Chemical Machining Process and its Types.Umar Saeed
The detail overview on how chemical machining removes material to produce high quality parts, its different processes and types. I also includes figure and video which will help you understand the process easily.
UNCONVENTIONAL MACHINING PROCESS CLASSIFICATION-MECHANICAL ENERGY METHODS-ELECTRICAL ENERGY METHODS-CHEMICAL ENERGY METHODS-ELECTRO CHEMICAL ENERGY METHODS-THERMALENERGY METHODS.
Non Traditional Machining is playing vital role in now a days in mechanical Industries so student it should be need sound knowledge in this particular subject due to impact of this subject i am prepare in this materials it is most useful for my students...
All The Best ...
By: Author-Prof.S.Sathishkumar
Chemical Machining Process and its Types.Umar Saeed
The detail overview on how chemical machining removes material to produce high quality parts, its different processes and types. I also includes figure and video which will help you understand the process easily.
UNCONVENTIONAL MACHINING PROCESS CLASSIFICATION-MECHANICAL ENERGY METHODS-ELECTRICAL ENERGY METHODS-CHEMICAL ENERGY METHODS-ELECTRO CHEMICAL ENERGY METHODS-THERMALENERGY METHODS.
Non Traditional Machining is playing vital role in now a days in mechanical Industries so student it should be need sound knowledge in this particular subject due to impact of this subject i am prepare in this materials it is most useful for my students...
All The Best ...
By: Author-Prof.S.Sathishkumar
I unit -_introduction_to_unconventional_machining_processesShanmathyAR2
Unconventional machining Process – Need – classification – merits, demerits and applications.
Abrasive Jet Machining – Water Jet Machining – Abrasive Water Jet Machining - Ultrasonic
Machining. (AJM, WJM, AWJM and USM). Working Principles – equipment used – Process
parameters – MRR- Applications.
REFRIGERATION AND AIR CONDITIONING
Vapour compression refrigeration cycle - working principle - Effect of super heat and sub cooling - performance calculations - working principle of vapour absorption system - ammonia - water, lithium bromide water systems (description only) - air conditioning system - types and working principles
STEAM NOZZLES AND TURBINES
Flow of steam through nozzles, shapes of nozzles, effect of friction, critical pressure ratio, supersaturated flow - impulse and reaction principles, velocity diagram, work done and efficiency – types of compounding - governors.
AIR COMPRESSORS
Classification - working principle - type of compressors, work of compression with and without clearance - volumetric efficiency - isothermal and isentropic efficiency of reciprocating compressors - multistage air compressor with inter cooling.
GAS POWER CYCLES
Cycles: Otto, Diesel, Dual, Brayton - Calculation of mean effective pressure - Air standard efficiency - Comparison of cycles
INTERNAL COMBUSTION ENGINES
Classification - Components and their function - valve timing diagram and port timing diagram - actual and theoretical p-v diagram of two stroke and four stroke engines – carburettor - diesel pump and injector system - battery and magneto ignition system - principles of combustion and detonation in CI engines - lubrication and cooling systems - performance parameters and calculations.
Electric Vehicles: History of electric vehicles - components of electric vehicle – layout & working of electric vehicles – comparison with internal combustion engine - advantages and disadvantages of EV.
Hybrid Vehicles: Components of hybrid vehicles – layout & working principle of hybrid vehicles - comparison with electric vehicles - advantages and disadvantages of hybrid vehicles.
UNIT-IV-STEERING, BRAKES AND SUSPENSION SYSTEMS.pptxDineshKumar4165
Steering geometry and types of steering gear box-Power Steering- Pneumatic and Hydraulic Braking Systems - Antilock Braking System (ABS)- Electronic brake force distribution (EBD) and Traction Control - Types of Front Axle- types of Suspension systems
UNIT-II-ENGINE AUXILIARY SYSTEMS &TURBOCHARGERDineshKumar4165
Electronically controlled gasoline injection system for SI engines, Electronically controlled diesel injection system, Unit injector system, Rotary distributor type and common rail direct injection system, Electronic ignition system - Transistorized coil ignition system, capacitive discharge ignition system, Turbo chargers -Waste Gate Turbocharger, Variable Geomentry Turbocharger, Engine emission control by three way catalytic converter system, Emission norms (Euro and BS).
