PAK LER School of Mechanical engineering FMTH0301/Rev.5,3, Course Plan ‘Semester: V Year: 2019-20 Course Title: Advanced Machining Processes Colkse Coder GEMEES05 Total Contact hours: 40 Duration of ESA :3 hours ISA Marks: 50 ESA Marks: 60 Lesson Plan Author: Dr. T.V.Sreenath Date: 22.06.2019 Checked By: Dr. Veeresh G. Balikal ty, Date: 24.06.2019 Prerequisites: This subject requires student to the basic principle of ‘machining by conventional methods and type of machining process with respective to machine tools used in industries, Course Outcomes (COs): ‘At the end of the course the student should be able to: 1, Identity the importance of advanced machining processes in modern manufacturing industries. 2. Categorize the necessary elements and equipment forthe ultrasonic and abrasive jet machining techniques. 3. Analyze the mechanism of metal removal for thermal machining process. 4. Explicate the technical issues of processing in electro-thermal methods. 5. _Compreend the selective and nonselective material removal process of chemical machining 8. Relate the operational capabilties of hybrid machining system with non hybrid systemEvtniversity PAA KLEsrivesity CRETE) negate — ‘School of Mechanical engineering Course Articulation Matrix: Program Outcomes (PQs) 8) Course Title: Advanced Machining Processes Course Code: 15EMEE305 ‘Course Outcomes (CO) / Program Outcomes (PO) 1. Identify the importance of advanced machining processes in modern manufacturing industries 2 Categories the necessary elements and equipments for the ultrasonic and abrasive jet machining techniques 3. Analyze the mechanism of metal removal for thermal machining | | H process 4. Explicate the technical issues of processing in electro- thermal |_| H methods 5. Comprehend the selective and nonselective material removal process of chemical machining 6. Relate the operational capabilities of hybrid machining system with non] | M L hybrid system Degree of compliance L: Low M: Medium H: HighBQKLER ‘School of Mechanical engineering Course Content [Course Code: 1SEMEESOSCourse TiieAgvancsd Machining Processes TP: 30-0 Credits: 3 Contact Firs: 3 ISA Maric: 50 ESA marks: 60 Total Marks: 100 | Contents | ee feation moc, Of Production; Need and Capabiity analysis of various, | Processes, Gossiftation and Selection of Non-Tradtional Machining Technologies, Hybrid | Abrasive Jet Machining (AJM): Machin; | ° ing setup, parametric analysis, Process capabilities. gitasonic machining (USM): Machining setup, Mecone oF Cutting - Model Proposed by | Shaw, Parametric analysis, Process Capabilities, Abrasive Flow Machining, Magnetic Abrasive Finishing, Water jet cuting (WiC) Unit - 2 | i Chapter 3: Thermal Advanced Machining Processes | Plasma Arc Machining (PAM): Working System, Elements of PAM, Process Performance, | | PAM Parameters, Process Characteristics, Safety Precautions, Electric Discharge | , Machining (EDM): Working Principle, Analysis, Process Variables, Process Characteristics, | | Applications I | Chapter 4: Thermo-electric Advanced Machining Processes | Electron Beam Machining (EBM): Working Principle, Process Parameters, Characteristics | of The Process, Application of EBM, Laser Beam Machining (LBM): Working Principle, | popes of Laser, Process Characteristics, Applications, lon Beam Machining (IBM): Working | Principle, Process Parameters, Applications | Unit-3 | Chapter 5: Chemical Machining Processes | | Chemical Machining: Elements of process, Process Characteristics of CHM Electro | | Chemical Machining: Elements and Characteristics and Theory of ECM | | Chapter 6: Hybrid Processes ‘lectro chemical yrinding (ECG), Electrochemical ‘spark machining (ECSM), | sicctochemial are machining (ECAM) and electro discharge abrasive grinding (EDAG). mentioned in the approved syllabus) Text Book (List of books 4. Jain V. K. “Advanced Machining Processes” Allied Publishers, Private Limited 2004. Company Limited, New Delhi.2001 Teaching Hrs: 3 Exam Duration: 3 hrs | T | | 7 2. Pandey P. C. and Shan H. S., "Moder Machining Processes’, TATA McGraw Hill Publishing‘School of Mechanical engineering oo References 1. HMT, “Production Technology’, TATA McGraw Hill.2000 : 2. Adithan M, "Modem Machining Methods", S. Chand & Company, New Delhi. 