COURSE FILE  
 
of 
 
Modern Machining & Forming Methods 
(​PE602ME​) 
 
ACADEMIC YEAR 2018-19: V SEMESTER 
 
 

   

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DEPARTMENT OF MECHANICAL ENGINEERING  
 
COURSE DESCRIPTION FILE 
 
Academic Year & Semester  2018-19 
Course Code  PE602ME 
Course Title  MODERN MACHINING & METAL FORMING 
Curriculum Regulation  CBCS – OU (Affiliated Colleges) 
Semester  V Sem 
Course Instructor  Mr. A Rajasekhar 

I. PREREQUISITE(S): 
Level  Credits  Semester  Prerequisites 
UG  4  1  MACHINE TOOLS 

II. SCHEME OF INSTRUCTIONS 

Lectures  Tutorials  Practicals  Credits 
3  1  -  3 

III. SCHEME OF EVALUATION & GRADING 

S. No  Component  Duration  Maximum Marks 
Continuous Internal Evaluation 
     
(CIE) 
1.  Internal Examination – I  60 minutes  20 
2.  Internal Examination - II  60 minutes  20 
Average of the two internal 
    20 
exams 
3.  Assignments  -  5 
4.  Quizzes  -  5 
  CIE (Total)    30 
Semester End Examination 
5.  3 hours  70 
(University Examination) 
    TOTAL  100 
 
 
 
 
Marks >85 70 to <85 60 to <70 55 to <60 50 to <55 40 to <50 <40 Absent

Grade S A B C D E F Ab
Grade 10 9 8 7 6 5 0 -
 
 

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 IV. SYLLABUS 
Targe
Unit  Syllabus Description  t 
Hours 
Comparison between the traditional & modern machining methods. 
Ultrasonic Machining (USM): Introduction, process description, abrasive slurry, 
Abrasive materials and their characteristics.   
Functions of liquid medium in slurry, Types of Transducers, effect of process 
parameters, applications and limitations. 
I  12 
Abrasive Jet Machining (AJM): Principle of operation, process details, process 
variables and their effect on MRR and accuracy. Equation for MRR. Advantages, 
disadvantages and applications.  
Water Jet Machining (WJM): Schematic diagram, equipment used, advantages 
and .. applications.  
Electro Discharge Machining (EDM): Process description with schematic diagram, 
process parameters, functions and characteristics of dielectric medium, dielectric 
fluids, over cut and side taper: Flushing,  
Mechanism of metal removal, crater volume, types of power supply circuits, 
mathematical analysis of metal removal rate (MRR), characteristics of spark 
eroded surfaces, advantages, disadvantages and applications. 
II  12 
Wire EDM: Process description and applications.  
Electro-Chemical Machining (ECM): Schematic of the process parameters, function 
and characteristics of electrolyte, chemistry of the process, Equation for specific 
MRR and electrode feed rate, advantages, limitations and applications.,  
Rotary Machining, Hot machining, high speed machining, description of each 
process, process parameters, advantages and applications.   
LASER Beam Machining (LBM): Principle of LASER Beam production, materials 
used, thermal analysis of the process, process parameters,   
equations for power density and machining rate, advantages, limitations and 
applications. 
Plasma Arc Machining (PAM): Introduction equipment used, process description 
III  and parameters, types of plasma arc; Transferred arc and non transferred arc and  8 
process applications 
Electron Beam Machining (EBM): Schematic of the process, process parameters, 
principle of production of Electron beam, equipment used, Advantages, 
disadvantages and applications 
ION Etching: Process description and applications. 
Rubber Pad Forming: Principle of the process, process details and its types; Guerin, 
wheelon, Marfoming and Hydro forming processes and applications.  
Electro-Hydraulic forming (EHF): Schematic of the process description and its 
applications.  
IV  8 
High Energy Rate Forming (HERF): HERF hammers, principle of explosive forming, 
Explosive materials, types of explosive forming,  
Stand off operation and contact operation, the pressure pulse, Gas bubble and the 
process applications. 
Stretch Forming: Introduction, types of stretch forming: stretch draw forming, 
rotary stretch forming or stretch wrapping, compression forming,Radial draw 
V  8 
forming. Stretch forming equipment and accessories, accuracy and surface finish, 
process variables and limitations.  