Types of automobiles, vehicle construction and different layouts, chassis, frame and body, resistances to vehicle aerodynamics (various resistances and moments involved), IC engines-components functions and materials, variable valve timing (VVT).
UNIT 5 RECENT TRENDS IN NON-TRADITIONAL MACHINING PROCESSES.pptxDineshKumar4165
Recent developments in non-traditional machining processes, their working principles, equipments, effect of process parameters, applications, advantages and limitations. Comparison of non-traditional machining processes.
UNIT 4 ADVANCED NANO FINISHING PROCESSES.pptxDineshKumar4165
Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, magneto rheological abrasive flow finishing their working principles, equipments, effect of process parameters, applications, advantages and limitations
UNIT 3 CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES.pptxDineshKumar4165
Chemical machining and Electro-Chemical machining (CHM and ECM)- Etchants – Maskant - techniques of applying maskants - Process Parameters – Surface finish and MRR-Applications. Principles of ECM- equipments-Surface Roughness and MRR - Electrical circuit-Process Parameters- ECG and ECH - Applications.
Numerical control (NC) machine tools - CNC: types, constructional details, special features - design considerations of CNC machines for improving machining accuracy -structural members - slide ways - linear bearings - ball screws - spindle drives and feed drives.
Centre lathe, constructional features, various operations and specifications, taper turning methods, thread cutting methods, special attachments, machining time and power estimation. Capstan and turret lathes – Automatic lathe: single spindle, swiss type, screw type, multi spindle - Turret Indexing mechanism - Bar feed mechanism
HEAP SORT ILLUSTRATED WITH HEAPIFY, BUILD HEAP FOR DYNAMIC ARRAYS.
Heap sort is a comparison-based sorting technique based on Binary Heap data structure. It is similar to the selection sort where we first find the minimum element and place the minimum element at the beginning. Repeat the same process for the remaining elements.
KuberTENes Birthday Bash Guadalajara - K8sGPT first impressionsVictor Morales
K8sGPT is a tool that analyzes and diagnoses Kubernetes clusters. This presentation was used to share the requirements and dependencies to deploy K8sGPT in a local environment.
Online aptitude test management system project report.pdfKamal Acharya
The purpose of on-line aptitude test system is to take online test in an efficient manner and no time wasting for checking the paper. The main objective of on-line aptitude test system is to efficiently evaluate the candidate thoroughly through a fully automated system that not only saves lot of time but also gives fast results. For students they give papers according to their convenience and time and there is no need of using extra thing like paper, pen etc. This can be used in educational institutions as well as in corporate world. Can be used anywhere any time as it is a web based application (user Location doesn’t matter). No restriction that examiner has to be present when the candidate takes the test.
Every time when lecturers/professors need to conduct examinations they have to sit down think about the questions and then create a whole new set of questions for each and every exam. In some cases the professor may want to give an open book online exam that is the student can take the exam any time anywhere, but the student might have to answer the questions in a limited time period. The professor may want to change the sequence of questions for every student. The problem that a student has is whenever a date for the exam is declared the student has to take it and there is no way he can take it at some other time. This project will create an interface for the examiner to create and store questions in a repository. It will also create an interface for the student to take examinations at his convenience and the questions and/or exams may be timed. Thereby creating an application which can be used by examiners and examinee’s simultaneously.
Examination System is very useful for Teachers/Professors. As in the teaching profession, you are responsible for writing question papers. In the conventional method, you write the question paper on paper, keep question papers separate from answers and all this information you have to keep in a locker to avoid unauthorized access. Using the Examination System you can create a question paper and everything will be written to a single exam file in encrypted format. You can set the General and Administrator password to avoid unauthorized access to your question paper. Every time you start the examination, the program shuffles all the questions and selects them randomly from the database, which reduces the chances of memorizing the questions.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
NUMERICAL SIMULATIONS OF HEAT AND MASS TRANSFER IN CONDENSING HEAT EXCHANGERS...ssuser7dcef0
Power plants release a large amount of water vapor into the
atmosphere through the stack. The flue gas can be a potential
source for obtaining much needed cooling water for a power
plant. If a power plant could recover and reuse a portion of this
moisture, it could reduce its total cooling water intake
requirement. One of the most practical way to recover water
from flue gas is to use a condensing heat exchanger. The power
plant could also recover latent heat due to condensation as well
as sensible heat due to lowering the flue gas exit temperature.
