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NPTEL Syllabus
Advanced Machining Processes - Video course COURSE OUTLINE This course on 'Advanced Machining Processes' is also known as "Unconventional Machining Processes", Modern Machining Processes", and "New Technology". It deals with the latest machining processes named as "Advanced Machining Processes". They have been divided into three parts: Part 1 deals with mechanical type advanced machining processes such as Ultrasonic machining, water jet machining, abrasive water jet machining.It also includes micro-/nano-finishing processes viz, abrasive flow finishing, magnetic abrasive finishing, etc. Part 2 deals with thermal machining processes for example, electric discharge machining, laser beam machining, electron beam machining, etc. Part 3 elaborates chemical and electrochemical machining processes.It includes some hybrid machining processes namely, electrochemical grinding, electric discharge grinding and similar others.
COURSE DETAIL Sl.No
NPTEL http://nptel.iitm.ac.in
Mechanical Engineering Pre-requisites: The candidate/reader should have the background of metal cutting and basics of physics and chemistry. Additional Reading:
Topics
Hours
Related research papers. ASM Handbooks.
1.
INTRODUCTION
1
Why do we need advanced machining processes (AMPs)?
Prof. Vijay K. Jain Department of Mechanical EngineeringIIT Kanpur
Advanced machining processes Remarks
2.
MECHANICAL ADVANCED MACHINING PROCESSES
2
ABRASIVE JET MACHINING ( AJM ) Introduction - Abrasive Jet Machining Setup - Gas Propulsion System - Abrasive Feeder Machining Chamber - AJM Nozzle - Abrasives. PARAMETRIC ANALYSIS - Stand-off-Distance Abrasive Flow Rate - Nozzle Pressure - Mixing Ratio. PROCESS CAPABILITIES APPLICATIONS PROBLEMS
3.
ULTRASONIC MACHINING ( USM ) INTRODUCTION ULTRASONIC MACHINING SYSTEM
Coordinators:
2
ULTRASONIC MACHINING SYSTEM MECHANICS OF CUTTING PARAMETRIC ANALYSIS PROCESS CAPABILITIES APPLICATIONS PROBLEMS
4.
ABRASIVE FLOW FINISHING
2
ABRASIVE FLOW FINISHING WORKING PRINCIPLE ABRASIVE FLOW MACHINING SYSTEM Machine - Tooling - Media. PROCESS VARIABLES PROCESS PERFORMANCE ANALYSIS AND MODELING OF ABRASIVE FLOW MACHINED SURFACES - Number of Active Grains - Wear of Abrasive Grains. APPLICATIONS - Aerospace - Dies and Molds. REVIEW QUESTIONS
5.
MAGNETIC ABRASIVE FINISHING (MAF)
2
INTRODUCTION WORKING PRINCIPLE OF MAF MATERIAL REMOVAL (OR STOCK REMOVAL) AND SURFACE FINISH - Bonded and Unbonded Magnetic Abrasives - Machining Fluid - Magnetic Flux Density. ANALYSIS REVIEW QUESTIONS
6.
WATER JET CUTTING ( WJC )
1
INTRODUCTION WJM MACHINE PROCESS CHARACTERISTICS PROCESS PERFORMANCE APPLICATIONS BIBLIOGRAPHY SELF TEST QUESTIONS REVIEW QUESTIONS
7.
ABRASIVE WATER JET MACHINING ( AWJM ) WORKING PRINCIPLE AWJM MACHINE - Pumping System - Abrasive
2
Feed System - Abrasive Jet Nozzle - Catcher. PROCESS CHARACTERISTICS WATER - Water Jet Pressure During Slotting Water Flow Rate. ABRASIVES - Abrasive Flow Rate - Abrasive Particle Size - Abrasive Material. CUTTING PARAMETERS - Traverse Speed Number of es - Stand-off-Distance - Visual Examination. PROCESS CAPABILITIES APPLICATIONS REVIEW QUESTIONS
8.
THERMOELECTRIC ADVANCED MACHINING PROCESSES ELECTRIC DISCHARGE MACHINING ( EDM )
3
INTRODUCTION WORKING PRINCIPLE OF EDM R-C PULSE GENERATOR EDM MACHINE - Power Supply - Dielectric System - Electrodes - Servo system - Electrode Refeeding - Power Delivered to the Discharging Circuit. CNC-EDM ANALYSIS - Analysis of R-C Circuits - Current in discharging Circuit - Material Removal in RC Circuits - Surface Finish. PROCESS VARIABLES - Dielectric Pollution and its Effects. PROCESS CHARACTERISTICS - Gap Cleaning. APPLICATIONS
9.
