DSEC/Mechanical Engineering/ME8073/IV/VII

DHANALAKSHMI SRINIVASAN ENGINEERING COLLEGE

PERAMBALUR-621212
COURSE PLAN
Name of the Faculty Mr.R.KALAIYARASAN
Designation/Department Assistant Professor
Course Code/Name ME8073 / Unconventional machining processes
Year/Section/Department IV / B / Mechanical Engineering
Credits Details L: 3 T: 0 P: 0 C: 3
Total Contact Hours Required 45

Syllabus:

No. of
UNIT I INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES
Periods : 9
Unconventional machining Process – Need – classification – merits, demerits and applications. Abrasive Jet
Machining – Water Jet Machining – Abrasive Water Jet Machining - Ultrasonic Machining. (AJM, WJM, AWJM
and USM). Working Principles – equipment used – Process parameters – MRR- Applications.
No. of
UNIT II THERMAL AND ELECTRICAL ENERGY BASED PROCESSES
Periods : 9
Electric Discharge Machining (EDM) – Wire cut EDM – Working Principle-equipments-Process Parameters-
Surface Finish and MRR- electrode / Tool – Power and control Circuits-Tool Wear – Dielectric – Flushing ––
Applications. Laser Beam machining and drilling, (LBM), plasma, Arc machining (PAM) and Electron Beam
Machining (EBM). Principles – Equipment –Types - Beam control techniques – Applications.
No. of
UNIT III CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
Periods : 9
Chemical machining and Electro-Chemical machining (CHM and ECM)- Etchants – Maskant - techniques of
applying maskants - Process Parameters – Surface finish and MRR-Applications. Principles of ECM-
equipments-Surface Roughness and MRR Electrical circuit-Process Parameters- ECG and ECH - Applications.
No. of
UNIT IV ADVANCED NANO FINISHING PROCESSES
Periods : 9
Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing, magneto rheological
finishing, magneto rheological abrasive flow finishing their working principles, equipments, effect of process
parameters, applications, advantages and limitations.
No. of
UNIT V RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES
Periods : 9

Recent developments in non-traditional machining processes, their working principles, equipments, effect of
process parameters, applications, advantages and limitations. Comparison of non-traditional machining
processes.

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Objective:

 To learn about various unconventional machining processes, the various process

parameters and their influence on performance and their applications

Text Book:

T1: Vijay.K. Jain “Advanced Machining Processes” Allied Publishers Pvt. Ltd., New Delhi, 2007

T2: Pandey P.C. and Shan H.S. “Modern Machining Processes” Tata McGraw-Hill, New Delhi,
2007.

Reference Book:

R1: Benedict. G.F. “Nontraditional Manufacturing Processes”, Marcel Dekker Inc., New York, 1987.

R2: Mc Geough, “Advanced Methods of Machining”, Chapman and Hall, London, 1998.

R3: Paul De Garmo, J.T.Black, and Ronald. A.Kohser, “Material and Processes in Manufacturing”
Prentice Hall of India Pvt. Ltd., 8thEdition, New Delhi , 2001.

Website:

W1Non-traditional Manufacturing. (http://nptel.ac.in/courses/112105126/36)

W2Ultrasonic Machining.(http://nptel.ac.in/courses/112105126/37)
W3WJM and AJM.(http://nptel.ac.in/courses/112105126/38)
W4Electro Chemical Machining.(http://nptel.ac.in/courses/112105126/39)
W5Electro-discharge Machining.(http://nptel.ac.in/courses/112105126/40)
W6Electron Beam and Laser Beam (http://nptel.ac.in/courses/112105126/41)
Online Mode of Study (if Any):

OMS 1: https://nptel.ac.in/courses/112/105/112105249/

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Course Plan:

Number of
Topic Reference Page Mode of Cumulative
Topic Periods
Number Detail Number Teaching Period
Required
UNIT I
Unconventional machining BB
1 Process. T1 1-2 1 1
PPT

