratio
·[font=Times New Roman]         [/font]Mass Flow Rate
·[font=Times New Roman]         [/font]Nozzle Tip Clearance / Stand off distance (SOD)
·[font=Times New Roman]         [/font]Work Material
·[font=Times New Roman]         [/font]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
·[font=Times New Roman]         [/font]Advantage – Disadvantage  - Application
Abrasive Water Jet Machining
·[font=Times New Roman]         [/font]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)
·[font=Times New Roman]         [/font]Advantage – Disadvantage – Application
Ultrasonic Machining (USM)
·[font=Times New Roman]         [/font]Principle – Description
Process Parameters
1.       Material Removal Rate
o[font=Times New Roman]   [/font]Grain size of Abrasive
o[font=Times New Roman]   [/font]Frequency
o[font=Times New Roman]   [/font]Concentration of sherry
o[font=Times New Roman]   [/font]Amplitude of Vibration
o[font=Times New Roman]   [/font]Abrasive Materials
o[font=Times New Roman]   [/font]Feed Force
o[font=Times New Roman]   [/font]Hardness Ratio
o[font=Times New Roman]   [/font]Viscosity of Slurry
2.       Tool Material
3.       Wear Rate
4.       Abrasive Materials and Abrasive Slurry
5.       Surface Finish
Work Material
Advantage of USM
Disadvantage of USM
Application of USM
 
UNIT III ELECTRICAL ENERGY BASED PROCESSES
Electric Discharge Machining (EDM)
·[font=Times New Roman]         [/font]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
·[font=Times New Roman]         [/font]Advantage – Disadvantage – Applications
Wire Cut EDM
·[font=Times New Roman]         [/font]Construction and Working
·[font=Times New Roman]         [/font]Process Parameter
·[font=Times New Roman]         [/font]Advantage
·[font=Times New Roman]         [/font]Disadvantage
·[font=Times New Roman]         [/font]Applications

UNIT IV CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
Introduction
Chemical Machining
·[font=Times New Roman]         [/font]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
·[font=Times New Roman]         [/font]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

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