ELECTRIC DISCHARGE GRINDING ( EDG ) AND ELECTRIC DISCHARGE DIAMOND GRINDING (EDDG)
1.5
ELECTRIC DISCHARGE GRINDING ELECTRICAL DISCHARGE DIAMOND GRINDING - Working Principle - Capabilities and Applications.
10.
WIRE ELECTRIC DISCHARGE MACHINING WORKING PRINCIPLE WIRE EDM MACHINE - Power Supply System Dielectric System - Positioning System - Wire Drive System. ADVANCES IN WIRECUT STRATIFIED WIRE
1.5
STRATIFIED WIRE PROCESS VARIABLES PROCESS CHARACTERISTICS APPLICATIONS PROBLEMS REVIEW QUESTIONS
11.
LASER BEAM MACHINING
3
PRODUCTION OF LASERS WORKING PRINCIPLE OF LASER BEAM MACHINING TYPES OF LASERS - Solid Lasers - Gas Lasers. PROCESS CHARACTERISTICS APPLICATIONS - Drilling - Cutting - Marking Miscellaneous Applications. REVIEW QUESTIONS
12.
PLASMA ARC MACHINING
1
WORKING PRINCIPLE PLASMA ARC CUTTING SYSTEM ELEMENTS OF A PLASMA ARC CUTTING SYSTEM PROCESS PERFORMANCE APPLICATIONS REVIEW QUESTIONS
13.
ELECTRON BEAM MACHINING
2
WORKING PRINCIPLE ELECTRON BEAM MACHINING SYSTEM Electron Beam Gun - Power Supply - Vacuum System and Machining Chamber. PROCESS PARAMETERS CHARACTERISTICS OF THE PROCESS APPLICATIONS PROBLEMS
14.
FOCUSSED ION BEAM MACHINING
2
Working Principle - FIB machining system - Parametric analysis - Applications - Problems.
15.
ELECTROCHEMICAL AND CHEMICAL ADVANCED MACHINING PROCESSES ELECTROCHEMICAL MACHINING
4
INTRODUCTION ELECTROLYSIS ELECTROCHEMICAL MACHINING (ECM) ECM MACHINE TOOL - Power Source Electrolyte Supply and Cleaning System - Tool and Tool Feed System - Workpiece and Work Holding Device. ADVANTAGES AND LIMITATIONS APPLICATIONS MECHANICAL PROPERTIES OF ECM'D PARTS THEORY OF ECM - Faraday's Laws of Electrolysis. ELECTROCHEMICAL EQUIVALENT OF ALLOYS - Material Removal Rate in ECM - Interelectrode Gap in ECM - Zero Feed Rate - Finite Feed Rate - Self Regulating Feature Generalized Equation for Inter-electrode Gap. MAXIMUM PERMISSIBLE FEED RATE IN ECM ELECTROLYTE CONDUCTIVITY (K) Temperature - Hydrogen Bubbles. PROBLEMS
16.
ELECTROCHEMICAL GRINDING
1
INTRODUCTION ECG MACHINE TOOL PROCESS CHARACTERISTICS APPLICATIONS REVIEW PROBLEMS
17.
ELECTROSTREAM DRILLING
1
INTRODUCTION PROCESS PERFORMANCE BIBLIOGRAPHY REVIEW QUESTIONS
18.
ELECTROCHEMICAL DEBURRING INTRODUCTION - Definition of Burr - Types of Burrs - Basic Approach on Deburring. CLASSIFICATION OF DEBURRING PROCESSES ELECTROCHEMICAL DEBURRING (ECD e) Principle of Working. APPLICATIONS SPECIFIC FEATURES OF ECD e MACHINE
1.5
REVIEW QUESTIONS
19.
SHAPED TUBE ELECTROLYTIC MACHINING
1
INTRODUCTION - Working Principle - Applications.
20.
CHEMICAL MACHINING ( ChM )
2
INTRODUCTION MASKANTS - Cut And Peel - Screen Printing Photo-resist Mask-ant. ETCHANT ADVANTAGES AND LIMITATIONS REVIEW QUESTIONS
21.
ANODE SHAPE PREDICTION AND TOOL DESIGN FOR ECM PROCESSES
3
INTRODUCTION ANODE SHAPE PREDICTION - Cosθ Method Empirical Approach - Nomographic Approach Numerical Approach - Numerical Methods. TOOL (CATHODE) DESIGN FOR ECM PROCESS Cosθ Method Correction Factor Method SOME EXERCISES
1.5
References: 1. Advanced Machining Processes by V.K.Jain, Allied Publishers, New Delhi. 2. Modern Machining Processes by P.C.Pandey, Tata McGraw Hill, New Delhi. 3. Unconventional Machining Processes by P.K.Mishra 4. Advanced Machining Methods by JAMcGeough, Chapman and Halls, UK. A t venture by IISc and IITs, funded by MHRD, Govt of India
http://nptel.iitm.ac.in
Advanced Machining Processes - Video course COURSE OUTLINE This course on 'Advanced Machining Processes' is also known as "Unconventional Machining Processes", Modern Machining Processes", and "New Technology". It deals with the latest machining processes named as "Advanced Machining Processes". They have been divided into three parts: Part 1 deals with mechanical type advanced machining processes such as Ultrasonic machining, water jet machining, abrasive water jet machining.It also includes micro-/nano-finishing processes viz, abrasive flow finishing, magnetic abrasive finishing, etc. Part 2 deals with thermal machining processes for example, electric discharge machining, laser beam machining, electron beam machining, etc. Part 3 elaborates chemical and electrochemical machining processes.It includes some hybrid machining processes namely, electrochemical grinding, electric discharge grinding and similar others.
