Lovely Professional University, Punjab

Course Code MEC442 Course Category Course Title NON TRADITIONAL MACHINING PROCESSES Courses with conceptual focus Course Planner 15854::Jasvinder Singh Lectures 3.0 Tutorials Practicals Credits 0.0 0.0 3.0

TextBooks Sr No T-1 Title Modern Machining Processes Reference Books Sr No R-1 Other Reading Sr No OR-1 OR-2 Journals articles as Compulsary reading (specific articles, complete reference) International journal of Mechanical seciences with articles on machining , International Journal of Machining and Machinability of Materials , Title Advanced Machining processes Author V.K.Jain Edition 2nd Year 2007 Publisher Name Allied Publishers Author PC Pandey, H.S.Shan Edition 1st Year 2000 Publisher Name Mc graw Hill

Relevant Websites Sr No RW-1 RW-2 RW-3 (Web address) (only if relevant to the course) http://www.en.wikipedia.org/wiki/machine_tool http://nptel.iitm.ac.in/ http://www.springer.com Salient Features Machine tool, machine tool materials PPTs of differents types machining processes Advanced Analysis of Nontraditional Machining

LTP week distribution: (LTP Weeks) Weeks before MTE Weeks After MTE Spill Over 7 6 2

Detailed Plan For Lectures

Week Number Lecture Number Broad Topic(Sub Topic) Chapters/Sections of Text/reference books Other Readings, Lecture Description Relevant Websites, Audio Visual Aids, software and Virtual Labs Learning Outcomes Pedagogical Tool Demonstration/ Case Study / Images / animation / ppt etc. Planned

Week 1

Lecture 1

Introduction(Why do we need advanced machining processes) Introduction(Classification and Hybrid processes)

T-1:Chapter-1 P1

Why do we need advanced machining processes Classification and Hybrid processes Application Introduction to Ultrasonic machining Cutting tool system design Cutting tool system design Theory of Shaw and Kazantsev Theory of Shaw and Kazantsev Theory of Shaw and Kazantsev Mechanism of cutting Mechanism of cutting Effect of parameters Variable in AJM

What is the need of machining Classification Application Introduction of USM

Slide Show by teacher

T-1:Chapter-1 P2 T-1:Chapter-2 P37 T-1:Chapter-2 P7

Slide Show by teacher Slide Show by teacher Slide Show by teacher

Lecture 2

Ultrasonic Machining Process (Application) Ultrasonic Machining Process (Introduction to Ultrasonic machining)

Lecture 3 Week 2 Lecture 4 Lecture 5 Lecture 6 Week 3 Lecture 7 Lecture 8 Lecture 9 Week 4 Lecture 10 Lecture 11

Ultrasonic Machining Process (Cutting tool system design) Ultrasonic Machining Process (Cutting tool system design) Ultrasonic Machining Process (Theory of Shaw and Kazantsev) Ultrasonic Machining Process (Theory of Shaw and Kazantsev) Ultrasonic Machining Process (Theory of Shaw and Kazantsev) Ultrasonic Machining Process (Mechanism of cutting) Ultrasonic Machining Process (Mechanism of cutting) Ultrasonic Machining Process (Effect of parameters) Abrasive Jet Machining Process (Variable in AJM) Abrasive Jet Machining Process (Introduction to Abrasive jet machining)

T-1:Chapter-2 P14 T-1:Chapter-2 P14 T-1:Chapter-2 P27 T-1:Chapter-2 P27 T-1:Chapter-2 P27 T-1:Chapter-2 P24 T-1:Chapter-2 P24 T-1:Chapter-2 P10 T-1:Chapter-2 P40 T-1:Chapter-2 P39

mechanism of cutting tool system design mechanism of cutting tool system design Theory of Miller and Shaw Theory of Miller and Shaw Theory of Miller and Shaw mechanism of cutting mechanism of cutting How parameters effected different varibles of AJM

Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher

Introduction to Abrasive learn about AJM jet machining Process variables details What is process variables Applications Applictions

Lecture 12

Abrasive Jet Machining Process (Process variables details) Abrasive Jet Machining Process (Applications)

T-1:Chapter-2 P40 T-1:Chapter-2 P39 T-1:Chapter-2 P44 T-1:Chapter-2 P39 T-1:Chapter-3 P52 T-1:Chapter-3 P61