Additionally, harmful acids released from the stack can be
reduced in a condensing heat exchanger by acid condensation. reduced in a condensing heat exchanger by acid condensation.
Condensation of vapors in flue gas is a complicated
phenomenon since heat and mass transfer of water vapor and
various acids simultaneously occur in the presence of noncondensable
gases such as nitrogen and oxygen. Design of a
condenser depends on the knowledge and understanding of the
heat and mass transfer processes. A computer program for
numerical simulations of water (H2O) and sulfuric acid (H2SO4)
condensation in a flue gas condensing heat exchanger was
developed using MATLAB. Governing equations based on
mass and energy balances for the system were derived to
predict variables such as flue gas exit temperature, cooling
water outlet temperature, mole fraction and condensation rates
of water and sulfuric acid vapors. The equations were solved
using an iterative solution technique with calculations of heat
and mass transfer coefficients and physical properties.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
Traditionally, dealing with real-time data pipelines has involved significant overhead, even for straightforward tasks like data transformation or masking. However, in this talk, we’ll venture into the dynamic realm of WebAssembly (WASM) and discover how it can revolutionize the creation of stateless streaming pipelines within a Kafka (Redpanda) broker. These pipelines are adept at managing low-latency, high-data-volume scenarios.
Water billing management system project report.pdfKamal Acharya
Our project entitled “Water Billing Management System” aims is to generate Water bill with all the charges and penalty. Manual system that is employed is extremely laborious and quite inadequate. It only makes the process more difficult and hard.
The aim of our project is to develop a system that is meant to partially computerize the work performed in the Water Board like generating monthly Water bill, record of consuming unit of water, store record of the customer and previous unpaid record.
We used HTML/PHP as front end and MYSQL as back end for developing our project. HTML is primarily a visual design environment. We can create a android application by designing the form and that make up the user interface. Adding android application code to the form and the objects such as buttons and text boxes on them and adding any required support code in additional modular.
MySQL is free open source database that facilitates the effective management of the databases by connecting them to the software. It is a stable ,reliable and the powerful solution with the advanced features and advantages which are as follows: Data Security.MySQL is free open source database that facilitates the effective management of the databases by connecting them to the software.
Water billing management system project report.pdf
UNIT- 1 INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES.pptx
1. KONGUNADU COLLEGE OF ENGINEERING AND TECHNOLOGY
(AUTONOMOUS)
NAMAKKAL- TRICHY MAIN ROAD, THOTTIAM, TRICHY
DEPARTMENT OF MECHANICAL ENGINEERING
20ME503PE –UNCONVENTIONAL MACHINING
PROCESSES
FIFTH SEMESTER
PRESENTED BY
M.DINESHKUMAR,
ASSISTANT PROFESSOR,
DEPARTMENT OF MECHANICAL ENGINEERING,
KONGUNADU COLLEGE OF ENGINEERING AND TECHNOLOGY.
3. TOPICS
Unconventional machining Process – Need – classification –
merits, demerits and applications. Abrasive Jet Machining –
Water Jet Machining – Abrasive Water Jet Machining –
Ultrasonic Machining. (AJM, WJM, AWJM and USM).
Working Principles – equipment used – Process parameters –
MRR- Applications.
4. Conventional Machining Processes
4
• In conventional machining processes, metal is
removed by using some sort of tool which is
harder than the workpiece and it is subjected
to wear.
• Tool and workpiece are in direct contact
13. Need for Unconventional Machining
13
• Greatly improved thermal, mechanical and chemical properties of modern
materials – Not able to machine thru conventional methods.
• Ceramics & Composites – high cost of machining and damage caused during
machining – big hurdles to use these materials.
• In addition to advanced materials, more complex shapes, low rigidity structures
and micro-machined components with tight tolerances and fine surface finish
are often needed.
• To meet these demands, new processes are developed.
• Play a considerable role in aircraft, automobile, tool, die and mold making
industries.
14. Need for Unconventional Machining
14
• Very high hardness and strength of the material. (above 400 HB.)
• The work piece is 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.
• Temperature rise or residual stress in the work piece are undesirable.