9
 Tube spinning: Introduction, methods of tube spinning, Backward spinning, 
Forward spinning, machines and tools used. Machine variables, speeds and feeds, 
effect of tube spinning on work metal properties and applications.  
Hydrostatic Forming: Process principle, description and applications 
Water Hammer Forming (WHF): Schematic diagram of the process, principle of 
operation, process variables, work materials, process limitations and applications 
  Total   48 
 
Suggested Reading: 

1. P.C. Pandey and H.S. Shah, Modern Machining Process, Tata McGraw Hill Publishing Co. 
Ltd., New Delhi, 1980.  
2. A. Bhattacharya, New Technology, The Institution of Engineers (India), 1984.  
3. Davies and Austin, Developments in High Speed Metal Forming, The Machinery Publishing 
Co. Ltd., 1985.  
4. Production Technology, HMT. 

V. E – RESOURCES 
YouTube Playlist containing all demonstration videos. 
https://www.youtube.com/watch?v=UyK7Ph6yosk&list=PL4FeG6TUj1LkOdf0JdbNbxuFlL5LksUW
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VI. COURSE OBJECTIVES: 

Course Overview:   
The course objective is to introduce the basic principles of Modern Machining & Forming Methods, 
which are in use in the current industry. After learning this course, you should have the ability to:  
● Identify the suitable processes used for the manufacture of a particular product. 
● Choose the right kind of process when specifications & process variables are given. 
● Gain knowledge about different energy domains of the modern machining & forming 
processes. 
● Have basic understanding of the process principles of modern machining methods. 

VII. COURSE OUTCOMES 

Code  Taxonomy 
After completing this course the student will be able to: 
No  Level 
Analyze the suitable processes used for the manufacture of a different 
CO1  Analyze 
product 
Evaluate the processes & identify suitable processes when product 
CO2  Evaluate 
specifications & quality requirements are given. 
Recall knowledge about different energy domains of the modern 
CO3  Remember 
machining & forming processes. 
CO4  Explain the process principles of different Metal forming methods.  Understand 
Evaluate the different modern machining processes & prepare reports, 
CO5  Evaluate 
presentations about the same for further discussions. 

10
 Carry out case studies of large scale or global industries & evaluate 
CO6  Evaluate 
suitability of modern methods in small scale or local industries. 
 

VIII. MAPPING OF COs WITH POs & PSOs 

PO  PO  PO 
PO / CO  PO1  PO2  PO3  PO4  PO5  PO6  PO7  PO8  PO9  PS01  PSO2  PSO3 
10  11  12 
C 501.1  3  3  -  -  -  -  -  -  -  -  -  -  -  3  - 
C 501.2  3  2  -  -  -  -  -  -  -  -  -  -  -  3  - 
C 501.3  3  1  -  3  -  -  -  -  -  -  -  -  -  3  - 
C 501.4  3  1  -  -  -  -  -  -  -  -  -  -  -  3  - 
C 501.5  3  -  -  1  -  -  -  -  -  -  -  -  -  3  - 
C 501.6  -  2  2  3  -  -  -  -  -  -  -  -  -  3  - 
C501  3.0  1.8  2.0  2.3  -  -  -  -  -  -  -  -  -  3.0  - 
 
Gaps identified based on the mapping: 
 
1. The syllabus covers theory, concepts of the Modern Machining Methods but doesn't cover the 
create level exercises. The Program Outcomes from 5 to 12 are not directly addressed. 
 
