Non-Traditional Machining 2022 Scheme VTU Notes VTU University 4th SEM Mechanical Engineering | BME405A notes

Scheme & Syllabus Copy of Non-Traditional Machining 2022 Scheme VTU Notes

Non-Traditional Machining-BME405A 2022 Scheme VTU Notes Syllabus copy

Non-Traditional Machining-BME405A 2022 Scheme VTU Notes

Module 1: Introduction to Non-traditional Machining

• Need for Non-traditional Machining Processes
• Comparison between traditional and non-traditional machining.
• General classification of non-traditional machining processes.
• Classification based on the nature of energy employed in machining.
• Selection of non-traditional machining processes.
• Specific advantages, limitations, and applications of non-traditional machining processes.

Module 2: Ultrasonic Machining (USM) and Abrasive Jet Machining (AJM)

• Ultrasonic Machining (USM):

  • Introduction, Equipment, and Material Process.
  • Effect of Process Parameters: Amplitude and frequency, abrasive grain diameter, slurry, tool, and work material.
  • Process Characteristics: Material removal rate, tool wear, accuracy, surface finish.
  • Applications, Advantages, and Limitations of USM.

• Abrasive Jet Machining (AJM):

  • Introduction, Equipment, and Process of Material Removal.
  • Process Variables: Carrier gas, type of abrasive, work material, stand-off distance (SOD).
  • Process Characteristics: Material removal rate, nozzle wear, accuracy, surface finish.
  • Applications, Advantages, and Limitations of AJM.

Module 3: Electrochemical Machining (ECM) and Chemical Machining (CHM)

• Electrochemical Machining (ECM):

  • Introduction, Principle of ECM, ECM Equipment, and Elements of ECM Operation.
  • ECM Process Characteristics: Material removal rate, accuracy, surface finish.
  • Process Parameters: Current density, tool feed rate, gap between tool and workpiece, velocity of electrolyte flow, type of electrolyte, concentration, and temperature.
  • ECM Tooling: Tooling techniques and materials for ECM.
  • Applications of ECM, Electrochemical Grinding (ECG), and Electrochemical Honing (ECH).
  • Advantages, Disadvantages, and Applications of ECG and ECH.

• Chemical Machining (CHM):

  • Elements of the Process: Resists (maskants), Etchants.
  • Types of Chemical Machining: Chemical blanking and chemical milling processes.
  • Process Characteristics of CHM: Material removal rate, accuracy, surface finish.
  • Advantages, Limitations, and Applications of Chemical Machining.

Module 4: Electrical Discharge Machining (EDM) and Plasma Arc Machining (PAM)

• Electrical Discharge Machining (EDM):

  • Introduction, Mechanism of Metal Removal.
  • EDM Equipment: Spark erosion generator (relaxation type), dielectric medium, and electrode feed control system.
  • Flushing Types: Pressure flushing, suction flushing, side flushing, pulsed flushing.
  • EDM Process Parameters: Spark frequency, current, spark gap, surface finish, Heat-Affected Zone (HAZ).
  • Advantages, Limitations, and Applications of EDM.
  • Electrical Discharge Grinding and Traveling Wire EDM.

• Plasma Arc Machining (PAM):

  • Introduction, Non-thermal generation of plasma, Equipment and Mechanism of Metal Removal.
  • Plasma torch, process parameters, and process characteristics.
  • Safety precautions.
  • Applications, Advantages, and Limitations of PAM.

Module 5: Laser Beam Machining (LBM) and Electron Beam Machining (EBM)

• Laser Beam Machining (LBM):

  • Introduction, Generation of LASER.
  • Equipment and Mechanism of Metal Removal.
  • LBM Parameters and Characteristics.
  • Applications, Advantages, and Limitations of LBM.

• Electron Beam Machining (EBM):

  • Introduction, Principle, Equipment, and Mechanism of Metal Removal.
  • Applications, Advantages, and Limitations of EBM.