MICRO PROJECT ON

Course: Advanced Manufacturing Process

Course Code: 22563
Academic Year: 2021-2022
Semester: 5I

Name: Ayush Kshirsagar

Roll No.: 2031
Enrollment No: 1901410298

Name of Micro Project Guide: Mr. Viraj Prabhu

All India Shri Shivaji Memorial Society’s Polytechnic

Kennedy Road, Near RTO, Pune-411001

All India Shri Shivaji Memorial Society’s Polytechnic, Pune-01

 CERTIFICATE
Certified that this micro project report titled ‘Prepare a list of industrial
components which are produced through non-conventional machining’ is
the bonafide work of Ms. /Mr. Ayush Kshirsagar Roll no 2031 of Second
year diploma in Mechanical engineering for the course: Advanced
Manufacturing Process Course code: 22563 during the academic year 2021-
2022 who carried out the micro project work under my supervision.

Mr. Viraj Prabhu

Name & signature
Subject teacher

Acknowledgement
I would like to express my special thanks of gratitude to my teacher Mr. Viraj Prabhu as
well as our principal Prof. S.K. GIRAM Sir who gave me the golden opportunity to do this
wonderful project on the topic ‘Prepare a list of industrial components which are
produced through non-conventional machining’ also helped me in doing a lot of research
and I came to know about so many new things I am really thankful to them.
Secondly, I would also like to thank my parents and friends who helped me a lot in finalizing
project within the limited time frame.

INDEX
Sr. No. Content Page No.

1. Micro Project Proposal

2. Rationale

3. Aims/Benefits of the Micro Project

4. Course Outcome achieved

5. Literature Review

6. Actual Methodology Followed

7. Actual Resources Used

8. Output of the Micro Projects

9. Skill Developed / Learning outcome of the

Micro Project
10. Applications of the Micro Project
 ANNEXURE I

Micro Project Proposal

Types of Spring

1.0 Aims/Benefit of the Micro Project

1.This project will help me to know more about the process and its working principles
2. We also understand the topic in deep for future study.
3. The main purpose of this project is to know detail knowledge and use of mechanical field

2.0 Course Outcomes Addressed:

3.0 Proposed Methodology

1. Finalize the topic

2. Find and Collect information
3. Arrange information
4. Proofread the information
5. Review from the teacher
6. Edit project report as per the suggestions of the teacher
7. Proofread and finalize the report
8. Submission of the report
4.0 Action Plan:

Sr. No. Detail of Activity Planned Planned Name of Responsible

Start date Finish Team Members
Date

1. Finalize the topic 4/10/21 5/10/21 Ayush Kshirsagar

2. Find and collect 7/10/21 14/10/21 Ayush Kshirsagar

information
3. Arrange information 20/10/21 20/10/21 Ayush Kshirsagar

4. Edit project report 22/10/21 28/10/21 Ayush Kshirsagar

5. Submission of report 30/11/21 15/12/21 Ayush Kshirsagar

5.0 Resource Required:

Sr. No. Name of Resource/Material Specification Qty. Remark

1. Internet 1https://blog.bit 4
sathy.ac.in/non-
conventional-
machines/
2.https://www.m
echanicalbooster
.com/
3.https://learnme
chanical.com/las
er-beam-
machining/
4.https://www.m
echanicalfunda.c
om/

2. Book Advance
manufacturing
process
3. Magazine -

ANNEXURE - II
 Micro Project Report
‘Prepare a list of industrial components which are produced through non-
conventional machining’

1.0 Rationale

2.0 Aims/Benefits of the Micro Project:

1.This project will help me to know about non convectional process and its type
2.And we also understand the topic in deep for future study.
3. The main purpose of this project is to know detail knowledge of and use of it for better
understanding

3.0 Course Outcomes Achieved:

4.0 Literature Review

1. https://blog.bitsathy.ac.in/non-conventional-machines/

2. https://www.mechanicalbooster.com/

3. https://learnmechanical.com/laser-beam-machining/

4. https://www.mechanicalfunda.com/
5.0 Actual Methodology

Sr. No./ Date Time Work Done

Hour No.
1 2/10/2021 9:00 to 10:00 Finalized the topic

2. 4/10/21 5:00 to 6:00 Collected the information of micro project

3. 6/10/21 6:00 to 7:00 Arrange the information in proper order

4. 8/10/21 4:00 to 5:00 Created the word document of micro

project
5. 13/10/21 4.00 to 5.00 Proof the document

6. 16/10/21 3:00 to 4:00 Make the change in document according to

correct information.

