Engineering Tutorials

ME- 446 E MODERN MANUFACTURING PROCESSES

Sessional : 50 Marks
Theory : 100 Marks

Unit I Mechanical Processes: Ultrasonic Machining- Elements of process, cutting tool system design, effect of parameters, economic considerations, applications, limitations of the process, advantages and disadvantages. Abrasive Jet Machining- Variables in AJM, metal removal rate in AJM. Water Jet Machining- Jet cutting equipments, process details, advantages and applications.

Unit II Electrochemical and Chemical Metal Removal Processes: Electrochemical Machining- Elements of ECM process, tool work gap, chemistry of the process, metal removal rate, accuracy, surface finish and other work material characteristics, economics, advantages, applications, limitations. Electrochemical Grinding – Material removal, surface finish, accuracy, advantages, applications.

Unit III Thermal Metal Removal Processes: Electric Discharge Machining (EDM) or spark erosion machining processes, mechanism of metal removal, spark erosion generators, electrode feed control, dielectric fluids, flushing, electrodes for spark erosion, selection of electrode material, tool electrode design, surface finish, machining accuracy, machine tool selection, applications. Wire cut EDM. Laser beam machining (LBM)- Apparatus, material removal, cutting speed and accuracy of cut, metallurgical effects, advantages and limitations.

Unit IV Plasma Arc Machining (PAM): Plasma, non thermal generation of plasma, mechanism of metal removal, PAM parameters, equipments for D.C. plasma torch unit, safety precautions, economics, other applications of plasma jets. Electron Beam Machining (EBM) – Generation and control of electron beam, theory of electron beam machining, process capabilities and limitations.

Text Books :

1. Modern Machining Processes – P.C.Pandey, H.S.Shan, Tata McGraw Hill

2. Machining Science- Ghosh and Malik, Affiliated East-West Press

Reference Books :

1. Non Traditional Manufacturing Processes- Benedict G.F, Marcel Dekker

2. Advanced Methods of Machining- Mc Geongh J.A, Chapman and Hall

Note: In the semester examination, the examiner will set eight questions in all , taking at least 2 questions from each unit. The students will be required to attempt only five questions.

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