1995 Evaluation Scheme ISA Scheme [assessment [weightage in Marke Course Unitization for ISA Exams and End Semester Assessment No. of No. of No. of Topica / Chapters Teaching | Questions | Questions | Questions in in Minor in Minor ESA Exam 1 Exam 2 Unit | 1. | Introduction to Advanced 03 1 Machining Processes z 4 2, | Mechanical Advanced 2 ‘ 1 Machining Processes - Unit 3. | Thermal Advanced 08 = Machining Processes 1 1 1 4. | Thermo-electric Advanced 07 = i 1 Machining Processes 1 Unit tt 3 | 6 | Chemical Machining 05 = A 1 Processes 6._| Hybrid Processes 05 a = 1 Note 1. Each Question carries 20 marks and may consists of sub-questions. 2. Mixing of sub-questions from different chapters within unit (only for Unit | and Unit 11) is allowed in Minor |, Il and ESA i 3, Answer 5 full questions of 20 marks each (two full questions from Unit |, ! and one full questions from Unit II) out of 8 questions in ESA. 4KLE feces! a ‘Schoo! of Mechanical engineering Course Assessment Plan ‘Course outcomes (COs) Weightage agnosia ata ESA assessment Assignment % 1. Identify the importance of 10 a . advanced machining processes in modem manufacturing industries 2. Categories the necessary 25 v oy elements and equipments for the ultrasonic and abrasive jet machining techniques ‘3. Analyze the mechanism of metal 25 v u removal for thermal machining process 4. Explicate the technical issues of | 20 v 4 processing in electro- thermal methods ‘5. Comprehend the selective and 40 v v nonselective material removal process of chemical machining 6. Relate the operational 10 cf a capabilities of hybrid machining system with non hybrid system Weightage % (100) | 35 45 20 wd BuyKLESieniy ‘School of Mechanical engineering Plan Chapter wit introduction to Advanced ‘Number and Title:1 ‘At the end of the topic student should be able to: ining | Planned Hours: 03 your answer by taking suitable examples [ane Tis odeoren coe [et | oA, 7] confer the drawback of machining process in nontraditional] 4 | 12 | 24 methods, 2 | Clarity how non-conventional machining processes are categorized. | 1 | 2 | 2-1 3 _| Identify and solve the important machining process parameters and | 4 3 | 24 its effect on the product during unconventional machining, ce Lesson Schedule Class No. Portion covered per hour 1. History and Need and Capability analysis of various processes, 2. Classification of Non-Conventional machining process. 3, Hybrid Processes, Cases Review Questions ‘SLNo Questions Tos [st [PI Code |_| Identify the main reasons for using modern machining technology in] 4 | 9 | 2.4.1 industry and what are the short comes in conventional process. 2 | sustify the conditions that make the different machining process with obligatory solutions when compared with conventional 2 us | 2.1.1 manufacturing process 3 _| Predict the un conventional machining process that can be used successfully design and manufacture of tool for pressure die 3 ig | 2.1.2 casting. 