ME F315

Advanced Manufacturing Processes

Topic: Non-traditional machining

processes

N Suresh Kumar Reddy

BITS Pilani PhD (IIT D), Post Doc (ENSMN, France)
Professor/Mechanical Engineering Department
Hyderabad Campus
BITS Pilani, Hyderabad Campus, India
SWITCH OFF YOUR MOBILES / KEEP IN SILENT MODE IN
CLASS ROOM

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Non-traditional Introduction, Ultrasonic Machining, Abrasive Jet T1
machining Machining, EDM, ECM, LBM, EBM, ECG and 6
processes Chemical Machining

T2 Amitabha Ghosh and Asok Kumar Mallik, “Manufacturing Science”, Affiliated

East-West Press, New Delhi, 1985.

BITS Pilani, Pilani Campus

 EBM

How it Works

• A stream of electrons is started by

a voltage differential at the cathode. The
concave shape of the cathode grid
concentrates the stream through the
anode.

• The anode applies a potential field that

accelerates the electrons.

• The electron stream is then forced

through a valve in the electron beam
machine.
• The beam is focused onto the surface of
the work material, heating, melting, and
vaporizing the material.

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EBM

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 Characteristics

Mechanics of material removal – melting, vaporization

• Medium – vacuum
• Tool – beam of electrons moving at very high velocity
• Maximum MRR = 10 mm3/min
• Specific power consumption = 450 W/mm3/min
• Critical parameters – accelerating voltage, beam diameter, work speed,
melting temperature
• Materials application – all materials
• Shape application – drilling fine holes, cutting contours in sheets,
cutting narrow slots
• Limitations – very high specific energy consumption, necessity of
vacuum, expensive machine

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Specific power consumption in EBM for various
materials

Table: Specific power consumption in EBM for various materials

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Example

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Solution

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Mechanics of EBM

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Example

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Solution

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BITS Pilani, Hyderabad Campus
BITS Pilani, Hyderabad Campus
Abrasive jet machining

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Process characteristics in AJM

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The nozzle

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Effect of nozzle tip distance

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Summary of AJM

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Material removal models in
AJM

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BITS Pilani, Hyderabad Campus
Brittle Material

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BITS Pilani, Hyderabad Campus
BITS Pilani, Hyderabad Campus
BITS Pilani, Hyderabad Campus
BITS Pilani, Hyderabad Campus
BITS Pilani, Hyderabad Campus
 AMP Syllabus and Text
book
Topic Learning Objectives
Metal cutting theory T3/ Chapter 6
A brief overview of different metal cutting processes
T3/Chapter 10
Non-traditional Introduction, Ultrasonic Machining, Abrasive Jet Machining, EDM, ECM, LBM, EBM, ECG and Chemical
T2/Chapter 6
machining processes Machining
Micro-manufacturing T1/Chapter 34
technologies Introduction, Chemistry-based, Electron-beam lithography
T2/Chapter 7 (7.2)
Introduction to
computer aided Introduction, developments in conventional machine tools, CIM, FMS, Modern developments in machine
manufacturing (CAM) tools

CNC machines NC and CNC Machines, Operation of NC/CNC, Definition of terms often used in numerical control, T3/ Chapter 12, 13 &14
Positional control
CNC part
Introduction, Programming for NC/CNC Machining, Some commonly used G codes
programming
Surface Technologies Meaning of tribology, Lubrication, Wear, Cost of friction and wear T1/Chapter 31 & 32
Additive
Introduction to Additive manufacturing processes T1/Chapter 19
manufacturing
Modelling &
simulation of
Introduction and purpose of Modelling & simulation of manufacturing processes Class notes
manufacturing
processes
Fabrication project Design and material selection

1. Serope Kalpakjian and Steven R. Schmid, “Manufactuirng Engineering and Technology,” Pearson Education (Low Cost Indian Edition),
4/e, 2001, New Delhi
2. Amitabha Ghosh and Asok Kumar Mallik, “Manufacturing Science”, Affiliated East-West Press, New Delhi, 1985.
3. B.L. Juneja, G.S. Sekhon and Nitin Seth, “Fundamentals of Metal Cutting and Machine Tools”, New Age International Publications,
Delhi. 2010.

BITS Pilani, Hyderabad Campus