7. 20/10/21 4.00 to 5.00 Take the review from the teacher.

8. 25/10/21 4.00 to 5.00 Edit according to teacher suggestion.

9. 28/10/21 4:00 to 5:00 Proof the read information.

10. 4/10/21 4.00 to 5.00 Arrange the information in proper order.

11. 8/10/21 4:00 to 5:00 Make the editing.

12. 15/10/21 4:00 to 5:00 Take print out of micro project.

13. 20/10/21 3:00 to 4:00 Show micro project guide.

14. 24/10/21 6:00 to 7:00 Proof and report the project.

15. 28/11/21 4.00 to 5.00 Proof read and finalized the topic

16. 15/12/21 3:00 to 4:00 Submitted the project

6.0 Actual Resource Required:

Sr. No. Name of Resource/Material Specification Qty. Remark

1. Internet 1.https://blog.bitsathy.a 4
c.in/non-conventional-
machines/
2.
https://www.mechanical
booster.com/
3.https://learnmechanica
l.com/laser-beam-
machining/
4.https://www.mechanic
alfunda.com/

2. Book Advanced 1
Manufacturing
Process
3. Magazine - -

Outputs of the Micro project.

 Non – Convectional Machining?

 Types of Non-Conventional Machines

The different types of non-conventional machines are listed below.

1 Electrical discharge machining (EDM)

2 Electron beam machining (EBM)

3 Plasma arc machining, (PAM)

4 Laser beam machining (LBM)

5 Ion-Beam machining (IBM)

6 Ultrasonic machining (USM)

7 Abrasive jet machining (AJM)

8 Water jet cutting (WJC)

9 Electrochemical machining (ECM)

10 Electrochemical grinding (ECG) and

11 Chemical machining (CHM)

 Working of Non-Conventional Machines

i. Abrasive Jet Machining

       In this process, a small layer of material is removed from the workpiece
using abrasive particles of aluminium oxide, silicon carbide, or glass
powder with particle size 10 to 50 microns. The larger size particles used for
rough machining and smaller size for finish work.

In AJM the compressed air or high-pressure gas is supplied to the mixing

chamber at a pressure of 2 to 8 kg/cm2. In mixing chamfer abrasive
particles from the feeder and high-pressure gas are mixed. A vibrator is used
to maintain the required amplitude in the mixing chamber to control the
flow of abrasive. These abrasives gas mixer finally pass through the nozzle
at very high speed (150 to 300 m/min). Since nozzles are subjected to very
high abrasion wear, they are made of hard materials such as tungsten
carbide or ceramic. The high-speed abrasive particles strike the workpiece
surface, where the material is to be removed. Due to the repeated impact, a
small bit of material is separated from that surface. The metal removal rate
in AJM depends on the nozzle diameter, the composition of the abrasive gas
mixture, the hardness of abrasives, velocity of jet, distance of workpiece
from the jet, and the workpiece material.

 Advantages
a) Low initial Investment

b) No direct control of tool and work piece

c) Easy to operate

d) Maintenance Required is less

ii Ultrasonic Machining (USM)

Also called as ultrasonic vibration machining is a machining process in

which material is removed from the surface of a part by low amplitude and
high frequency vibration of a tool against surface of material in the presence
of abrasive particles.

The motion of the tool takes place vertically or orthogonal to the surface of
the part. The tool travel with an amplitude of 0.05 mm to 0.125 mm (0.002
in to 0.005 in).

The slurry is formed by mixing fine abrasive grains in the water. This slurry
is made to flow across the w/p and the tip of the tool during machining
process. The abrasive gain particles in the slurry helps in the removal of the
material form the surface of the w/p. The grain sizes of the abrasive material
are typically ranges from 100 to 1000. The smaller grains (i.e. higher
number of grain) results in smooth surface finishes.

