THE OXFORD COLLE GE OF ENGINEERING

HOSUR ROAD, BOMMANAHALLI, BANGALORE - 68

DEPARTMENT OF MECHANICAL ENGINEERING

Lesson Plan
Date: 17/01/2015
Subject code /Title
Course / Branch
Semester / Academic Year

: 10ME665 / Non Traditional Machining

: Mechanical Engineering
: 2015

Objectives of Course :
To gain the knowledge in modern manufacturing methods towards increasingly complex needs of
modern society

To understand the basics of the present trends in machining

Prerequisites : Basics of traditional manufacturing processes
Module/
Unit

1.

3.

9.

Hour

Date

Books Referred & Pages

Topic
Introduction: History, Classification

4/02/15

VI

5/02/15

III,V

6/02/15

12/02/15

tool materials & tool size, abrasive

slurry, cutting tool system design

VI

13/02/15

III,V

14/02/15

19/02/15

Effect of parameter: Effect of

amplitude and frequency and
vibration,
Effect of abrasive grain diameter,
effect of applied static load, effect of
slurry, tool & work material
USM process characteristics:
Material removal rate, tool wear,

VI

20/02/15

III,V

21/02/15

25/02/15

VI

26/02/15

III,V

27/02/15

05/03/15

VI

06/03/15

Modern machining processPandey and Shan, Tata McGraw

Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000

comparison between conventional

and
Non-conventional machining process
selection.
Ultrasonic Machining (Usm): Mode Modern machining processIntroduction, equipm ent
Pandey a
Shan, Tata McGraw Hill 2000

Accuracy, surface finish,

applications, advantages &
Disadvantages of USM.
Abrasive Jet Machining (AJM):
Introduction, Equipment
Variables in AJM: Carrier Gas, Type
of abrasive, size of abrasive grain,
velocity of the abrasive jet, mean
number. abrasive particles per unit
volume of the carrier
gas, work material, stand off distance
(SOD),
nozzle design, shape of cut. Process
characteristics-Material removal rate,
Nozzle wear, Accuracy & surface
finish.
Applications, advantages &
Disadvantages of AJM. Water Jet
Machining: Principal, Equipment,
Operation, Application, Advantages
and

Modern machining processPandey and Shan, Tata McGraw

Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Non-traditional machining
hand book-carl summer
Non-traditional machining
hand book-carl summer
Non-traditional machining
hand book-carl summer

Non-traditional machining
hand book-carl summer
Non-traditional machining
hand book-carl summer
Non-traditional machining
hand book-carl summer

limitations of water Jet machinery

V

11/03/15

Electrochemical Machining
(ECM): Introduction, study of ECM
machine,
elements of ECM process : Cathode
tool, Anode work piece, source of
DC power, Electrolyte,
chemistry of the process, ECM
Process characteristics ,

VI

12/03/15

III,V

13/03/15

18/03/15

Material removal rate, Accuracy,

surface finish, ECM Tooling,

VI

19/03/15

ECM tooling technique & example,

Tool & insulation materials, Tool
size Electrolyte
flow arrangement,
Handling of slug, Economics of
ECM, Applications such
as Electrochemical turning,
Electrochemical Grinding,
Electrochemical Honing, deburring,
Advantages, Limitations.

15.

III,V

22.

20/03/15

25/03/15

VI

26/03/15

III,V

27/03/15

V,VII

01/04/15

VI

09/04/15

III,V

10/04/15

V,VII

15/04/15

VI

16/04/15

III,V

17/04/15

V,VII

22/04/15

VI

23/04/15

III,V

24/04/15

V,VII

29/04/15

VI

30/04/15

VI

06/05/15

V,VII

13/05/15

VI

14/05/15

Chemical Machining (CHM):

Introduction, elements of process,
Chemical blanking process :
Preparation of work piece,
preparation of masters, masking with
photo resists, etching for blanking,
accuracy of chemical blanking,
applications of chemical blanking,
chemical milling (contour
machining): process steps masking,
Etching, process characteristics of
CHM:
material removal rate, accuracy,
surface finish
Hydrogen embrittlement, advantages
& application of CHM.
Electrical Discharge Machining
(EDM): Introduction, mechanism of
metal
removal,
dielectric fluid, spark generator,
EDM tools (electrodes) Electrode
feed control,
Electrode manufacture, Electrode
wear, EDM tool design, choice of
machining operation,
electrode material selection, under
sizing and
length of electrode
machining time. Flushing; pressure
flushing, suction flushing,
side flushing, pulsed flushing
synchronized with electrode
movement,
EDM process characteristics: metal
removal rate, accuracy, surface
finish,
Heat Affected Zone. Machine tool
selection, Application, EDM
accessories / applications
electrical discharge grinding,
Traveling Edm

Modern machining processPandey and Shan, Tata McGraw

Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001
Production Technology, HMT
Tata McGraw Hill. 2001

III,V

15/05/15

Plasma Arc Machining (Pam):

Introduction, equipment,

V,VII

20/05/15

VI

21/05/15

non-thermal generation of plasma,

selection gas,
Mechanism of metal removal, PAM
parameters,

III,V

22/05/15

process characteristics. Safety

precautions

--------

ex.class

Applications, Advantages and

limitations.

Modern machining processPandey and Shan, Tata McGraw

Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000

--------

ex.class

-------

ex.class

-------

ex.class

Laser Beam Machining (Lbm):

Introduction
equipment of LBM mechanism of
metalremoval,
LBM parameters,

-------

ex.class

Process characteristics

-------

ex.class

-------

ex.class

Applications, Advantages &

limitations.
Electron Beam Machining (Ebm)
:introduction

-------

ex.class

Principles, equipment

-------

ex.class

equipment,
operations,apps,advantages, &
limitations

Self-study Topics (Out of- Syllabus)

Sl. No.
Self study Topics
1
Advanced analysis of ntm methods
2

Present trends in industries towards ntm

Laser machining of metal-matrix composites

Laser machining of super alloys

Assignment Topics
Sl. No.
1
Water jet cutting

Non-traditional machining
hand book-carl summer
Non-traditional machining
hand book-carl summer
Non-traditional machining
hand book-carl summer
Non-traditional machining
hand book-carl summer
Non-traditional machining
hand book-carl summer
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Modern machining processPandey and Shan, Tata McGraw
Hill 2000
Suggested Reference
production technology, hmt tata
mcgraw hill. 2001
non-conventional machining,
p.k.mishra, the institution of
engineers (india) test book series2005.
production technology, hmt tata
mcgraw hill. 2001
handbook: machining volume
16, joseph r. davis (editor),
american society of metals (asm)

Assignment Topics

Submission due on
3/3/2015

Ion beam machining

4/4/2015

Edm drilling

10/5/2015

Students Feedback about the course from Last Year:

1.
2.
Action Plan proposed to accommodate the Feedback:
1.
2.

HOD

Faculty