4 | Do you think that, there is a possibilty of total replacement of traditional machining process by nontraditional process? Justify 1 is | 2.44Peg KLE SER) nee ‘School of Mechanical engineering _—__ ee S— Course Code and Tiie:1SEMEES / Advanced Machining Processes Chapter Number and Title vanced Machining | Planned Hours: 42 coarientn 2 Mechanical A Learning Outcoms At the end of the topic student should be able to: Co's | BL CA ‘SLNO Topic Outcomes: Code 1 Exhibit the short comes in conventional mechanical process and | 2 | 12 | 2.1 State the objectives of unconventional mechanical process: 2 Confer with previous portant process parameters 2 24 influencing MRR in Usain aaa i 2 3 | Show with evidence that ex ‘of tool cone used in USM Feet affect the cutting rate ree 2 4 Design the compound acou: USM by considering various a 22 actuator system mic heed of zt J 5 Present the information of latest developments in ultrasonic} 13 22 machine process. 6 Recommend the suitable process which can avoid sticking of! 5 | 13 | 22 abrasive grains in AJM Lesson Schedule: Class No. Portion covered per hour 1, Introduction, Equipment, Tool materials & tool size, Abrasive slurry 2. — Cutting tool system. 3. Effect of amplitude, frequency and vibration, Effect of grain diameter. 4. Effect of applied load, 5. Effect of slurry, Tool and work material, 6. _ USM process characteristics 7. USM process characteristics continued 8. Applications, Advantages & Disadvantages. Numerical problems 9. Variables in AJM: Standoff distance (SOD). 10. Nozzle design consideration 11. Magnetic Abrasive Finishing. 12. Water jet cutting Review Questions ‘SLNO Questions To's [BL |PIGode “Non conventional mechanical process leads to enhancement in 1 | mechanical property of the material than convention process “| 1 | L3 | 2.1.4 justify the statement with help of neat sketch Deliberate with neat sketch the effects of Amplitude, frequency, 2. | vibration ,Effect of grain diameter ,Effect of applied load, ,Effect of | 2 | 12 | 2.1.2 Slurry in USM process aKLE University RE) __ cera et — ‘School of Mechanical engineering ‘A hole is to be drilled in 20mm thick tungsten carbide sheet by Ultrasonie method. The slury is made of 1 part of 320 grit (18 micron radius) boron carbide mixed with 1 % parts of water. The Static stress is 1.4 kg/em? and the amplitude of too! oscilation is, 0.025 mm. The machine operates at 25,000 cycles/Sec. the compression fracture strength of WC is 225kg/mm*, Calculate the time required to perform driling. Assume that only one pulse out of 10 pulses is effective What are the constituents of slurry used in ultrasonic machining? And suggest proper tool geometry for this process. 213 Collect the information of negatives aspects of USM find the appropriate solution to the problem by combing different work and tool materials. 12 224 222 Explore how vibration control can be done in case of USM process “AJM technique, when applied to ductile materials, leads to a low rate of metal removal’ justify the above statement with neat sketch 3 223Learning Outcomes: ‘At the end of the topic student should be able to: ‘SLNO Chapter Number and Titie: 3.Thermal Advanced Machining Processes [ Course Gode and Tite: 4SEMEES ppg Se Code and Tite: 1SEMEE3 7 Advanced Machining Processes Planned Hours: 08 Topic Outcomes co's [BL CACode. 1 Present the developments L : 388 and its interfaci at SE Ta il Pa Z 22 Recommend the ‘Suitable avoid defects on the an non paces peers ah 3 | 22 ‘Suggest the shortcomings rocess and understand the sighificance of EOM prosesa, "erm! P 24 Investigate the parameters i is ike resistance, gap setting and Capacitance on performance of EDM process 3S | ts 24 Explore the problems in cutti ic dis > ing operation on electric discharge machining. find out the causes for it and present the same. 3 | 1 24 Present the developments of EDM process and its interfacing with other machining operations 22 Recommend the suitable process which can avoid recast cast layer on the surface of work piece in EDM 3 | 22 PNOMeunan Lesson Schedule Class No. Portion covered per hour Non-thermal generation of plasma, PAM, Selection of gas. ‘Mechanism of Metal removal. Introduction to spark machining. Mechanism of metal removal. Dielectric