Plan of Action / Corrective measures: 
1) Industrial visit would be greatly helpful for students to understand the concepts from real 
life professionals. 
2) Teaching of professional ethics can be integrated in the course by encouraging students to 
do the assignments and quizzes honestly and to teach them to report the experimental 
observation without manipulation. 
3) Team work and technical communication is encouraged by giving the student group 
assignments and group tasks to solve a complex problem in parts. 
Revised Mapping closing the gaps: 
PO  PO  PO 
PO / CO  PO1  PO2  PO3  PO4  PO5  PO6  PO7  PO8  PO9  PS01  PSO2  PSO3 
10  11  12 
C 501.1  3  3  -  -  2  -  1  -  -  -  2  -  -  3  - 
C 501.2  3  2  -  -  2  -  1  -  -  -  2  -  -  3  - 
C 501.3  3  1  -  3  -  -  1  -  -  -  2  -  -  3  - 
C 501.4  3  1  -  -  -  -  1  -  -  -  2  -  -  3  - 
C 501.5  3  -  -  1  3  -  -  -  2  -  -  -  -  3  - 
C 501.6  -  2  2  3  -  2  -  -  -  2  -  3  -  3  - 
C501  3.0  1.8  2.0  2.3  2.3  2.0  1.0    2.0  2.0  2.0  3.0    3.0   
 
   

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 CO-PO/PSO mapping Justification 
 
Mapped POs & PSOs (Direct):  PO1, PO2, PO3, PO4,  
Mapped POs & PSOs (Corrective measures): PO5, PO8, P09, P10, PO11 
Course outcomes: 
 
Analyze the suitable processes used for the manufacture of a different 
CO1  Analyze 
product 
PO  Mapping 
Justification 
Mapped  Level 
Identifying the process would first require the student to remember all the 
information regarding the different processes, their concepts, applications, 
PO1  3  advantages & disadvantages 
Every process has different parameters & would need analysis skills of the 
PO2  2  students to a great extent. 
Students would need to analyse the alternative modern technologies that 
are needed for materials which otherwise are very difficult to machine with 
PO5  2  traditional approaches. 
while deciding the suitability of the particular process the student needs to 
PO6  1  consider its effects on society & legalities. 
PO7  1  The student must also assess the effect of each process on the environment. 
The student must be able to assess if a process is viable for small scale / 
PO11  2  large scale application & with what financial benefits. 
     

Evaluate the processes & identify suitable processes when product 

CO2  Evaluate 
specifications & quality requirements are given. 
PO  Mapping 
Justification 
Mapped  Level 
Identifying the process would first require the student to remember all the 
information regarding not only the product but also different processes, their 
PO1  3  concepts, applications, advantages & disadvantages 
Every process has different parameters & would need analysis skills of the 
PO2  3  students to a great extent. 
Students would need to analyse the alternative modern technologies that 
are needed for materials which otherwise are very difficult to machine with 
PO5  2  traditional approaches. 
while deciding the suitability of the particular process the student needs to 
PO6  1  consider its effects on society & legalities. 
PO7  1  The student must also assess the effect of each process on the environment. 
The student must be able to assess if a process is viable for small scale / 
PO11  2  large scale application & with what financial benefits. 

12
 

Recall knowledge about different energy domains of the modern 

CO3  Remember 
machining & forming processes. 
PO  Mapping 
Justification 
Mapped  Level 
Identifying the process would first require the student to remember all the 
information regarding the different processes, their concepts, applications, 
PO1  3  advantages & disadvantages 
Every process has different parameters & would need analysis skills of the 
PO2  2  students to a great extent. 
Students would need to analyse the alternative modern technologies that 
are needed for materials which otherwise are very difficult to machine with 
PO5  2  traditional approaches. 
while deciding the suitability of the particular process the student needs to 
PO6  1  consider its effects on society & legalities. 
PO7  1  The student must also assess the effect of each process on the environment. 
The student must be able to assess if a process is viable for small scale / 
PO11  2  large scale application & with what financial benefits. 
 

