Name of the Faculty Deepak Xavier Departme Mechanical Engineering

Employee Code 6024 Scheme KTU 16 nt

Semester S6 Batch 2017-2021
Name of the Subject Advanced Manufacturing Technology Subject Code ME 306
Department Mechanical Engineering
SYLLABUS
Powder Metallurgy- Programmable Logic Controllers- CNC- non-traditional and micro
machining process - high velocity forming of metals-material additional process

DETAILED SYLLABUS

Module I (8 hours)
 Introduction:
o Need and comparison between
 Traditional
 Non-traditional and
 Micro & Nano machining process
 Powder Metallurgy
o Need of P/M
o Powder Production methods
 Atomization
 Electrolysıs
 Reduction of oxides
 Carbonyls
o Process parameters
o Characteristics of powder produce
 Powder characteristics
o Properties of fine powder
o Size
o Size distribution
o Shape, compressibility
o Purity etc.
 Powder Metallurgy:
o Mixing
o Compaction
o Techniques
o Pressure distribution
o HIP & CIP
 Sintering
o Mechanism of sintering

A.P.J.Abdul Kalam Technological University (APJAKTU) Department of Mechanical Engineering

 o Driving force for pore shirking
o Solid and liquid phase sintering
 Impregnation and Infiltration
o Advantages
o Disadvantages and
o Specific applications of P/M
 Programmable Logic Controllers (PLC):
o Need
o Relays
o Logic ladder program
o Timers
o Simple problems only
o Point to point
o Straight cut and contouring positioning
o Incremental and absolute system
 Open loop and closed loop systems
o Control loops in contouring systems
o Principle of operation

Module II (8 hours)
 DDA integrator

o Principle of operation
o Exponential deceleration
 Liner
 Circular and
 Complete interpolator
 NC part programming

o Part programming fundamentals

o Manual programming
o NC coordinate systems and axes
 Sequence number
 Preparatory functions
 Dimension words
 Speed word
 Feed world
 Tool world
 Miscellaneous functions
 Computer aided part programming

A.P.J.Abdul Kalam Technological University (APJAKTU) Department of Mechanical Engineering

 o CNC language
o APT language structure
o Geometry commands
o Motion commands
o Postprocessor commands
o Compilation control commands
 Programming exercises
o Simple problems on turning and drilling etc
o Machining centers
o 5 axis machining

Module III (7 hours)

 Electric Discharge Machining (EDM):

o Mechanism of metal removal
o Dielectric fluid
o Spark generation
o Recast layer
o Attributes of process characteristics on MRR
o Accuracy
o HAZ etc
 Wire EDM,
o applications and
o Accessories
o Advantages & Disadvantages
 Ultrasonic Machining (USM)
o Mechanics of cutting
o Effects of parameters on
 amplitude
 frequency of vibration
 grain diameter
 slurry
o Tool material attributes &
o Hardness of work material
o Applications
 Electro chemical machining (ECM)
o Mechanism of metal removal (MRR)
o Attributes of process characteristics on MRR
 Accuracy

A.P.J.Abdul Kalam Technological University (APJAKTU) Department of Mechanical Engineering

  Surface roughness etc.,
o Application
o Limitations

Module IV (7 hours)
 Laser Beam Machining (LBM)
o Mechanism of metal removal
o Attributes of process characteristics on MRR
o Accuracy etc.,
 Electron Beam Machining (EBM),
o Mechanism of metal removal,
o attributes of process characteristics on MRR,
o accuracy etc.,
 Plasma Arc Machining (PAM)
o Mechanism of metal removal
o Attributes of process characteristics on MRR
o Accuracy etc.,
 Ion Beam Machining (IBM)
o Mechanism of metal removal
o Attributes of process characteristics on MRR
o Accuracy etc.,
o Structure of HAZ compared with conventional process
o Application
o Comparative study of advantages and limitations of each process
o Abrasive Jet Machining (AJM)
o Working principle
o Mechanism of metal removal
o Influence of process parameters
o Applications
o Advantages & disadvantages
o Abrasive Water Jet Machining (AWJM)
o Working principle
o Mechanism of metal removal
o Influence of process parameters
o Applications
o Advantages & disadvantages
Module V (8 hours)

 High velocity forming of metals

A.P.J.Abdul Kalam Technological University (APJAKTU) Department of Mechanical Engineering

 o Effects of high speeds on the stress strain relationship
 Steel
 Aluminum
 Copper
o Comparison of conventional and high velocity forming methods
o Deformation velocity
o Material behavior
o Strain distribution
o Stress waves
o Deformation in solids
 Types of elastic body waves
o Relation at free boundaries
o Relative particle velocity
 Sheet metal forming
o Explosive forming
o Process variable
o Properties of explosively formed parts, etc.
 Electro hydraulic forming
o Theory
o Process variables, etc.,
o Comparison with explosive forming.

Module VI (8 hours)
 Micromachining
o Diamond turn mechanism
o Material removal mechanism
o Applications
 Advanced finishing processes
o Abrasive Flow Machining
o Magnetic Abrasive Finishing
o Magnetorheological Abrasive Flow Finishing
o Magnetic Float Polishing
o Elastic Emission Machining
 Material addition process
o stereo-lithography
o Selective laser sintering
o 3D Printing
o Fused deposition modeling
o Laminated object Manufacturing

A.P.J.Abdul Kalam Technological University (APJAKTU) Department of Mechanical Engineering

 o laser engineered net-shaping
o Laser welding
o LIGA process

FACULTY IN-CHARGE HEAD OF THE DEPARTMENT

A.P.J.Abdul Kalam Technological University (APJAKTU) Department of Mechanical Engineering