1.

INTRODUCTION

• Why do we need advanced machining processes (AMPs)?

• Advanced machining processes

• Remarks

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2.

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

2

3.

ULTRASONIC MACHINING ( USM )

• INTRODUCTION

• ULTRASONIC MACHINING SYSTEM

• MECHANICS OF CUTTING

• PARAMETRIC ANALYSIS

• PROCESS CAPABILITIES

• APPLICATIONS

• PROBLEMS

2

4.

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

2

5.

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

2

6.

WATER JET CUTTING ( WJC )

• INTRODUCTION

• WJM MACHINE

• PROCESS CHARACTERISTICS

• PROCESS PERFORMANCE

• APPLICATIONS

• BIBLIOGRAPHY

• SELF TEST QUESTIONS

• REVIEW QUESTIONS

1

7.

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

2

8.

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

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9.

ELECTRIC DISCHARGE GRINDING ( EDG ) AND ELECTRIC DISCHARGE DIAMOND GRINDING (EDDG)

• ELECTRIC DISCHARGE GRINDING

• ELECTRICAL DISCHARGE DIAMOND GRINDING - Working Principle - Capabilities and Applications.

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10.

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

1.5

11.

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

3

12.

PLASMA ARC MACHINING

• WORKING PRINCIPLE

• PLASMA ARC CUTTING SYSTEM

• ELEMENTS OF A PLASMA ARC CUTTING SYSTEM

• PROCESS PERFORMANCE

• APPLICATIONS

• REVIEW QUESTIONS

1

13.

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

2

14.

FOCUSSED ION BEAM MACHINING

Working Principle - FIB machining system - Parametric analysis - Applications - Problems.

2

15.

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

4

16.

ELECTROCHEMICAL GRINDING

• INTRODUCTION

• ECG MACHINE TOOL

• PROCESS CHARACTERISTICS

• APPLICATIONS

• REVIEW PROBLEMS

1

17.

ELECTROSTREAM DRILLING

• INTRODUCTION

• PROCESS PERFORMANCE

• BIBLIOGRAPHY

• REVIEW QUESTIONS

1

18.

ELECTROCHEMICAL DEBURRING

• INTRODUCTION - Definition of Burr - Types of Burrs - Basic Approach on Deburring.

• CLASSIFICATION OF DEBURRING PROCESSES

• ELECTROCHEMICAL DEBURRING (ECD_e) - Principle of Working.

• APPLICATIONS

• SPECIFIC FEATURES OF ECD_e MACHINE

• REVIEW QUESTIONS

1.5

19.

SHAPED TUBE ELECTROLYTIC MACHINING

INTRODUCTION - Working Principle - Applications.

1

20.

CHEMICAL MACHINING ( ChM )

• INTRODUCTION

• MASKANTS - Cut And Peel - Screen Printing - Photo-resist Mask-ant.

• ETCHANT

• ADVANTAGES AND LIMITATIONS

• REVIEW QUESTIONS

2

21.

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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