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Lecture Details :
Advanced Machining Processes by Prof. Vijay K. Jain, Department of Mechanical Engineering, IIT Kanpur. For more details on NPTEL visit http://nptel.iitm.ac.in
Course Description :
Contents:
INTRODUCTION : Why do we need advanced machining processes (AMPs) - Advanced machining processes - Remarks
MECHANICAL ADVANCED MACHINING PROCESSES : ABRASIVE JET MACHINING ( AJM ) - Introduction - Abrasive Jet Machining Setup - Gas Propulsion System - Abrasive Feeder - Machining Chamber - AJM Nozzle - Abrasives,PARAMETRIC ANALYSIS - Stand-off-Distance - Abrasive Flow Rate - Nozzle Pressure - Mixing Ratio, PROCESS CAPABILITIES, APPLICATIONS,PROBLEMS.
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ULTRASONIC MACHINING ( USM ) : INTRODUCTION - ULTRASONIC MACHINING SYSTEM - MECHANICS OF CUTTING - PARAMETRIC ANALYSIS - PROCESS CAPABILITIES - APPLICATIONS - PROBLEMS
ABRASIVE FLOW FINISHING : ABRASIVE FLOW FINISHING,WORKING PRINCIPLE,ABRASIVE FLOW MACHINING SYSTEM - Machine - Tooling - Media,PROCESS VARIABLES,PROCESS PERFORMANCE,ANALYSIS AND MODELING OF ABRASIVE FLOW MACHINED SURFACES - Number of Active Grains - Wear of,Abrasive Grains - APPLICATIONS - Aerospace - Dies and Molds - REVIEW QUESTIONS
MAGNETIC ABRASIVE FINISHING (MAF) : INTRODUCTION,WORKING PRINCIPLE OF MAF,MATERIAL REMOVAL (OR STOCK REMOVAL) AND SURFACE FINISH - Bonded and Unbonded Magnetic,Abrasives - Machining Fluid - Magnetic Flux Density,ANALYSIS,REVIEW QUESTIONS
WATER JET CUTTING ( WJC ) : INTRODUCTION,WJM MACHINE,PROCESS CHARACTERISTICS,PROCESS PERFORMANCE,APPLICATIONS,BIBLIOGRAPHY,SELF TEST QUESTIONS,REVIEW QUESTIONS
ABRASIVE WATER JET MACHINING ( AWJM ) : WORKING PRINCIPLE,AWJM MACHINE - Pumping System - Abrasive Feed System - Abrasive Jet Nozzle - Catcher,PROCESS CHARACTERISTICS,WATER - Water Jet Pressure During Slotting - Water Flow Rate,ABRASIVES - Abrasive Flow Rate - Abrasive Particle Size - Abrasive Material,CUTTING PARAMETERS - Traverse Speed - Number of Passes - Stand-off-Distance - Visual Examination,PROCESS CAPABILITIES,APPLICATIONS,REVIEW QUESTIONS
THERMOELECTRIC ADVANCED MACHINING PROCESSES,ELECTRIC DISCHARGE MACHINING ( EDM ) : INTRODUCTION,WORKING PRINCIPLE OF EDM,R-C PULSE GENERATOR,EDM MACHINE - Power Supply - Dielectric System - Electrodes - Servo system - Electrode Refeeding - Power,Delivered to the Discharging Circuit,CNC-EDM,ANALYSIS - Analysis of R-C Circuits - Current in discharging Circuit - Material Removal in RC Circuits - Surface Finish,PROCESS VARIABLES - Dielectric Pollution and its Effects,PROCESS CHARACTERISTICS - Gap Cleaning,APPLICATIONS
ELECTRIC DISCHARGE GRINDING ( EDG ) AND ELECTRIC DISCHARGE DIAMOND GRINDING (EDDG)
ELECTRIC DISCHARGE GRINDING : ELECTRICAL DISCHARGE DIAMOND GRINDING - Working Principle - Capabilities and Applications.