fluid, Spark generator. Electrode feed control, Tool material selection. Flushing and its methods. EDM process characteristic: Metal removal rate, Accuracy surface finish Heat affected zone study Machine too! selection, Application Review Questions ‘SLNo Questions Tos [BL PI Code ‘Confer some of the important considerations in the designing modem plasma torch with latest developments 2.22 Explore the need of non-transferred and transferred mode of plasma arc with applications 2.23 Explore the factors causing the improper working of flushing in EDM. Recommend different modes of flushing methods 2.44 that power delivered by RC circuit in EDM is higher than ae and show that resistance will be of 30% in RC circuit 2.12 4, SEE ——Technological REQ KLE tives ‘School of Mechanical engineering Itis required to drill a hole of 1.69 mm diameter to a depth of 7.32 mm in steel sheet using R-C circuit by electro-ischarge mactining method using a brass electrode. ‘The surface finish required is to be 20 micron. Determine the source voltage to be set up for a ‘condenser and resistance setting of 120 micron-farads and 100 ‘ohms respectively. Also find out the time required for drilling, Assume sparking period=100p-sec. Given that i) surface | roughness=K; (1/2CU*) Katy Ks microns where K, Ky and Kg are constants and their values for brass electrode and steel work piece are 13, 0.45 and 0.22 respectively. C= capacitance of the condenser in farads Us voltage across the capacitor ‘G= pulse duration in p-sec ii) Metal removal rate =1.421.U® mm*/sec (t.=charging time) “Carbon steel cutting is not recommended using oxygen gas in EDM justify the statement and gives suggestion to overcome this problem through extensive literature survey. 222 Indentify the factors responsible for the selection of electrode material in EDM. If in a RC type generator, to get an idle time of 500 ps for open circuit voltage of 100 V and maximum charging voltage of 70 V, Determine charging resistance Rc, Assume C = 100 pF 223 ieee!Course Code and Tite:1SEMEES 7 Advanced Machining Processes Chapter Number and Tite: Planned Hours: 07 Processes 4.Thermo-electrie Advanced Machining Learning Outcomes: At the end of the topic student ‘Should be able to: ‘SLNo Topic Outcomes: BL cA Code Suggest the shortcomi and appreciate ati ahs Pcens ties ele ern EE 24 Investigate the parameter fall thermo electric Pit FS on performance © “3 24 Explore the problems in real cutting operation in EBMIBMLEM etc L3 24 Present the developments in EBM,LBMIBM etc 22 Recommend the suitable process which can avoid defects on the Surface of work piece all thermoelectric process L3 22 NOMeene Lesson Schedule: Class No. Portion covered per hour Electron Beam Machining (EBM): Working Principle Process Parameters, Characteristics of The Process Application of EBM, Laser Beam Machining (LBM): Working Principle ‘Types of Laser, Process Characteristics, Applications, lon Beam Machining (IBM) ‘Working Principle, Process Parameters Applications Review Questions SLNo Questions To's BL PI Code Explain with neat sketch principal and operation in Laser beam machining techniques, mention its shortcomings 2441 Discuss the parameters that govern the machining process in IBM process 212 Elaborate the problems faced in the industry by thermo electric process how this can be reduced 213 Mention the developments in hybrid system of thermo electric machining process. ir) 2.22 ‘Suggest the industries where thermo electric process can be successfully used. 2.23 "”Technological KLE Savers Caine) __ erator ag ‘School of Mechanical end! "ed Machining Proc it (EES / Advanct [Course Code and Tie: 15EM! Sila FTOSSaREE [Chapter Number and Title:6. Chemical M Learning Outcomes: be able to: Planned Hours: 05 5 ‘Atthe end of the topic student should mes o's [BL |CA ‘SLNO Topic Learning Ovtco’ c = 7] Beno the pian cherical machining acton and suggestihe | 5 | 12 | 24 methods for controlling the process J TEiucidate the steps Invowved in chemical machining process for] 5 | 2 | 2.1 various application fors on which selection of resist foruse in| 5 | ,3 | 2.1 3 | Identity the process fact chemical machining Lesson Schedule Class No. Portion covered per hour 4. Introduction, Elements of process 2, Chemical blanking and its applications 3. Chemical milling (Contour machining) 4, Process Characteristics of CHM 5. Hydrogen embitterment, Advantages and Application. Review Questions SSLNo | Questions TLOs [BL | PI Code 1 | Write a note on capacity of maskants and etchants materials for| 4 244 given different job materials 128 ae 2 | Explicate the different steps in r i Expl steps involved in chemical blanking with neat | 2 | 1> | 2.42 3 | Identify the factors on which the selection of a resi i chemical machining depends? Seen ae | 2.4.3 tePARLE Ser Se 1 onoo of Mechanical engineering [ Course Code and Tite: 1SEMEES 7 Advanced Machining Procestee Chapter Number and Title: 6. Hybria Processes Planned Hours: 08 Learning Outcom At the end of the topic student should be able to: NO GA F Topic Leaming Outcomes COs [Bt | ode 1. | Explore the drawback the methods for; 6 L2 24 controling the process" ECG and propane 2. | Elucidate the procedi 1 ocess for various 24 eae lure involved in ECSM process 6 |w 3.| Identify the process variable and show there affect on/ 6 ae performance of ECAM Tesson Schedule: Class No. Portion covered per hour 1. Electro chemical grinding (ECG) 2. Electrochemical spark machining (ECSM) 3. Electrochemical arc machining (ECAM) 4, Electro discharge abrasive grinding (EDAG) 5. Applications for the above Review Questions i Tos [BL [PI ‘S1.No | Questions rae +} confer how all type of materials are removed in the electro | 1 i | 244 ‘sparking machining process. 2 | Explicate mechanism involved in CAM process 2 | w | 212 3] comprehend electro discharge abrasive grinding and electro = (ree fen Shemical spark machining based on operating capability 1DNote: Answer any TWO full questions Use neat sketch where ever required, (a Categories the modem manufacturing methods ‘based on nature of energy employed. One of the limitations of ultrasonic process is that of the cutting rate obtained is not competitive. Write a note on studies made and the results achieved to ‘overcome this limitation “Non conventional mechanical process leads to enhancement in mechanical property of the material than convention process * justify the statement with help of neat sketch Pr i i [2] Deliberate with neat sketch the effects of Amplitude, frequency, vibration ,Effect of grain diameter ,Effect of applied load, ,Effect of Slurry in USM process ‘Summaries the developments in abrasive water jet ‘machining how itis helpful to overcome problems of AIM Explore the assumptions made by Miller-Shaw while deriving for USM process? Glass is being machined at a MRR of 6 mm3/min by Al203 abrasive grits having a grit dia of 180 ym. If 100 pm grits were used, what would be the MRR? If the feed force is increased by 50% along with a reduction in concentration by 70%. What would be the effect on MRR? 4 EyM E lode! Question Paper for Minor Examination (ISA)-2 Course Code: 18EMEE3 Duration:75 minut Note: An Swer any TWO full qu; Use neat shatch wn aumnon® Q.No Questions \Suggest the jeaize the en eCO™INgS in die sinking operations and 'gnificance ‘other non conventional thermal 211] 13 process. Db fina EDM he effects of cheney Telaxation circuit, discuss INQ resis setting, capacitance on MRR how “seea'mie Ope of me 212 lcompared with pulse generator. 