COURSE DETAIL Sl.No
NPTEL http://nptel.iitm.ac.in
Mechanical Engineering Pre-requisites: The candidate/reader should have the background of metal cutting and basics of physics and chemistry. Additional Reading:
Topics
Hours
Related research papers. ASM Handbooks.
1.
INTRODUCTION
1
Why do we need advanced machining processes (AMPs)?
Prof. Vijay K. Jain Department of Mechanical EngineeringIIT Kanpur
Advanced machining processes Remarks
2.
MECHANICAL ADVANCED MACHINING PROCESSES
2
ABRASIVE JET MACHINING ( AJM ) Introduction - Abrasive Jet Machining Setup - Gas Propulsion System - Abrasive Feeder Machining Chamber - AJM Nozzle - Abrasives. PARAMETRIC ANALYSIS - Stand-off-Distance Abrasive Flow Rate - Nozzle Pressure - Mixing Ratio. PROCESS CAPABILITIES APPLICATIONS PROBLEMS
3.
ULTRASONIC MACHINING ( USM ) INTRODUCTION ULTRASONIC MACHINING SYSTEM
Coordinators:
2
ULTRASONIC MACHINING SYSTEM MECHANICS OF CUTTING PARAMETRIC ANALYSIS PROCESS CAPABILITIES APPLICATIONS PROBLEMS
4.
ABRASIVE FLOW FINISHING
2
ABRASIVE FLOW FINISHING WORKING PRINCIPLE ABRASIVE FLOW MACHINING SYSTEM Machine - Tooling - Media. PROCESS VARIABLES PROCESS PERFORMANCE ANALYSIS AND MODELING OF ABRASIVE FLOW MACHINED SURFACES - Number of Active Grains - Wear of Abrasive Grains. APPLICATIONS - Aerospace - Dies and Molds. REVIEW QUESTIONS
5.
MAGNETIC ABRASIVE FINISHING (MAF)
2
INTRODUCTION WORKING PRINCIPLE OF MAF MATERIAL REMOVAL (OR STOCK REMOVAL) AND SURFACE FINISH - Bonded and Unbonded Magnetic Abrasives - Machining Fluid - Magnetic Flux Density. ANALYSIS REVIEW QUESTIONS
6.
WATER JET CUTTING ( WJC )
1
INTRODUCTION WJM MACHINE PROCESS CHARACTERISTICS PROCESS PERFORMANCE APPLICATIONS BIBLIOGRAPHY SELF TEST QUESTIONS REVIEW QUESTIONS
7.
ABRASIVE WATER JET MACHINING ( AWJM ) WORKING PRINCIPLE AWJM MACHINE - Pumping System - Abrasive
2
Feed System - Abrasive Jet Nozzle - Catcher. PROCESS CHARACTERISTICS WATER - Water Jet Pressure During Slotting Water Flow Rate. ABRASIVES - Abrasive Flow Rate - Abrasive Particle Size - Abrasive Material. CUTTING PARAMETERS - Traverse Speed Number of es - Stand-off-Distance - Visual Examination. PROCESS CAPABILITIES APPLICATIONS REVIEW QUESTIONS
8.
THERMOELECTRIC ADVANCED MACHINING PROCESSES ELECTRIC DISCHARGE MACHINING ( EDM )
3
INTRODUCTION WORKING PRINCIPLE OF EDM R-C PULSE GENERATOR EDM MACHINE - Power Supply - Dielectric System - Electrodes - Servo system - Electrode Refeeding - Power Delivered to the Discharging Circuit. CNC-EDM ANALYSIS - Analysis of R-C Circuits - Current in discharging Circuit - Material Removal in RC Circuits - Surface Finish. PROCESS VARIABLES - Dielectric Pollution and its Effects. PROCESS CHARACTERISTICS - Gap Cleaning. APPLICATIONS
9.
ELECTRIC DISCHARGE GRINDING ( EDG ) AND ELECTRIC DISCHARGE DIAMOND GRINDING (EDDG)
1.5
ELECTRIC DISCHARGE GRINDING ELECTRICAL DISCHARGE DIAMOND GRINDING - Working Principle - Capabilities and Applications.