WIRE ELECTRIC DISCHARGE MACHINING : WORKING PRINCIPLE,WIRE EDM MACHINE - Power Supply System - Dielectric System - Positioning System - Wire Drive System,ADVANCES IN WIRECUT,STRATIFIED WIRE,PROCESS VARIABLES,PROCESS CHARACTERISTICS,APPLICATIONS,PROBLEMS,REVIEW QUESTIONS
LASER BEAM MACHINING : PRODUCTION OF LASERS,WORKING PRINCIPLE OF LASER BEAM MACHINING,TYPES OF LASERS - Solid Lasers - Gas Lasers,PROCESS CHARACTERISTICS,APPLICATIONS - Drilling - Cutting - Marking - Miscellaneous Applications,REVIEW QUESTIONS
PLASMA ARC MACHINING : WORKING PRINCIPLE,PLASMA ARC CUTTING SYSTEM,ELEMENTS OF A PLASMA ARC CUTTING SYSTEM,PROCESS PERFORMANCE,APPLICATIONS,REVIEW QUESTIONS
ELECTRON BEAM MACHINING : WORKING PRINCIPLE,ELECTRON BEAM MACHINING SYSTEM - Electron Beam Gun - Power Supply - Vacuum System and Machining,Chamber,PROCESS PARAMETERS,CHARACTERISTICS OF THE PROCESS,APPLICATIONS,PROBLEMS
FOCUSSED ION BEAM MACHINING : Working Principle - FIB machining system - Parametric analysis - Applications - Problems.
ELECTROCHEMICAL AND CHEMICAL ADVANCED MACHINING PROCESSES : ELECTROCHEMICAL MACHINING,INTRODUCTION,ELECTROLYSIS,ELECTROCHEMICAL MACHINING (ECM),ECM MACHINE TOOL - Power Source - Electrolyte Supply and Cleaning System - Tool and Tool Feed System -Workpiece and Work Holding Device,ADVANTAGES AND LIMITATIONS,APPLICATIONS,MECHANICAL PROPERTIES OF ECM'D PARTS,THEORY OF ECM - Faraday's Laws of Electrolysis,ELECTROCHEMICAL EQUIVALENT OF ALLOYS - Material Removal Rate in ECM - Inter-electrode Gap in ECM - Zero Feed Rate - Finite Feed Rate - Self Regulating Feature - Generalized Equation for Inter-electrode Gap,MAXIMUM PERMISSIBLE FEED RATE IN ECM,ELECTROLYTE CONDUCTIVITY (K) - Temperature - Hydrogen Bubbles,PROBLEMS
ELECTROCHEMICAL GRINDING : INTRODUCTION,ECG MACHINE TOOL,PROCESS CHARACTERISTICS,APPLICATIONS,REVIEW PROBLEMS
ELECTROSTREAM DRILLING : INTRODUCTION,PROCESS PERFORMANCE,BIBLIOGRAPHY,REVIEW QUESTIONS
ELECTROCHEMICAL DEBURRING : INTRODUCTION - Definition of Burr - Types of Burrs - Basic Approach on Deburring,CLASSIFICATION OF DEBURRING PROCESSES,ELECTROCHEMICAL DEBURRING (ECDe) - Principle of Working,APPLICATIONS,SPECIFIC FEATURES OF ECDe MACHINE,REVIEW QUESTIONS
SHAPED TUBE ELECTROLYTIC MACHINING : INTRODUCTION - Working Principle - Applications.
CHEMICAL MACHINING ( ChM ) : INTRODUCTION,MASKANTS - Cut And Peel - Screen Printing - Photo-resist Mask-ant,ETCHANT,ADVANTAGES AND LIMITATIONS,REVIEW QUESTIONS
ANODE SHAPE PREDICTION AND TOOL DESIGN FOR ECM PROCESSES : INTRODUCTION,ANODE SHAPE PREDICTION - Cosθ Method - Empirical Approach - Nomographic Approach - Numerical,Approach - Numerical Methods,TOOL (CATHODE) DESIGN FOR ECM PROCESS,Cosθ Method,Correction Factor Method,SOME EXERCISES
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