This machining process is usually used to machine brittle materials and

materials that have high hardness.
An electric current at high frequency (in the ultrasonic range i.e. 18 kHz to
40 kHz) is used to generate mechanical vibration of low amplitude and high
frequency. The mechanical vibration generated is used for machining the
surface of a part in the presence of abrasive grain particles in the form of
slurry. The slurry flows across the tool and workpiece. When the tool
presses against the w/p, the slurry containing abrasive particle chips off the
materials from the surface.

 Advantages
1. This machining method is capable of machining brittle and hard material
with high precision.
2. It can machine fragile materials such glass and non-conductive metals
which are not machined by non-traditional methods such as
electrochemical machining or electrical discharge machining.
3. It is capable of producing high tolerance parts.
4. There is no distortion produced in the worked material. And this is
because, no heat is generated by the sonotrode against the w/p.
5. There is no change observed in the physical properties of the material.
6. The machined parts produced require fewer finishing process because of
absence of burrs in the process.

iii Electro-Chemical Machining (ECM)

Is a machining process in which electrochemical process is used to remove

materials from the workpiece. In the process, workpiece is taken as anode
and tool is taken as cathode. The two electrodes workpiece and tool is
immersed in an electrolyte (such as NaCl). When the voltage is applied
across the two electrodes, the material removal from the workpiece starts.
The workpiece and tool is placed very close to each other without touching.
In ECM the material removal takes place at atomic level so it produces a
mirror finish surface
ECM working is opposite to the electrochemical or galvanic coating or
deposition process.

During electrochemical machining process, the reactions take place at the

electrodes i.e. at the anode (workpiece) and cathode (tool) and within the
electrolyte.

Let’s take an example of machining low carbon steel which is mainly

composed of ferrous alloys (Fe). We generally use neutral salt solution of
sodium chloride (NaCl) as the electrolyte to machine ferrous alloys. The
ionic dissociation of NaCl and water takes place in the electrolyte as shown
below.

As the potential difference is applied across the electrode, the movement of

ions starts in between the tool and w/p. The positive ions moves towards the
tool (cathode) and negative ions move towards the workpiece.

Working of Electrochemical Machining

 First, the workpiece is assembled in the fixture and the tool is brought
close to the workpiece. The tool and workpiece is immersed in a
suitable electrolyte.
 After that, a potential difference is applied across the w/p (anode) and
tool (cathode). The removal of material starts. The material is removed
 in the same manner as we have discussed above in the working
principle.
 Tool feed system advances the tool towards the w/p and always keeps
a required gap in between them. The material from the w/p comes out
as positive ions and combine with the ions present in the electrolyte
and precipitates as sludge. Hydrogen gas is liberated at the cathode
during the machining process.
 Since the dissociation of the material from the w/p takes place at
atomic level, so it gives excellent surface finish.
 The sludge from the tank is taken out and separated from the
electrolyte. The electrolyte after filtration again transported to the tank
for the ECM process
 Advantages
1. Negligible tool wear.
2. Complex and concave curvature parts can be produced easily by the
use of convex and concave tools.
3. No forces and residual stress are produced, because there is no direct
contact between tool and workpiece.
4. An excellent surface finish is produced.
5. Less heat is generated.

iv Electrical Discharge Machining (EDM)

Electrical discharge machining (EDM), also known as spark machining,

spark eroding, die sinking, wire burning or wire erosion, is a metal
fabrication process whereby a desired shape is obtained by using electrical
discharges (sparks).[1] Material is removed from the work piece by a series
of rapidly recurring current discharges between two electrodes, separated by
a dielectric liquid and subject to an electric voltage. One of the electrodes is
called the tool-electrode, or simply the tool or electrode, while the other is
called the workpiece-electrode, or work piece. The process depends upon
the tool and work piece not making physical contact.
 When the voltage between the two electrodes is increased, the intensity
of the electric field in the volume between the electrodes becomes
greater, causing dielectric break down of the liquid, and produces an
electric arc. As a result, material is removed from the electrodes. Once
the current stops (or is stopped, depending on the type of generator), new
liquid dielectric is conveyed into the inter-electrode volume, enabling the
solid particles (debris) to be carried away and the insulating properties of
the dielectric to be restored. Adding new liquid dielectric in the inter-
electrode volume is commonly referred to as flushing. After a current
flow, the voltage between the electrodes is restored to what it was before
the breakdown, so that a new liquid dielectric breakdown can occur to
repeat the cycle.

