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Unit-I
Unconventional machining process-Need-Clarification-Brief overview of all
techniques
Part-A
1. Need of the unconventional M/cing
*Sustain productivity with increasing strength of the work material.
*Maintain productivity with desired shape, accuracy, and surface
integrity requirements.
*Improve the capability of automation system and decreasing their
sophistication (decreasing the investment cost) requirements.
2. Define unconventional M/cing process
There is a need for m/c tools and processes which can accurately and
easily m/c the most difficult – to – m/c materials to intricate and accurate shapes.
The m/c tools should be easily adaptable for automation as well. In order to meet
this challenge, a number of newer material removal processes have been
developed to the level of commercial utilization. These newer methods are also
called as unconventional M/cing process.
3. Classification of advanced m/cing processes.
*Mechanical
*Thermoelectric
*Electrochemical & chemical
4. Types of mechanical advanced m/cing processes.
*Abrasive jet m/cing
*Ultrasonic m/cing
*Water jet m/cing
*Abrasive water jet m/cing
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* Abrasive flow m/cing
*Magnetic abrasive finishing
5. Types of Thermoelectric advanced m/cing processes
.
*Plasma arc m/cing
*Laser beam m/cing
*Electron beam m/cing
*Electric discharge m/cing
*Ion beam m/cing
6. Types of Electrochemical advanced m/cing processes.
*Electrochemical m/cing
*Chemical m/cing
*Bio chemical m/cing
PART-B
1. How the developments in the area of materials are partly responsible for
evolution of advanced m/cing techniques.
2. Enlist the requirements that demand the use of AMPs
3 What are the industrial needs for unconventional m/cing processes?
4. How the unconventional m/cing processes are classified?
UNIT-II
Abrasive Jet M/Cing, Water Jet M/Cing, Ultrasonic M/Cing – working principles,
equipment used, process parameters, MRR-variation techniques used-
Applications
PART-A
1. Define abrasive jet m/cing
This is the process of removal materials by impact erosion through the
action of a concentrated, high velocity stream of the grit abrasives entrained in a
high velocity gas stream. It differs from conventional sand blasting process for its
fineness of particle size and controllable m/cing parameters.
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2. Define Material Removal Rate of abrasive jet m/cing
The material is removed from the work piece due to impact erosion of
the high velocity particles. The kinetic energy of the particle is utilized to cause the
micro-indention in the work material and the material removal is a measure of the
indentation.
3. What are the applications of abrasive jet m/cing
*This is used for abrading and frosting glass more economically as
compared to etching or grinding.
*Cleaning of metallic smears on ceramics, oxides on metals, resistive
coatings etc.
*cutting and m/cing of fragile material like germanium, silicon
*It is a good method for deburring small hole like in hypodermic needles
and for small milled slots in hard metallic components.
4. What are the Limitations of abrasive jet m/cing
*The volumetric or stock removal rate is very low
*Elastomers or soft plastics are not amenable to abrasive jet treatment
*Abrasive powders cannot be reused
*Short stand – off distance when used for cutting, damages the nozzle.
5. Define Water jet m/cing
This employs a fine, high pressure, high velocity jet of water, which
when bombarded on the work piece erodes the material. High pressure water jet
has two properties which make it potentially useful .
6. What are the process parameters of water jet m/cing
*Material removal rate
*Geometry and finish of work piece
*Wear rate of the nozzle
7. What are the applications of abrasive jet m/cing
*It is used to cut many nonmetallic like Keplar, Glass epoxy, graphite,
boron, F.R.P . Corrugated board, Leather and many other brittle materials
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*It used mostly in shoe making industry and now has entered into steel
plant to descale the chilled layer of steel ingots, in aircraft industries to profile
cutting of FRP aircraft structures even glass windows.
8. Define Ultrasonic m/cing
This is an impact erosion process to m/cine materials where the work
material is removed by repetitive impact of abrasive particles carried in a liquid
medium in the form slurry under the action of a shaped vibrating tool attached to
a vibrating mechanical system.
9. What are the applications of Ultrasonic m/cing
*M/cing semi conducting materials such as germanium and silicon
*Making instruments and optical parts of glass, Quartz, Fluoride and
barium titanate
*Cutting of industrial diamonds.
*Cutting holes with curved or spiral center line and cutting threads in
glass and mineral or metallo- ceramic
10.What are the Limitations of Ultrasonic m/cing
*Non-metal because of poor electric conductivity that cannot be m/ced
by EDM and ECM can very well be m/ced by USM.
PART-B
1. How do the operating parameters affect the m/cing process in AJM
process
2. Give reasons for inaccuracies in AJM process (Hint: Explain through
velocity profile of the jet
3. Draw the schematic diagram of AJM system and label it.
4. Explain the working principle of Ultrasonic m/cing
5. Derive the expression for MRR in m/cing of ductile materials by
Ultrasonic
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6. Explain the working principle of Water jet m/cing
UNIT-III
Electric Discharge M/cing (EDM) - W orking principles-equipments, process
parameters-MRR-Electrode tool-power circuits-Tool wear – Dielectric flushing,
Wire cut EDM-Applications.
PART-A
1. principles of electric discharge m/cing
It involves finite discrete periodic sparks between tool-electrode and
conductive work- electrode separated by thin films of liquid dielectric that causes
the removal of work material.
