Teaching plan_FinalUNCONVENTIONAL MACHINING.pptx

CHM

1. Advanced Machining Process by G Praveen Kumar Assistant Professor ( Adhoc Faculty) IIITDM Kurnool Application No.: 220110ME0075

2. Overview Introduction to Non-traditional machining Need for development of NTM-processes Classification of NTM-Processes Mechanical energy based processes Thermal energy based processes Electro-chemical processes Chemical energy based non-conventional Applications of NTM-Processes

3. Machining – Produces finished products with high degree of accuracy. Tradition Machining Processes (like turning, drilling ,milling) use a sharp cutting tool to remove the from work piece by shear deformation . Introduction to Non Traditional Machining

4. Extremely hard and brittle materials or difficult to machine by traditional machining processes The work piece: too flexible or slender to support the cutting or grinding forces. The shape of the part is complex , such as internal and external profiles, or small diameter holes. Surface finish or tolerance better than those obtainable conventional process. Conventional machining involves the direct contact of tool and work-piece , whereas unconventional machining does not require the direct contact of tool and work piece. Need for the development of Nontraditional Machining Turbine Blade with cooling Holes

5. CLASSIFICATION OF NON-CONVENTIONAL MACHINING PROCESSES Non Traditional Machining Processes Mechani c al Processes Electro c hemi c a l Processes Thermal electro Processes Based on the principle form of energy nontraditional manufacturing process can be classified in to following groups . Classification of Nontraditional Machining Processes Chemical Pro c e s s e s Hybrid Process

6. A. Mechanical based NTM-Processes Erosion of work material by a high velocity stream of abrasives and/or fluid . Ultrasonic Machining Processes Abrasive Jet Machining Processes Abrasive Water Jet Machining Processes Teimouri et al, J Intell Manuf (2013).

7. Typical Parts Machined 1- The first picture on the left is a plastic sample that has inner grooves that are machined using USM. 2- The Second picture (in the middle is a plastic sample that has complex details on the surface 3- The third picture is a coin with the grooving done by USM USM WJM

8. B. Thermal based NTM-Processes Thermal energy applied to small portion of work surface, removes material by fusion and/or vaporization . Electro Discharge Machining Laser Beam Machining Electron Beam Machining Ion Beam Machining Plasma Arc Machining Wire cut EDM

9. Typical Parts Machined EDM and Wire EDM

10. C. Electrochemical based NTM-Processes Electrochemical energy removes material Electrochemical Machining Electrochemical Deburring Electrochemical Grinding

11. Typical Parts Machined ECM

12. D. Chemical based NTM-Processes C hemical etchants selectively (using a mask) remove a portion of a workpiece C hemical Machining

13. Typical Parts Machined CHM

14. Teaching @ IIITDM, Kurnool FACULTY DESIGNATION/ ROLE PROGRAM/ SEMESTER WORKLOAD THEORY AND LABORATORY DETAILS Temporary Faculty B. Tech./VI (Jul ’22 ) Theory 1 Theory : 1. Design of Machine Elements B. Tech./I ( Nov ’ 22 – Mar ’2 3 ) Theory 1 Theory : 1.Science of Engineering Materials B. Tech./I (Nov’ 22 – Mar ’23) Laboratory 1 Laboratory 1.Engineering Graphics B. Tech./VI (Jan ’22- Apr’ 23 ) Laboratory 1 Laboratory 1.Product design Practice Additional Load : (July22 – Till Date) Internship evaluation Faculty advisor

15. Thank you

16. Mechanism of processes Energy type Mechanism of material removal Energy source Processes Mechanical Plastic shear Mechanical motion of tool / job Con v ent i onal machining Mechanical /Fluid motion AJM, USM Electrochemical Ion displacement Electric current ECM Mechanical and e l e c t r o - c hem ic al Pl a s t i c s hear and i on displacement El e c t r i c c u r r ent and mechanical motion ECG Chemical Corrosive reaction Corrosive agent CHM Thermal Fusion and vaporization Electric spark EDM High speed electrons EBM Powerful radiation LBM Ionized substance IBM, PAM