 Advantages
1. Suits very small work pieces, where conventional cutting tools may
damage the part from excess cutting tool pressure.
2. There is no direct contact between tool and work piece.
3. Therefore, delicate sections and weak materials can be machined without
any distortion.
4. No burrs

v Laser Beam Machining (LBM)

Laser Beam Machining (LBM) is a form of machining process in which

laser beam is used for the machining of metallic and non-metallic materials.
In this process, a laser beam of high energy is made to strike on the
workpiece, the thermal energy of the laser gets transferred to the surface of
the w/p (workpiece). The heat so produced at the surface heats, melts and
vaporizes the materials from the w/p. Light amplification by stimulated
emission of radiation is called LASER
 Advantages
1. It can be focused to a very small diameter.
2. It produces a very high amount of energy, about 100 MW per square mm
of area.
3. It is capable of producing very accurately placed holes.
4. Laser beam machining has the ability to cut or engrave almost all types of
materials, when traditional machining process fails to cut or engrave any
material.

Vi Electron Beam Machining (EBM)

is a process where high-velocity electrons concentrated into a narrow beam

that are directed towards the work piece, creating heat and vaporizing the
material. EBM can be used for very precise cutting or boring of a wide
variety of metals. Surface finish is better and kerf width is narrower than
those for other thermal cutting processes.

EEBM process is best suitable for high melting point and high thermal
conductivity materials.
The EBM beam is operated in pulse mode. This is achieved by
appropriately biasing the biased grid located just after the cathode.
Switching pulses are given to the bias grid so as to achieve pulse duration of
as low as 50 μs to as long as 15 ms. Beam current is directly related to the
number of electrons emitted by the cathode or available in the beam. Beam
current can be as low as 200 μamp to 1 amp. Increasing the beam current
directly increases the energy per pulse. Similarly, increase in pulse duration
also enhances energy per pulse. High-energy pulses (in excess of 100
J/pulse) can machine larger holes on thicker plates. The energy density and
power density is governed by energy per pulse duration and spot size. Spot
size, on the other hand is controlled by the degree of focusing achieved by
the electromagnetic lenses. If a higher energy density is combined with a
smaller spot size, the material removal would be faster though the size of
the hole would be smaller. The plane of focusing would be on or just
beneath the surface of the work piece. The electron beam is generated by the
potential difference between the negatively-charged cathode and the
positively-charged anode

 Advantages
1. It is an excellent process for micro finishing (milligram/ s).
2. Very small holes can be machined in any type of material to high
accuracy.
3. Holes of different sizes and shapes can be machined.
4. There is no mechanical contact between the tool and the
workpiece.
5. It is a quicker process.
8.0 Skill development /Learning outcomes:

1. To work in time.

2. Make own decision

3. To make the report.

4. How to collect and edit information.

5. How it is important to make projects and understand it.

7.0 Applications of the Micro-Project:

Non-traditional machining (NTM) processes are now being widely used to

generate intricate and accurate shapes in materials, like titanium, stainless
steel, high strength temperature resistant (HSTR) alloys, fiber-reinforced
composites, ceramics, refractories and other difficult-to- machine alloys
having higher strength, hardness, toughness and other diverse material
properties. Generation of complex shapes in such materials by the
traditional machining processes is experienced to be difficult. Selection of
the most suitable nonconventional machining process (NCMP) for a given
machining application can be viewed as multi-criteria decision making
(MCDM) problem with many conflicting and diverse criteria. To aid these
selection processes, different MCDM methods have been proposed. This
paper introduces the use of an almost unexplored MCDM,OCRA and
NCMP selection problem

Mr. Viraj Prabhu

(Name and Signature of faculty)