20. 20
Chemical & Electrochemical Based Processes
ECM - Electro –Chemical Machining
ECD - Electro Chemical Deburring
ECG – Electro –Chemical Grinding
ECH – Electro – Chemical Honing
21. 21
Thermal Based Processes
LBM - Laser Beam Machining
PAM – Plasma Arc Machining
EBM - Electron Beam Machining
IBM – Ion Beam Machining
22. Mechanical based Unconventional Processes
22
USM – Through mechanical abrasion in a
medium (solid abrasive particles
suspended in the fluid)
WJM – Cutting by a jet of fluid
AWJM – Abrasives in fluid jet.
IJM – Ice particles in fluid jet.
Abrasives or ice – Enhances
cutting action.
27. Chemical & Electrochemical
based Unconventional Processes
27
CHM – uses Chemical
dissolution action in
an etchant.
ECM – uses Electrochemical
dissolution action in
an electrolytic cell.
29. PROCESS SELECTION
29
Based on the following points
1. Physical Parameters
2. Shapes to be machined
3. Process Capability or Machining Characteristics
4. Economic Considerations
43. ADVANTAGES
of UCM
43
• High Accuracy and surface finish in process
• Less Rejected pieces
• Increase productivity
• Tool material need not be harder than work piece
material.
• Easy to machine harder and brittle materials
• There is no residual stresses in the machined material
50. CONSTRUCTION AND WORKING OF AJM
Construction:
• It consists of mixing chamber, nozzle, pressure gauge, hopper, filter,
compressor vibrating device, regulator, etc.
• The gases generally used in this process are nitrogen, carbon dioxide or
compressed air.
• The various abrasive particles are aluminum oxide, silicon carbide, glass
powder, dolomite and specially prepared sodium bicarbonate Aluminum oxide
(A12,O3,) is a general-purpose abrasive and it is used in sizes of 10, 25 and 50
microns. Silicon carbide (SiC) is used for faster cutting on extremely hard
materials.
51. • It is used in sizes of 25 and 50 microns. Dolomite of 200 grit size is found suitable
for light cleaning and etching Glass powder of diameter 0.30 to 0.60 mm are used
for light polishing and deburring.
• As the nozzle is subjected to a great degree of abrasion wear, it is made up of hard
materials such as tungsten carbide, synthetic sapphire (ceramic), etc., to reduce the
wear rate.
• Nozzles made of tungsten carbide have an average life of 12 to 20 hours whereas
synthetic sapphire nozzle have an average life of 300 hours. Nozzle tip clearance
from work is kept at a distance of 0.25 to 0.75 mm.
• The abrasive powder feed rate is controlled by the amplitude of the vibration of
mixing chamber. A pressure regulator controls the gas or air flow and pressure. To
control the size and shape of the cut, either the workpiece or the nozzle is moved by
a well-designed mechanism such as cam mechanism, pantograph mechanism, etc.
52. Working:
• Dry air or gas (N2, or CO₂) is entered into the compressor through a
filter where the pressure of air or gas is increased.
• The pressure of the air varies from 2 kg/cm² to 8 kg/cm²
• Compressed air or high-pressure gas is supplied to the mixing
chamber through a pipe line. This pipe line carries a pressure gauge
and a regulator to control the air or gas flow and its pressure.
• The fine abrasive particles are collected in the hopper and fed into
the mixing chamber. A regulator is incorporated in the line to control
the flow of abrasive particles.
53. • The mixture of pressurized air and abrasive particles from the mixing chamber
flows into the nozzle at a considerable speed.
• Nozzle is used to increase the speed of the abrasive particles and it is increased
up to 300 m/s.
• This high-speed stream of abrasive particles from the nozzle, impact the
workpiece to be machined. Due to repeated impacts, small chips of material get
loosened and a fresh surface is exposed.
• A vibrator is fixed at the bottom of the mixing chamber. When it vibrates, the
amplitude of the vibrations controls the flow of abrasive particles.
54. • This process is widely used for machining hard and brittle materials, non-
metallic materials (germanium, glass, ceramics and mica) of thin sections.
This process is capable of performing drilling, cutting, deburring, etching
and cleaning the surfaces.
• Abrasive Jet Machining (AJM) process differs from sand blasting process.
AJM is basically meant for metal removal with the use of small abrasive
particles, whereas the sand blasting process is a surface cleaning process
which does not involve any metal cutting.
55. Construction details
.