Understan
CO4  Explain the process principles of different Metal forming methods. 
d 
PO  Mapping 
Justification 
Mapped  Level 
Knowledge about the different energy domains would be required by 
PO1  3  students with commendable amount of information to be remembered. 
Every energy domain has different conditions & would need analysis skills of 
PO2  1  the students to a great extent. 
Students would need to conduct investigations about the previous 
PO4  3  executions to find which energy domain carries the required end result. 
while deciding the suitability of the particular process the student needs to 
PO6  1  consider its effects on society & legalities. 
The student must also assess the effect of the energy domain on the 
PO7  1  environment. 
The student must be able to assess if the energy domain is viable for small 
PO11  2  scale / large scale application & with what financial benefits. 
 
 
 
 
 
 
 

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 Evaluate the different modern machining processes & prepare reports, 
CO5  Evaluate 
presentations about the same for further discussions. 
PO  Mapping 
Justification 
Mapped  Level 
Knowledge about the different new tools like Ms Word, Google suite, 
PO1  2  Powerpoint etc.. would be needed. 
The information collection must consider the publications in journals & news 
PO4  1  regarding the latest developments taking place in the industry. 
Students will be required to submit assignments chosing the best of the IT 
resources available that allow them maximum collaborative assistance & 
PO5  3  accessibility. 
Students would be required to submit original data & not copy from some 
PO8  1  other places. 
PO9  2  Students would be required to work in teams to complete the assignment. 
 

Carry out case studies of large scale or global industries & evaluate 
CO6  Evaluate 
suitability of modern methods in small scale or local industries. 
PO  Mapping 
Justification 
Mapped  Level 
Knowledge about the different new tools like Ms Word, Google suite, 
PO2  2 
Powerpoint etc.. would be needed. 
The information collection must consider the publications in journals & news 
PO3  2 
regarding the latest developments taking place in the industry. 
Students will be required to submit assignments choosing the best of the IT 
PO4  3  resources available that allow them maximum collaborative assistance & 
accessibility. 
Students would be required to submit original data & not copy from some 
PO6  2 
other places. 
PO10  2  Students would be required to work in teams to complete the assignment. 
Student will be inspired to carry out life long research in the area to keep 
PO12  3 
himself abreast of latest developments 
       
 

IX. TEACHING-LEARNING METHODOLOGY ADOPTED 

1. Chalk and Talk     
2. PPTs, Animations and Videos for illustrations 
3. Learning by Watching (Industrial Visit)   
4. Collaborative Learning (Think Pair Share)   
5. Group Assignment – Project 

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 X. METHOD OF ASSESSMENT OF COs and POs: 
COs  Relevant POs  Mode of Assessment 
PO1: ENGINEERING KNOWLEDGE 
PO2: PROBLEM ANALYSIS 
Assignments, Quizzes, Internal 
PO3: DESIGN/ DEVELOPMENT OF 
C302.1-C302. Examinations and 
SOLUTIONS 
6  External Examination 
PO4: CONDUCT INVESTIGATION ON 
result  
COMPLEX PROBLEMS 
PSO1: PROFESSIONAL COMPETENCE 
Exercises to learn through ICT 
tools and internet 
C302.1-C302.
PO5: MODERN TOOL USAGE  websites, Usage of Excel 
6 
worksheets for problem 
solving 
C302.1-C302.
PO8: ETHICS  Assignments, Quizzes 
6 
Group Assignments, Writing skills 
C302.1-C302. PO9: INDIVIDUAL AND TEAM WORK  in documenting 
6  PO10: COMMUNICATION  assignments, 
Presentations 

XI. LESSON PLAN: 

The course plan is meant as a guideline. There may be changes in actual execution. 
 
