UNIT I INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES 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.

UNIT II THERMAL AND ELECTRICAL ENERGY BASED PROCESSES 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 - Beamcontrol
techniques – Applications.

UNIT III CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES 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.

UNIT IV ADVANCED NANO FINISHING PROCESSES 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.

UNIT V RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES 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.

TOTAL: 45 PERIODS

OUTCOMES:

Upon the completion of this course the students will be able to

CO1 Explain the need for unconventional machining processes and its classification

CO2 Compare various thermal energy and electrical energy based unconventional

machining processes.
CO3 Summarize various chemical and electro-chemical energy based unconventional

machining processes.

CO4 Explain various nano abrasives based unconventional machining processes.

CO5 Distinguish various recent trends based unconventional machining processes.

TEXT BOOKS:

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

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

1. Benedict. G.F. “Nontraditional Manufacturing Processes”, Marcel Dekker Inc., New York, 1987. 2. Mc
Geough, “Advanced Methods of Machining”, Chapman and Hall, London, 1998. 3. 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.

Related Website URLs

W1: http://nptel.ac.in/courses/112107078/

W2: http://nptel.ac.in/courses/112105127/pdf/LM-35.pdf

W3: www.me.iitb.ac.in/~ramesh/courses/ME338/non_trad.pdf

W4:http://www.nitc.ac.in/dept/me/jagadeesha/mev303/OVERVIEW_OF_NT

M_PROCESSES.pdf

Related Video Course

Materials (min. 3 no.s)

V1: https://www.youtube.com/watch?v=-wy28w8SxxA

V2: https://www.youtube.com/watch?v=crgujRcyhhE

V3: https://www.youtube.com/watch?v=pI1QGpmKqow

V4: https://www.youtube.com/watch?v=2W4xZYRkWGo

V5: https://www.youtube.com/watch?v=588EJInHLsc

In recent years an increasing demand for the machining of components of complex shapes made of
hard, difficult – to – machine materials with exacting tolerances and surface finish has resulted in the
development of a number of new machining processes. Some of these methods have been commercially
exploited while others are still in their experimental stages. There has been a rapid growth in the
development of harder and difficult to machine metals and alloys during the last two decades.
Conventional edged tool machining is uneconomical for such materials and the degree of accuracy and
surface finish attainable is poor. The advancing strength level would have a catastrophic effect on the
total machining bill if there was no corresponding improvement in machining technology. In view of this
seriousness of this problem, Merchant (1960) emphasized the need for the development of newer
concepts in metal machining. The newer machining processes, so developed are often called modern
machining processes or unconventional machining methods. Modern machining methods are classified
according to the type of fundamental machining energy employed, for example mechanical,
electrochemical, chemical or thermoelectric.

Description

An unconventional machining process is a specialized subject for mechanical engineering

branch. It provides an insight of machines associated with specialized production. The purpose

of this course is also to learn the need for various non–traditional machining methods.

ME8073 UNCONVENTIONAL MACHINING PROCESSES LTPPC30003

OBJECTIVE:  To learn about various unconventional machining processes, the various process
parameters and their influence on performance and their applications

UNIT I INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES 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.

UNIT II THERMAL AND ELECTRICAL ENERGY BASED PROCESSES 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 - Beamcontrol techniques – Applications.

UNIT III CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES 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.

UNIT IV ADVANCED NANO FINISHING PROCESSES 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.

UNIT V RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES 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.

TOTAL: 45 PERIODS