X10683 (me8073)
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This document contains questions from a mechanical engineering exam on unconventional machining processes. Part A contains 10 short answer questions asking students to list various mechanical energy based unconventional machining processes, elements and characteristics of ultrasonic machining, process parameters of plasma arc machining, power supply circuits used in electro discharge machining, types of electrochemical machining operations, Faraday's second law of electrolysis, criteria for classifying advanced machining processes, process parameters of abrasive flow machining, need for developing unconventional machining methods, and differences between conventional and unconventional machining. Part B contains 5 long answer questions asking students to discuss process variables and accuracy in abrasive jet machining, working principle and
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This document proposes a CAD system to reduce or eliminate supports in additive manufacturing using process parameter optimization and model modification. It involves:
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Stress and Durability Analysis of Threaded Connections in a Cast Aluminum Cyl...
Bolted connections involve sharp notched components that are therefore sensitive to fatigue loading. In internal combustion engines, the journal bearings of the crankshaft are supported by bearing caps which are bolted to the cylinder block. These threaded connections are a fatigue concern as cracking may be experienced on dynamometer tests of new engines. The critical element of this application however is not the steel studs rather the threaded bolt holes in the cast engine block. While the nominal stress concept is applicable to the fatigue design of studs, a local stress approach has to be adopted to assess the fatigue strength of threaded bolt holes.
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This document proposes a CAD system to reduce or eliminate supports in additive manufacturing using process parameter optimization and model modification. It involves:
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Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
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NON-CONVENTIONAL MACHINING PROCESSES
Advanced machining processes
Utilize chemical, electrical, and high-energy beams
Situations where traditional machining processes are
unsatisfactory or uneconomical:
– Workpiece material is too hard, strong, or tough.
– Workpiece is too flexible to resist cutting forces or too difficult
to clamp.
– Part shape is very complex with internal or external profiles
or small holes.
– Requirements for surface finish and tolerances are very high.
– Temperature rise or residual stresses are undesirable or
unacceptable.
So to eliminate this disadvantages non conventional machines can be used
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This document contains questions and study material about unconventional machining processes. It covers various mechanical, electrical, chemical, electrochemical, and thermal energy based processes.
The document is divided into 5 units covering different unconventional machining techniques:
1. Mechanical energy based processes like abrasive jet machining and water jet machining.
2. Electrical energy based processes like electrical discharge machining.
3. Chemical and electrochemical energy based processes like electrochemical machining.
4. Thermal energy based processes like laser beam machining and plasma arc machining.
Each unit provides questions to test understanding of the principles, parameters, advantages, limitations and applications of the different unconventional
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manganese alloyed cold-work tool steel, processed with electrodes made of copper. The values of surface
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THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...
Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
30120140505019
This document analyzes the effect of different wire electrodes on the material removal rate (MRR) of an MS workpiece using wire electrical discharge machining (WEDM). Experiments were conducted using copper, brass, and zinc-coated brass wire electrodes at various levels of current and pulse duration. The results showed that MRR was highest with copper wire and decreased with brass and zinc-coated brass wires. MRR also decreased with increasing current but increased with longer pulse duration. Statistical analysis through ANOVA confirmed that the wire material and pulse duration significantly affected the MRR while current had a lesser effect.
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30120140506011 2
This document summarizes a study on optimizing electric discharge machining (EDM) parameters to maximize material removal rate (MRR) and minimize electrode wear rate (EWR) when machining stainless steel 316 with a copper electrode. Experiments were conducted using a Taguchi design of experiments with four machining parameters (pulse on time, pulse off time, current, fluid pressure) each at three levels. Results showed that pulse off time and current had the most significant effects on MRR and EWR, respectively. Specifically, MRR increased with longer pulse off times while EWR decreased at higher currents. The optimal settings found were a current of 12 amps and long pulse off time to achieve maximum MRR during EDM of
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steel with copper electrode. The response is modeled using RSM on the experimental
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Advanced machining processes
Utilize chemical, electrical, and high-energy beams
Situations where traditional machining processes are
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unacceptable.
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The document is divided into 5 units covering different unconventional machining techniques:
1. Mechanical energy based processes like abrasive jet machining and water jet machining.
2. Electrical energy based processes like electrical discharge machining.
3. Chemical and electrochemical energy based processes like electrochemical machining.
4. Thermal energy based processes like laser beam machining and plasma arc machining.
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Surface roughness is the main indicator of technological performances of a component for electrical discharge machining (EDM). EDM process of manganese alloyed cold-work tool steel was modelled. In this paper we used the fuzzy logic (FL) and neural network (NN) to predict the effect of machining variables (discharge current and pulse duration) on the surface roughness of manganese alloyed cold-work tool steel in order to improve and increase its range of application. The experiments are carried out on
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Part B contains 5 long answer questions about topics such as pattern types for sand casting, gas welding flames and applications, rolling mill classifications, stretch forming methods, and plastic extrusion and injection moulding processes.
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This document summarizes a study on optimizing electric discharge machining (EDM) parameters to maximize material removal rate (MRR) and minimize electrode wear rate (EWR) when machining stainless steel 316 with a copper electrode. Experiments were conducted using a Taguchi design of experiments with four machining parameters (pulse on time, pulse off time, current, fluid pressure) each at three levels. Results showed that pulse off time and current had the most significant effects on MRR and EWR, respectively. Specifically, MRR increased with longer pulse off times while EWR decreased at higher currents. The optimal settings found were a current of 12 amps and long pulse off time to achieve maximum MRR during EDM of
Influence of process parameters on MRR in EDM of AISI D2 Steel: a RSM approach
Response Surface Methodology (RSM) is used to investigate the
effect of three controllable input variables namely: discharge current, pulse duration,
and pulse off time on material removal rate (MRR) in EDM process. To study the
proposed second-order polynomial model for MRR, a central composite design is
used to estimation the model coefficients of the three factors, which are believed to
influence the MRR in EDM process. Experiments were conducted on AISI D2 tool
steel with copper electrode. The response is modeled using RSM on the experimental
data. The significant coefficients are obtained by performing analysis of variance
(ANOVA) at 5% level of significance. It is found that discharge current, pulse duration,
and pulse off time and few of their interactions have significant effect on the MRR.
The model sufficiency is very satisfactory as the coefficient of determination (R2) is
found to be 97.6%.
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1. Electrochemical machining (ECM) is a non-traditional machining process that involves removing metal by anodic dissolution using a high-amperage electrical current passed through an electrolyte.
2. In ECM, the workpiece acts as an anode and is placed close to a cathode tool, with an electrolyte flowing between them. Metal dissolves from the workpiece and is carried away by the electrolyte.
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This document discusses using Grey relational analysis to optimize the parameters in rotary electrical discharge machining (EDM) of P20 steel. Experiments were conducted using an L18 orthogonal array to investigate the effects of workpiece polarity, discharge current, pulse on and off times, and tool rotational speed on material removal rate, tool wear rate, and surface roughness. Response tables and graphs were analyzed to determine the optimal parameter levels that maximize material removal rate while minimizing tool wear rate and surface roughness. Confirmation experiments validated the optimal results, demonstrating that Grey relational analysis is an effective technique for optimizing EDM process parameters.
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Chapter-1
Introduction to objective, scope and outcome the subject
Chapter 2
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Chapter 3
Surveying: Object Principles & Types of Surveying; Site Plans, Plans & Maps; Scales & Unit of different Measurements.
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