Slide Show by teacher Slide Show by teacher

Week 5

Lecture 13 Lecture 14 Lecture 15

Abrasive Jet Machining Process (Material removal rate in AJM) Abrasive Jet Machining Process (Advantages and disadvantages) Electrochemical Maching Process (Introduction to ECM) Electrochemical Maching Process (Chemistry of the process ECM process characteristics)

Material removal rate in How MRR increases or Slide Show by teacher AJM decreases Advantages and disadvantages Introduction to ECM Advantages and disadvantages Introduce to ECM Slide Show by teacher Slide Show by teacher Slide Show by teacher

Chemistry of the process how chemistry affects ECM process machining characteristics

Week 5

Lecture 15

Chemical Metal Removal Process (Introduction of Chemical machining) Electrochemical Maching Process (Elements of ECM process: Cathode tool and Anode work piece)

T-1:Chapter-3 P80

Introduction of Chemical Introduce to chemical machining maching Elements of ECM Differents types of process Cathode tool and ECM Parameters Anode work piece Electrochemical honning introduce to ECM honning Homework,Term Paper,Test 1

Slide Show by teacher

T-1:Chapter-3 P53

Slide Show by teacher

Week 6

Lecture 16 Lecture 17 Lecture 18

Electrochemical Maching Process (Electrochemical honning)

T-1:Chapter-3 P79

Slide Show by teacher

Electrochemical Maching Process (Material removal rate) Electrochemical Maching Process (Source of DC power) Electrochemical Maching Process (Electrolyte) Electrochemical Maching Process (Accuracy and Surface finish)

T-1:Chapter-3 P62 T-1:Chapter-3 P54 T-1:Chapter-3 P54 T-1:Chapter-3 P69 T-1:Chapter-3 P81

Material removal rate Source of DC power Electrolyte Accuracy and Surface finish Process characteristics Material removal rate, Accuracy and Surface finish

How MRR increases or Slide Show by teacher decreases What type of source of power is used in ECM Slide Show by teacher

Week 7

Lecture 19 Lecture 20

Know about electrolyte Slide Show by teacher how accuracy increases Slide Show by teacher or decreases MRR, Accuracy and surface finish Slide Show by teacher

Lecture 21

Chemical Metal Removal Process (Process characteristics: Material removal rate, Accuracy and Surface finish)

MID-TERM
Week 8 Lecture 22 Electrochemical Deburring (Working Principle of Electrochemical deburring) Electrochemical Deburring (Introduction of deburring) Lecture 23 Electrochemical Deburring (Advantages and disadvantages of the process) Electrochemical Deburring (Differences between deburring and honning) Lecture 24 Electron Beam Machining Process (Introduction to EBM) Electron Beam Machining Process (Neutral particle etching) Electron Beam Machining Process (Advantages and disadvantages) Electron Beam Machining Process (EBM characteristics) Week 9 Lecture 25 Electron Beam Machining Process (Applications) T-1:Chapter-3 P78 Working Principle of Electrochemical deburring working principle of ECM deburing Slide Show by teacher

T-1:Chapter-3 P78 T-1:Chapter-3 P79

Introduction of deburring Introduce deburing Advantages and disadvantages of the process Differences between deburring and honning Introduction to EBM Neutral particle etching Advantages and disadvantages EBM characteristics Applications Advantages and disadvantages of the process Differences between deburring and honning Introduce to EBM what is Neutral particle etching Advantages and disadvantages EBM characteristics Applications

Slide Show by teacher Slide Show by teacher

T-1:Chapter-3 P7879 T-1:Chapter-4 P134 T-1:Chapter-4 P142 T-1:Chapter-4 T-1:Chapter-4 P136 T-1:Chapter-4

Slide Show by teacher

Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher

Week 9

Lecture 26

Plasma Arc Machinig Process (Applications) Plasma Arc Machinig Process (Introduction and working principle of PAM)

T-1:Chapter-4 T-1:Chapter-4 P114

Applications

Applications

Slide Show by teacher Slide Show by teacher

Introduction and working Introduction and principle of PAM working principle of PAM Plasma arc machining parameters Plasma arc spraying Advantages and disadvantages Vibrating electrode system Electrode tool design Mechanism of metal removal Introduction of EDM Electrode feed control Selection of electrode material Introduction of Laser beam machining Plasma arc machining parameters What is Plasma arc spraying Advantages and disadvantages What is Vibrating electrode system what is Electrode tool design Mechanism of metal removal Introduction of EDM What is Electrode feed control How we select electrode material Introduce to LBM

