PES INSTITUTE OF TECHNOLOGY, BANGALORE SOUTH CAMPUS

DEPARTMENT OF MECHANICAL ENGINEERING

LESSON PLAN NON-TRADITIONAL MACHINING
Faculty name
: JAGADEESH BAGALI
Subject code
: 10ME665
Total No. of Lecture hrs: 52

Class
No
1
2
3
4
5

Text/
Reference page
Unit 1
T1Page.No.1-6
R3Page.No.1-7

6
7
8

Unit 2
T1Page.No.36-112
R3Page.No. 73-93

10
11
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Unit 3
T1Page.No.39-45
R3Page.No. 12-22
R3Page.No.45-52

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Unit 4
T1Page.No. 52-83
R3Page.No. 59-80

No. of Lecture hrs/week: 04

Topics to be covered

Introduction:
History
Classification
Conventional and Non-conventional machining process
Comparison between conventional and Non-conventional.
Conventional and Non-conventional machining process selection.
Ultrasonic Machining (USM):
Introduction
Equipment, tool materials & tool size.
abrasive slurry, cutting tool system design
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,
USM process characteristics Accuracy, surface finish, applications
Advantages & Disadvantages of USM

Process characteristics-Material removal rate, Nozzle wear, Accuracy

& surface finish.
Applications, advantages & Disadvantages of AJM
Water Jet Machining, Principal,
Equipment, Operation.
Application, Advantages and limitations of water Jet machinery
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 Material removal rate, Accuracy,
surface finish
ECM Tooling: ECM tooling technique & example, Tool & insulation
materials,.

26

Electrolyte flow arrangement, Handling of slug, Economics of ECM

28

Unit 5
T1Page.No. 80-83
R3Page.No.53-58

wise
9.61

9.61

15.3

25

13.5

38.5

11.5

50

11.5

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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,
standoff distance (SOD) nozzle design and shape of cut.

25

27

% of
syllabus
covered
Chap Cumul
ter
ative

Chemical Machining (CHM)

Introduction, elements of process,
chemical blanking process : Preparation of work piece and masters
Masking with photo resists preparation, etching for blanking,

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Unit 6
T1Page.No. 84-114
R1Page.No. 86-145

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Unit 7
T1Page.No.114-133
R3Page.No. 168-177

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Unit 8
T1Page.No.143-147
T1Page.No.134-141
R3Page.No. 160-166
R3Page.No.147-157

accuracy 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 wire EDM.
Plasma Arc Machining (PAM): Introduction, equipment.
non-thermal generation of plasma, selection of gas, Mechanism of
metal removal
PAM parameters.
process characteristics
Safety precautions, Applications, Advantages and limitations
Laser Beam Machining (LBM):
Introduction, equipment of LBM
mechanism of metal removal, LBM parameters
Process characteristics, Applications, Advantages & limitations.
Electron Beam Machining (EBM):
Principles, equipment.

15.3

77.3

9.61

86.5

13.5

100

Operations.
Applications.
Advantages and limitation of EBM.

TEXT BOOKS:
1. Modern machining process, Pandey and Shan, Tata McGraw Hill 2000
REFERENCE BOOKS:
1. Non-Conventional Machining, P.K.Mishra, The Institution of Engineers (India) Test book series,
Narosa Publishing House 2005.

2.production engineering by HMT -2005

Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

NON-TRADITIONAL MACHINING
QUESTION BANK
Subject code: 10ME665
Faculty name: JAGADEESH BAGALI
UNIT-1: INTRODUCTION
1.
2.
3.
4.

Why are nontraditional machining methods required as compared to conventional machining methods?
Discuss the history and development of nontraditional machining process.
How NTM differs from conventional machining?
Classify the NTM operations, giving an example for each. Briefly discuss the context under which
these NTM operations were developed.
5. Comment on the process selection for NTM processes.
6. What do you understand by the term Unconventional or nontraditional machining process? What is its
importance?
7. Compare various Nontraditional Machining methods regarding process economy.

UNIT-2: Ultrasonic Machining (USM):

1. Sketch and explain USM.
2. Discuss the effect of process parameters of USM on metal removal rate (MRR).
3. What do you mean by the term ultrasonic? Explain the principle process with a neat sketch.
4. Briefly discuss how MRR is influenced by the following parameters in USM
i) Frequency
ii) Grain size
iii) Applied static load
iv) slurry concentration
5.

6.
UNIT 3: Abrasive Jet Machining (AJM):

1.
2.

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i) Abrasive flow rate

ii) Mixing ratio
iii) Gas pressure
iv) Nozzle distance
3. Write a note on AJM process, with a neat sketch. State the process parameters.
4. What is the fundamental principle between AJM?
5. How does the operating parameter affect the machining process in AJM?
6. Why different abrasives produce different MRR?
7. i) What is the principle of water jet machining?
ii) Write a note on the special features of the equipment used in this method of machining.
iii) Give the practical applications of WJM.
UNIT 4: Electrochemical Machining (ECM):
1. Discuss Faradays laws with respect to ECM
2. Discuss electrochemical grinding
3. Discuss the effect of process parameters of ECM on MRR
4. Define electrochemical machining process and explain the elements of the ECM process.
5. Write and explain chemistry of electro chemical process
6. Explain electrochemical grinding with a schematic diagram.
7.

8.

UNIT 5: Chemical Machining (CHM):

1. With a block diagram, describe chemical blanking
2.
3.

4.Discuss the masking techniques for different production level.

5. What are the factors on which the selection of a resist for use in chemical machining depend?
6. Distinguish between cut and peel resists and photographic resists.
7. Explain chemical milling and blanking with a suitable block diagram.

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UNIT 6 Electrical Discharge Machining (EDM):

1.

2.

3.

4.

5.
6. Draw a neat sketch and explain wire cut EDM and electro discharge grinding.
7.Explain the principle and mechanism of metal removal in electro discharge machining
Process

UNIT 7: Plasma Arc Machining (PAM):

1. Write and explain metal removal mechanism in plasma arc machining.
2.

3.
4.
5.
6.
8. What are the safety precautions to be followed while operating PAM? State the advantages and
disadvantages for the same.
UNIT 8: Laser Beam Machining (LBM) and Electron Beam Machining (EBM
1.

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2.

3. Sketch and explain laser Beam machining.

4. Explain the mechanism of material removal in EBM
5. Explain the limitations of LBM
6. Write a note on
a. Electron beam machining.
b. Laser beam machining.
7.

8.

9.

10.

11.

Department of Mechanical Engineering