Gas
Used
Nitrogen , Carbon di-oxide ,
compressed air
Abrasive Particles
Used
Aluminium oxide
(10,25&50microns)
Silicon Carbide(25&50microns)
Glass Powder , Dolomite and
Specially Prepared sodium
bicarbonate
Nozzle
Tungsten Carbide ,
Synthetic Sapphire (Ceramic)
67. Abrasive Grain Size
• The various abrasive particles used in AJM process are aluminum oxide
(A12,O3,). silicon carbide (SiC), glass powder, dolomite and specially
prepared sodium bicarbonate Aluminum oxide is a general-purpose
abrasive and is used in sizes of 10, 25 and 50 microns.
• Silicon carbide is used for faster cutting on extremely hard materials. It is
used in sizes of 25 and 50 microns. Dolomite of 200 grit size is found
suitable for light cleaning and etching Glass powder of 0.30 to 0.60 mm are
used for light polishing and deburring.
• In general, larger sizes are used for rapid removal rate while smaller sizes
are used for good surface finish and precision as shown in Fig.
74. Advantages
1. We can cut all kind of materials
2. No heat produced in process , so no thermal damage
3. Very thin and brittle material can be machined
4. Low initial investment
5. Good Surface Finish
6. Intricate holes can be cut in hard and brittle material
75. Dis-Advantages
1. Low MRR
2. Soft Material cannot be machined
3. Machining accuracy is poor
4. Nozzle Wear Rate is High
5. Abrasive Powder cannot be reused
6. Embedding of Abrasive particle in work piece is the high
damage thing in this process
7. It requires Dust Collection System
83. .
.
Nozzle
Used to Increase the velocity of water jet
Made up of Sintered Diamond, Tungsten Carbide and
Synthetic Sapphire
Nozzle Exit Diameter 0.05 – 0.35mm
Velocity of Water Jet From Nozzle 920 m/s
115. Transducer
convert the high
frequency
electrical energy
into Mechanical
Vibrations
Oscillator convert the
Low frequency electrical
energy into high
frequency electrical
energy
20 – 30 HZ
Vibrations are
transferred to
tool material
Abrasive Slurry
Passed
Between the
vibrating tool
and work piece
The
refrigeration
system used
to cool the
abrasive
slurry to 5 –
6 Degree
celcius
119. MAGNETOSTRICTIVE TRANSDUCER
.
Change in length is independent of
the direction of the magnetic field
But depend only on the
magnitude of the field and
Nature of the material
121. MAGNETOSTRICTIVE TRANSDUCER
LT battery used to
heat the filament
So electrons are
produced
Those electrons
are accelerated
by HT Battery
So AC current
Produced in the
circuit
122. So Rod start
to vibrate
due to
magnetostric
tive effect
This vibrations rod
create Ultrasonic
Waves , which sent out
MAGNETOSTRICTIVE TRANSDUCER
124. Resonance
Frequency of the
oscillatory circuit
Frequency of Vibrating
Rod
=
Resonance will occur when
At resonance , the rod vibrates vigorously and ultrasonic
waves are produced at high frequencies
129. Definition - Piezoelectric
• Piezoelectric transducers are a type of electro
acoustic transducer that convert the electrical
charges produced by some forms of solid
materials into energy.
• The word "piezoelectric" literally means
electricity caused by pressure.
132. Working LT battery used to
heat the filament
So electrons are
produced
Those electrons are
accelerated by HT Battery
So AC current
Produced in the
circuit
This AC current Passes
through L1 and L2 and
its transferred to
Secondary circuit
This AC current passed to the plates A and B and it make the
Crystal to vibrate due to the principle of inverse piezoelectric
effect. The vibrations of crystal creates Ultrasonic waves
134. Advantages – Piezoelectric transducer
Disadvantages – Piezoelectric transducer
1. Piezoelectric quartz is high cost
2. Cutting and shaping of crystal is very complex.
146. Abrasive material
It Depend on
1.The type of material to be machined
2. Requirement of Surface finish
For Machining - Tungsten Carbide
- Die Steel
Boron Carbide
Silicon Carbide
Abrasives
For Machining - Glass
- Ceramics
Aluminium oxide
152. Process Parameters
Wear Ratio
1.5 : 1 For Tungsten Carbide Work Pieces
100 : 1 For Glass Work Pieces
50 : 1 For Quartz Work Pieces
75 : 1 For Ceramics
1 : 1 For Hardened tool steel Work Pieces