2a | It is required to afi Ia hole of 1.69 mm diameter to 2 cctiiot 7.32 mm in steel sheet using R-C circuit by < lscharge machining method using a brass eeatota The surface finish required is to be 20 micron. Jetermine the source voltage to be set up for a condenser and resistance setting of 120 micron-farads and 100 ohms respectively. Also find out the time required for drilling. Assume sparking period=100p-sec. Given that i) Surface roughness=K1 (1/2CU2) K2tp K3 microns where K1 K2 and K3 are constants and their values for brass electrode and steel work piece are 13, 0.45 and 0.22 respectively.C= capacitance ‘of the condenser in faradsU= voltage across the capacitor tp= pulse duration in p-secii) Metal removal rate =1,42tcU2 mm3/sec (tc= charging time) 213 222 Ls DB [Outline the developments in LBM process and its [interfacing with other machining operations Ja indentify the factors responsible for the selection of lelectrode material in EDM. If in a RC type generator, to Jgetan idle time of 500 ys for open circuit voltage of 100 V end maximum charging voltage of 70 V, Determine ce Re. Assume C = 100 uF 223 L3 [charging resistan BF the formation of KERF and DROSS is more in Plasma lgpray than Oxy-gas spraying’. Discuss how to overcome Ithis problem Marks | CLO 10 | 3 10 | 4 0 | 3 to | 4 to | 3 10 | 4 244 13KLE a in School of Mechanical engineering Note: Answer ny five full Questions selectir 208 question from Unit Lee 1a identify the ‘main reasons for using modem &chining tech vant industry and what are the short Comes ig {conventional process, Predict the un conventional ‘machining process be us that can Sea ecesshlly design and manutactne of too} {ot pressure aie casts semen mechanical process eagg to tancement in mechanical Property of the mataisa than conver wih} 10} 2], S micron radius) Boron carbige nc ‘of water. The Static stress is 1.4 glen? mache etude of tol ceciaton ne THM. the compas Paes at 35000 ase The ‘compression fracture strength of WC is 226kaimm= | 10 | 2 | > Calculate the time _ated fo perform dring. Assume 213 | 13 at only one pulse out ot 10 ul the lents Hi20° out the etlect of Sando Distance and grain 7 Size on accuracy of meta removal > AIM 2 | 2 © |AIM ‘echnigue, when appieg {0 ductile materia, Gav fo 3 low rate of metal remota sty the above statement with neat sketen Unita 4a tis required to data how of 1.89 mm diameter to a de 32 y eer Ct 7-32 mm in steel sheet 16PaCitance ey 13, O@S and oar reepeciively. 7 j Us Voltage acro the oitensarintarada Capacitor n in sec tee! cutting is not (B35 I LEM justy he cet ceeommended using oxygen 3 Me this probler lement and gives suggestion | 49 m through extensive literature 4 | 2 | 222 rator, to Us for open cirult voltage of Charging voltage of 70 v,| 19 | 3 | 2 | 223] Ls | istance Re. Assume C = 100 ; and = maximum, Determine charging resi ui [The formation of KERF and OR Ptasma pray’ than” Own’ OSS is more in ‘985 Spraying’. Discuss how to| 10 | 4 | 2 | 241 | u3 lovercome this problem Sa | Confer some of the important considerations in the designing modem plasma torch with atest | 10 | 3 2 | 222 | 2 developments b | Explore the need of nondransferred and wansferred ‘mode of plasma arc with applications idl Ee (ee ee Units 7a | Frplcate the ‘ferent steps imvoved in chemical ao]. |» | aaa blanking with neat sketch b | Identity the factors on whic the seeston of a Tso 1. | > [aig resist for use in chemical machining depends? 8a | Explore the crawoack in hybrd system and propose | 9 |g | 2 ara | up the methods for controling the process b | Calculate the machining rate and electrode feed rate when ion is electrochemical grinding, using a copper electrode and sodium chloride solution(specific resistance=5 ohm cm).the power supply data of the| 10 | 6 | 2 | 213] 13 machine is as follows; supply voltage 18 V-DC, current =5000 amp, tool work gap=0.5mm(constant) efficiency is 100%, for iron; N=56,n=2,d=7.87X10%gmim*