Advanced Machining Processes

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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 – 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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