BB
2 Need of UCM T1 1-2 1 2
PPT

BB
3 Classification of UCM. T1 3-4 1 3
PPT

BB
4 T1 10-13 1 4
Abrasive Jet Machining W3

BB
5 T1 15-19 1 5
Water Jet Machining W3

BB
6 Abrasive Water Jet T1 19-24 1 6
W3
Machining
BB
7 T1 28-33 1 7
Ultrasonic Machining W2

8 T1 13-27 BB 2 9
Process parameters-MRR
Outcome of Unit I: CO1:
Explain the need for unconventional machining processes and its classification
UNIT II

9 Electric Discharge Machining T1 25 BB 2 11

(EDM)
10 T2 59 BB 1 12
Wire cut EDM
11 T1 52 BB 1 13
Power and control Circuits

12 Tool Wear – Dielectric – T1 56 BB 1 14

Flushing
13 Laser Beam machining T2 97 PPT 1 15

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14 Laser Beam drilling T2 99 PPT 1 16

plasma, Arc machining T2 101 BB
15 1 17
(PAM)
Electron Beam Machining T2 BB
16 106 1 18
(EBM)
Outcome of Unit II: CO 2:
Compare various thermal energy and electrical energy based unconventional
machining processes.
UNIT III
17 T1 71 BB 2 20
Chemical machining
18 T1 75 BB 2 22
Electro-Chemical machining

Etchants – Maskant - T1 BB
19 77 1 23
techniques of applying
maskants

20 Process Parameters – T1 79 BB 1 24
Surface finish and MRR
21 Electro-Chemical Grinding T2 83 BB 1 25
22 Electro-Chemical Honning T2 85 BB 1 26
23 Applications. T1 96 BB 1 27
Outcome of Unit III:
CO 3:
Summarize various chemical and electro-chemical energy based unconventional machining
processes.
UNIT IV
24 T1 123 BB 2 29
Abrasive flow machining
25 T1 127 BB 1 30
chemo-mechanical polishing
magnetic abrasive T1 BB
26 130 1 31
finishing
magneto rheological T1 BB
27 137 1 32
finishing
magneto rheological T1 BB
28 140 2 34
abrasive flow finishing
29 process parameters T1 146 BB 1 35
applications, advantages T1 BB
30 149 1 36
and limitations

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Outcome of Unit IV:

CO 4:
Explain various nano abrasives based unconventional machining processes.

UNIT V
Recent developments in
31 W1 - - 3 39
non-traditional machining
working principles,
32 OMS - - 3 42
equipments
33 process parameters T2 179 BB 1 43
applications, advantages T2 BB
34 183 1 44
and limitations
Comparison of non-
35 traditional machining W1 - - 1 45
processes
Outcome of Unit V:
CO 5:
Distinguish various recent trends based unconventional machining processes
Course Outcome:

At the end of course:

Students should be able to do:

CO 1: Explain the need for unconventional machining processes and its classification
CO 2: Compare various thermal energy and electrical energy based unconventional
machining processes.
CO 3: Summarize various chemical and electro-chemical energy based unconventional machining processes.
CO 4: Explain various nano abrasives based unconventional machining processes.
CO 5: Distinguish various recent trends based unconventional machining processes

Course Outcome Vs Program Outcome Mapping:

CO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO 1 √ √ √ √ - - √ √ √ √ √ √

CO 2 √ √ √ - √ - - √ √ √ √ √

CO 3 - √ - √ √ - - √ √ - √ -

CO 4 - - - - - √ - - - - - -

CO 5 √ √ √ - - √ √ - - √ √ √

Content Beyond Syllabus:

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 Implementation of NON CONVENTIONAL PROCESS

Assignment:

Batch Total Mode of Assignment

Register Number Topics
Details Number MCQ/Seminar/PPT
Assignment 1 - MCQ 1-7
Batch 1 Assignment 2 - Seminar 17-20
Assignment 3 - PPT 27-30
Assignment 1 - Seminar 9-10
Batch 2 Assignment 2 - PPT 21-23
Assignment 3 - MCQ 31-33
Batch 3 Assignment 1 - PPT 13-16
Assignment 2 - MCQ 24-26
Assignment 3 - Seminar 34-35

SIM Questions: Questions of Anna University with Year mentioned (12 Q+12 Q+ 12 Q)

SIM 1
1. Classify the unconventional machining process on the basis of the type of energy employed.
Also, state the mechanism of material removal, transfer media and energy sources used.
(April/May 2018).
2. Discuss the effects of various process parameters of abrasive jet machining on accuracy and
MRR(May/June 2014)
3. Describe the working principle of AJM process with a neat sketch. May/June 2016
4. Explain the working principle of AJM process with a neat sketch.
5. List the factors which affect the MRR in USM and write short notes on each of them.
(April/May 2018)
6. Explain the working principle of AWJM process with a neat sketch.
7. Explain the working principle of USM process with a neat sketch.
8. Describe the working principle of EDM process with a neat sketch. [May/June2012,2016]
9. Discuss the recent development in EDM process. Also list out the disadvantages. (Nov/Dec
2017)
10. Explain the general arrangement of electrical discharge machining process and list out its
advantages, disadvantages and its application. (May/June2016)
11. what are the applications of water jet machining?(May/June2013)
12. Discuss the recent development in EDM process. Also list out the disadvantages. (Nov/Dec
2017)

SIM 2

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1. Sketch the electron beam machine and explain the function of each part. (May/June2013)
2. With the neat sketch explain the process of LBM with the effect of all the process parameters.
(April/May 2018)
3. Explain the process of PAM with a neat sketch. With respect to principle, equipment process
parameter, advantages, disadvantages and applications. (Nov/Dec 2015)
4. With the neat sketch explain the process of LBD with the effect of all the process parameters.
(April/May 2017)
5. Explain different types of plasma arc machining process with a neat sketch. Also state its
advantages, disadvantages and applications. (Nov/Dec 2016)
6. Explain in detail the ECM process with neat sketch describe and also mention the advantages
and application? (Nov/Dec 2013, 2016, 2017) (May/June 2016)
7. Describe the working principle and elements of chemical machining. (Nov/Dec 2017)
8. Explain the process of chemical blanking and chemical milling with neat sketch.
(May/Jun 2016)
9. What are the specific advantages of using CHM over electrochemical machining? Give some
of the practical applications of CHM process? (Nov/Dec 2013, 2017)
10. Describe the working principle and elements of Electro chemical Honing. (Nov/Dec 2015)
11. Describe the working principle and elements of Electro chemical Grinding.
12. Describe the advantages and disadvantages of chemical machining.

SIM 3

1. Write about Magnetic abrasive finishing?

2. Write about Abrasive flow machining?
3. Write about Electro stream drilling?
4. Write about shaped tube electrolytic machining?
5. Tabulate the comparison among various non-traditional machining processes in terms of the MRR.
Presentation in the form of table is preferred
6. Explain the reasons for the development of Unconventional Machining Processes. Discuss about
the criteria recommended in selection of these processes.
7. Compare the mechanical and electrical energy processes in terms of Physical parameters, shape
capabilities, process capability, and process economy.
8. Write about magneto rheological finishing?
9. Write about magneto rheological abrasive flow finishing?
10. Write about Magnetic abrasive finishing?
11. Write about Mechanical polishing?
12. Compare the chemical and electro chemical energy processes in terms of Physical parameters,
shape capabilities, process capability, and process economy.

Submission Details:

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Phase 1(Before AT 1) Phase 2 (Before AT 2) Phase 3 (Before AT 3)

Assignment 1 SIM 1 Assignment SIM 2 Assignment SIM 3
2 3

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