 
Sl  Teaching  Cumulative 
Unit  Topic / Concept 
No  Methods  Periods 

Comparison between the traditional & modern machining 

1  T1  1 
methods. 

2  Ultrasonic Machining (USM): Introduction, process description  T1  2 

3  abrasive slurry, Abrasive materials and their characteristics.  T1  3 

Functions of liquid medium in slurry, Types of Transducers, 
4  T1  4 
effect of process parameters, applications and limitations. 
I 
Abrasive Jet Machining (AJM): Principle of operation, process 
5  T1  5 
details, 
6  process variables and their effect on MRR and accuracy.  T1  6 
Equation for MRR. Advantages, disadvantages and 
7  T1  7 
applications. 
Water Jet Machining (WJM): Schematic diagram, equipment 
8  T1  8 
used, advantages and .. applications. 
"Electro Discharge Machining (EDM): Process description with 
9  T1  9 
schematic diagram, process parameters, 

II  functions and characteristics of dielectric medium, dielectric 

10  T1  10 
fluids, over cut and side taper: Flushing, 

15
 Mechanism of metal removal, crater volume, types of power 
11  T1  11 
supply circuits, 
mathematical analysis of metal removal rate (MRR), 
12  characteristics of spark eroded surfaces, advantages,  T1  12 
disadvantages and applications. 
13  Wire EDM: Process description and applications.  T1  13 
Electro-Chemical Machining (ECM): Schematic of the process 
14  T1  14 
parameters, function and characteristics of electrolyte, 
chemistry of the process, Equation for specific MRR and 
15  T1  15 
electrode feed rate, advantages, limitations and applications., 
high speed machining, description process parameters, 
16  T1  16 
advantages and applications. 
Rotary Machining, Hot machining, description of each process, 
17  T1  17 
process parameters, advantages and applications. 
LASER Beam Machining (LBM): Principle of LASER Beam 
18  T1  18 
production, materials used, 
19  thermal analysis of the process, process parameters,  T1  19 
equations for power density and machining rate, advantages, 
20  T1  20 
limitations and applications. 
Plasma Arc Machining (PAM): Introduction equipment used, 
21  T1  21 
III  process description and parameters, 
types of plasma arc; Transferred arc and non transferred arc 
22  T1  22 
and process applications 
23  Electron Beam Machining (EBM): Schematic of the process,  T1  23 
24  process parameters, principle of production of Electron beam,  T1  24 
25  equipment used, Advantages, disadvantages and applications  T1  25 
26  ION Etching: Process description and applications.  T1  26 
Rubber Pad Forming: Principle of the process, process details 
27  T1  27 
and 
28  its types; Guerin, wheelon,  T1  28 
29  Marfoming and Hydro forming processes and applications.  T1  29 
Electro-Hydraulic forming (EHF): Schematic of the process 
30  T1  30 
IV  description and its applications. 
High Energy Rate Forming (HERF): HERF hammers, principle of 
31  T1  31 
explosive forming, 
32  Explosive materials, types of explosive forming,  T1  32 
33  Stand off operation and contact operation, the pressure pulse,  T1  33 
34  Gas bubble and the process applications.  T1  34 

V  35  "Stretch Forming: Introduction, types of stretch forming: stretch  T1  35 

16
 draw forming, 
36  rotary stretch forming or stretch wrapping,  T1  36 
37  compression forming,Radial draw forming.  T1  37 
Stretch forming equipment and accessories, accuracy and 
38  T1  38 
surface finish, 
39  process variables and limitations.  T1  39 
Tube spinning: Introduction, methods of tube spinning, 
40  T1  40 
Backward spinning, 

41  Forward spinning, machines and tools used. Machine variables,  T1  41 

speeds and feeds, effect of tube spinning on work metal 

42  T1  42 
properties and applications. 

43  Hydrostatic Forming: Process principle,  T1  43 

44  description and applications  T1  44 

Total  44 
 
 
Prepared by: M​ r. A Rajasekhar 
 
Signature: 
Date :  
HOD, ME 

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