Plasma Arc Machinig Process T-1:Chapter-4 P116 (Plasma arc machining parameters) Lecture 27 Plasma Arc Machinig Process (Plasma arc spraying) Plasma Arc Machinig Process (Advantages and disadvantages) Week 10 Lecture 28 Electro-Discharge Machining Process(Vibrating electrode system) Electro-Discharge Machining Process(Electrode tool design) Electro-Discharge Machining Process(Mechanism of metal removal) Electro-Discharge Machining Process(Introduction of EDM) Electro-Discharge Machining Process(Electrode feed control) Electro-Discharge Machining Process(Selection of electrode material) Laser Beam Machining and Water Jet Machining Processes (Introduction of Laser beam machining) Laser Beam Machining and Water Jet Machining Processes(Process characteristics) Laser Beam Machining and Water Jet Machining Processes(Process characteristics) Laser Beam Machining and Water Jet Machining Processes (Introduction and working principle of water jet machining) Laser Beam Machining and Water Jet Machining Processes (Introduction and working principle of water jet machining) Laser Beam Machining and Water Jet Machining Processes (Applications) T-1:Chapter-4 P131 T-1:Chapter-4 T-1:Chapter-4

Slide Show by teacher Slide Show by teacher Slide Show by teacher Slide Show by teacher

Lecture 29 Lecture 30

T-1:Chapter-4 T-1:Chapter-4 P88

Slide Show by teacher Slide Show by teacher

Week 11

Lecture 31 Lecture 32 Lecture 33

T-1:Chapter-4 P85 T-1:Chapter-4 T-1:Chapter-4

Slide Show by teacher Slide Show by teacher Slide Show by teacher

Week 12

Lecture 34

T-1:Chapter-4 P143

Slide Show by teacher

Lecture 35

T-1:Chapter-4

Process characteristics

What are the process characteristics What are the process characteristics

Slide Show by teacher

Lecture 36

T-1:Chapter-4

Process characteristics

Slide Show by teacher

Week 13

Lecture 37

T-1:Chapter-4 P45

Introduction and working What is the working principle of water jet principle of Waterjet machining machining Introduction and working What is the working principle of water jet principle of Waterjet machining machining Applications Applications

Slide Show by teacher

Lecture 38

T-1:Chapter-4 P45

Slide Show by teacher

T-1:Chapter-4

Slide Show by teacher

Week 13

Lecture 39

Laser Beam Machining and Water Jet Machining Processes (Applications) Laser Beam Machining and Water Jet Machining Processes (Advantages and disadvantages)

T-1:Chapter-4

Applications

Applications

Slide Show by teacher

T-1:Chapter-4

Advantages and disadvantages

Advantages and disadvantages

Slide Show by teacher

SPILL OVER
Week 14 Lecture 40 T-1:revise book topics T-1:Revise syllabus Revision Student will able to revise all syllabus Student will able to revise all syllabus Slide Show by teacher

Lecture 41

Revision

Slide Show by teacher

Scheme for CA:

Component Homework,Term Paper,Test Frequency 2 Total :Out Of 3 Each Marks Total Marks 10 10 20 20

Details of Academic Task(s)

AT No. Objective Topic of the Academic Task Nature of Academic Task (group/individuals/field work Individual Evaluation Mode Allottment / submission Week 2/3

Test 1

To check the knowledge of students To evaluate the knowledge of students

Lecture-1 to Lecture-8

Marks of all questions 5 or multiple of 5 On the basis of quality of work On the basis of quality of work

Homework 1

Lecture-10 to Lecture-20

Individual

6/7

Term Paper 1

To check the general Lecture-22 to Lecture-35 knowledge of students

Individual

11 / 12

List of suggested topics for term paper[at least 15] (Student to spend about 15 hrs on any one specified term paper) Sr. No. Topic 1 Micro ultrasonic machining and its application in MEMS 2 Study of micro deburring technology using ultrasonic vibration 3 Properties of micro holes for nozzle by micro EDM 4 Recent development in Electrochemical micromachining.

5 Micro EDM and micro ECM in DI water 6 Laser micromachining for manufacturing MEMS device. 7 Focus ion beam milling depth control for 3D micro fabrication 8 Study on surface roughness in ion beam machining 9 Fabrication of nanometre structure using lithography 10 Surface roughness of carbide produced by water jet machining 11 Ultrasonic vibration drilling of micro holes in a glass 12 Ultrasonic machining using multi tools 13 Study of 3D Micro-Ultrasonic machining 14 Electrochemical Machinning and its applications 15 Analysis of Heat affected zone in Laser Beam Machining