2. Theroies of metal removal concepts
*High pressure theory
*static field theory
*High temperature theory
3. Types of electrode used in electric discharge m/cing
*metallic electrodes
**copper
**brass
**copper
** tungsten
**aluminum
*Non metallic
**Graphite
**Combined metallic and non metallic
**copper-graphite
4. write the advantages of copper graphite electrode
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**It is not affected by thermal shocks and can return mechanical
properties
** It does not distort because of high melting point and chemically does
not react
**Easily m/cable by conventional methods
5. write the disadvantages of copper graphite electrode
*It being a brittle material space cares must be taken at sharp corners
during manufacture
*m/cing in graphite dust of carbon to pollute the atmosphere
*High porosity allows moisture entrapped inside the tool which affects
the m/cing performance if care is not taken
6. What are the basic equipment used in EDM
*M/c tool structure with work positioning unit
*Servo head and for feed tool
*power supply
*Dielectric fluid system
7. What are the requirements of modern EDM?
*tool and work material
*Nature of dielectric fluid
*Flushing efficiency
*Servo mechanism response speed
*The parameters of m/cing pulse
7. What is the value of spark gap in EDM
0.013 to .13 mm
9. Applications of EDM
*It is used in automobiles, tools, and m/c tool components, and making
components in plastic injection moulding m/c
* It is used to removal of broken taps, drills, studs, remears, pins, etc.
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PART—B
1. Discuss the mechanism of material removal in EDM process
2. What are the types of EDM? Discuss the basic units of an EDM system
3. What are the types of pulse generators used in EDM? Discuss merits and
demerits each other
4. Explain the tools used in EDM process.
5. Explain the working principles of EDM. Also explain how the stratified
wire works
6. Write short notes on following
*Resolidification of molten metal in EDM
*Minimization of bowing wire in EDM
7. Explain the functions of an adaptive system used in EDM
UNIT-IV
Chemical m/cing and Electro-chemical m/cing (CHM and ECM)-Etchants-
Maskant-techniquesof applying maskants-process parameters-MRR-
Applications.
Principles of ECM-equipments-MRR-Electric circuit-process parameters-
ECG and ECH applications
PART-A
1. Principles of chemical m/cing
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The material is removed from the work piece by controlled dissolution
when in contact with strong chemical reagent
2. Classifications of maskants
*cut and peel type
*Photo resist
*Screen print
3. Applications of chemical m/cing
*Weight reduction of complex contours, impossible by mechanical
systems are possible.
*production of burr free surface
*Production of stress and crack free surfaces
*Less skill of operators are required
*Tooling costs are small
4. Principles of electrochemical m/cing
It is a process of anodic dissolution of work material by high current
flowing through an electrolyte between shaped tool and work piece.
The principle is exactly same as electroplating where the anode goes into
solution expecting the cathode deposition.
5. What are the equipment used in electrochemical m/cing
*Electrolyte tank
*D.C generator
*E.C.M m/c with fixture
*Sludge
*Electrolyte
6. Applications of ECM
*used for Die-sinking, drilling, broaching, honing, steel mill
applications, surfacing
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8. Disadvantages of ECM
*Difficulty in learning to use the process
*Heavy initial investment
*Spark damage may become sometimes more problematic
*Corrosion- free material requirement fro the structure and electrolyte
handling systems.
9. What are the tool materials used in ECM?
*high thermal & electric conductivity
*anti corrosive in nature
*high m/c ability
10. What are limitations of ECM?
*Only Electrically Conductive W/P
*Difficulties for hard spots, inclusions, sharp corners.
PART—B
1. Discuss the masking techniques for different production level
2. Discuss the procedure for manufacturing two stepped edge milling of thin
components
3. Describe the procedure for manufacturing of stepped and taper shaft like
components
4. Prove that ECM process highest accuracy is achieved at the highest
productivity
5. Discuss the procedure of manufacturing gas turbine blades
6. Enumerate some typical examples where ECM process can be efficiently
adopted
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UNIT-V
Laser beam m/cing(LBM),plasma arc m/cing(PAM),Electron beam
m/cing(EBM),-principles-equipment-types-beam control techniques-
Applications
PART—A
1. Principles Of LBM
Laser light is monochromatic, its wave length occupies a very narrow
portion of the spectrum ,hence ,a simple lens is able to focus and concentrate laser
light to spot of much smaller diameter and much higher density that than obtained
by other of light.
2. Types of lasers
*Solid state laser
*gas laser
3. Applications of LBM
*It is used for cutting difficult to m/c materials such as hardened steels,
composites, and ceramics
4. Characteristics of LBM
*can be focused to maximum intensity or to lower intensity as needed
*dedicated to an online process
*Power shared on a job or between stations
*Can be moved rapidly on the work
5. Advantages of LBM
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*No physical contact between work – tool pair, hence there is no
possibility of breakage or wear of tool
*Precision location is ensured by focusing of the beam
*Large aspect ratio can be achieved
*Very small holes can be drilled
6. Applications of EBM
*High speed perforation of small dia holes
*Through thickness cutting of any kind of material
*Engraving of metals and ceramics
*Thin film m/cing
7. Principles of PAC
An arc is a stable form of electric discharge between two electrodes in a
gaseous medium. A feature of a gaseous conduction is a continuous interchange
of energy between electrons, ions and neutral particles, the interchange occurring
during the collision resulting from their disorderly movement caused by beating.
8. What are the parameters affecting the cutting of work piece
*Plasma forming gases
*Stand off distances
*Speed of cutting
PART—B
1. What are the types used for material processing applications. Describe
how the system can be used for m/cing purpose
2. What are the different beam manipulation devices used for laser
processing of materials
3. With a neat sketch of the setup explain the principle of operation of EBM
setup for m/cing applications
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4. How the m/cing rate can be controlled in EBM process
5. Discuss the main industrial applications of plasma cutting systems
6. What are the different types of plasmatrons used in material cutting
applications
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