10.
WIRE ELECTRIC DISCHARGE MACHINING WORKING PRINCIPLE WIRE EDM MACHINE - Power Supply System Dielectric System - Positioning System - Wire Drive System. ADVANCES IN WIRECUT STRATIFIED WIRE
1.5
STRATIFIED WIRE PROCESS VARIABLES PROCESS CHARACTERISTICS APPLICATIONS PROBLEMS REVIEW QUESTIONS
11.
LASER BEAM MACHINING
3
PRODUCTION OF LASERS WORKING PRINCIPLE OF LASER BEAM MACHINING TYPES OF LASERS - Solid Lasers - Gas Lasers. PROCESS CHARACTERISTICS APPLICATIONS - Drilling - Cutting - Marking Miscellaneous Applications. REVIEW QUESTIONS
12.
PLASMA ARC MACHINING
1
WORKING PRINCIPLE PLASMA ARC CUTTING SYSTEM ELEMENTS OF A PLASMA ARC CUTTING SYSTEM PROCESS PERFORMANCE APPLICATIONS REVIEW QUESTIONS
13.
ELECTRON BEAM MACHINING
2
WORKING PRINCIPLE ELECTRON BEAM MACHINING SYSTEM Electron Beam Gun - Power Supply - Vacuum System and Machining Chamber. PROCESS PARAMETERS CHARACTERISTICS OF THE PROCESS APPLICATIONS PROBLEMS
14.
FOCUSSED ION BEAM MACHINING
2
Working Principle - FIB machining system - Parametric analysis - Applications - Problems.
15.
ELECTROCHEMICAL AND CHEMICAL ADVANCED MACHINING PROCESSES ELECTROCHEMICAL MACHINING
4
INTRODUCTION ELECTROLYSIS ELECTROCHEMICAL MACHINING (ECM) ECM MACHINE TOOL - Power Source Electrolyte Supply and Cleaning System - Tool and Tool Feed System - Workpiece and Work Holding Device. ADVANTAGES AND LIMITATIONS APPLICATIONS MECHANICAL PROPERTIES OF ECM'D PARTS THEORY OF ECM - Faraday's Laws of Electrolysis. ELECTROCHEMICAL EQUIVALENT OF ALLOYS - Material Removal Rate in ECM - Interelectrode Gap in ECM - Zero Feed Rate - Finite Feed Rate - Self Regulating Feature Generalized Equation for Inter-electrode Gap. MAXIMUM PERMISSIBLE FEED RATE IN ECM ELECTROLYTE CONDUCTIVITY (K) Temperature - Hydrogen Bubbles. PROBLEMS
16.
ELECTROCHEMICAL GRINDING
1
INTRODUCTION ECG MACHINE TOOL PROCESS CHARACTERISTICS APPLICATIONS REVIEW PROBLEMS
17.
ELECTROSTREAM DRILLING
1
INTRODUCTION PROCESS PERFORMANCE BIBLIOGRAPHY REVIEW QUESTIONS
18.
ELECTROCHEMICAL DEBURRING INTRODUCTION - Definition of Burr - Types of Burrs - Basic Approach on Deburring. CLASSIFICATION OF DEBURRING PROCESSES ELECTROCHEMICAL DEBURRING (ECD e) Principle of Working. APPLICATIONS SPECIFIC FEATURES OF ECD e MACHINE
1.5
REVIEW QUESTIONS
19.
SHAPED TUBE ELECTROLYTIC MACHINING
1
INTRODUCTION - Working Principle - Applications.
20.
CHEMICAL MACHINING ( ChM )
2
INTRODUCTION MASKANTS - Cut And Peel - Screen Printing Photo-resist Mask-ant. ETCHANT ADVANTAGES AND LIMITATIONS REVIEW QUESTIONS
21.
ANODE SHAPE PREDICTION AND TOOL DESIGN FOR ECM PROCESSES
3
INTRODUCTION ANODE SHAPE PREDICTION - Cosθ Method Empirical Approach - Nomographic Approach Numerical Approach - Numerical Methods. TOOL (CATHODE) DESIGN FOR ECM PROCESS Cosθ Method Correction Factor Method SOME EXERCISES
1.5
References: 1. Advanced Machining Processes by V.K.Jain, Allied Publishers, New Delhi. 2. Modern Machining Processes by P.C.Pandey, Tata McGraw Hill, New Delhi. 3. Unconventional Machining Processes by P.K.Mishra 4. Advanced Machining Methods by JAMcGeough, Chapman and Halls, UK. A t venture by IISc and IITs, funded by MHRD, Govt of India
http://nptel.iitm.ac.in
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