Ucmp Crouse File

SREYAS INSTITUTE OF ENGINEERING &
TECHNOLOGY
Nagole, Hyderabad 500 068
Department of
Mechanical Engineering
Academic Year:2015-16
Semester: B-Tech (IVI)
COURSE FILE
Faculty Details
Name of the Faculty : K L N Murthy
Designation
: Assistant Professor
Department
: MECHANICAL
Name of the Course : B.Tech / M.Tech
Batch
: 2012-16
Branch/Specialization: Mechanical Engg.
Regulations
: R09
Semester
: I / II
Course Details
Class
: I / II / III / IV
Size:
112
Title of the Subject
: Unconventional Machining Process
Subject Code
: 57030
Nature of the Subject: Core / Elective / Basic

No. of Weeks
: 16
No. of periods/week: 5
Note:
1.
The question papers in respect of Objective Tests (OT OT II and I) and Descriptive Tests (DT DT II and
I) of this subject should be included in the course file.
2.
Time Table and syllabus copy provided to you must also be filed in it.
3.
Attach marks statement of the students in respect of OT I, OT II DT I and DT II for this subject in your
course file.
4.
Photocopy of the best and the worst answer sheets for OT I, OT II, DT DT II, and I be included in the
course file.
5.
List of Assignments / Seminar topics you have given to the students should also be included in the course
file.
6.
The J. N. T. University End Examination Question Paper for this subject must be included in the course
file.
7.
The model Question papers must be attached to this course file
8.
Additional resources like OHP transparences, handouts, course material, lecture notes used may also be
filed in it.
9.
The end of the course file lecture notes also attached to this course
II/ME/2015
Cover Page
SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

2-50/5, Sy. No.107, Tattiannaram V,
G.S.I., Bandlaguda, Hyderabad 500 068
Department of
Syllabus
Semester: B-Tech (IV I)
UNIT I: Introduction
Need for non - traditional machining methods- Classification of modern machining processConsiderations in process selection. Materials applications.
UNIT II: Ultrasonic machining
Elements of the process, Mechanics of metal removal process parameters, Economic
considerations, Applications and limitations, recent development
.UNIT III: Abrasive jet machining, Water jet machining
Basic principles, Equipments, Process variables, Mechanics of metal removal, MRR,
Application and limitations
UNIT IV: Fundamentals of electro chemical machining
Electrochemical grinding, Electro- chemical honing and Deburring process, Metal removal
rate in ECM, Tool design, Surface finish and accuracy Economic aspects of ECM - Simple
problems for estimation of metal removal rate. Fundamentals of chemical machining,
advantages and applications.
UNIT V: General Principle and applications of EDM
Electric Discharge Grinding Electric discharge wire cutting processes - Power circuits for
EDM, Mechanics of metal removal in EDM, Process parameters, Selection of tool electrode
and dielectric fluids, Surface finish and machining accuracy, Characteristics of spark eroded
surface Machine tool selection. Wire EDM, Principle, applications.
UNIT VI: Generation and control of EBM
Theory of electron beam machining, Comparison of thermal and non-thermal processes,
General Principle and application of LBM, Thermal features, Cutting speed and accuracy of
cut.
UNIT VII: Application of plasma for machining Metal removal mechanism
Process parameters, Accuracy and surface finish, Applications of plasma in manufacturing
industries. Chemical machining- Principle. Maskants etchants, Applications.
UNIT VIII: Magnetic abrasive finishing
Abrasive flow finishing, Electrostream drilling, Shaped tube electrolytic machining.
Department of
II/ME/2015
BOOKS/REFERENCES
Page 2

Text Book
1. Advanced machining processes- VK Jain, Allied publishers
2. Modern Machining Process-Pandey P.C and Shah
3. Unconventional machining processes-C. Elanchezhain
References Books
1. Nonconventional machining P.K. Mishra
2. Nontraditional machining Weller
Journals/ Websites
www.iitg.ernet.in/aimtdr2014/PROCEEDINGS/papers/99.pdf
www.journals.elsevier.com/international-journal
www.slideshare.net/MECHV/non-traditional-machining
Department of
II/ME/2015
COURSE OBJECTIVES
Page 3

Student should be able to
1.
Need for the unconventional machining process, advantages of UMP over the
conventional machining process.
2.
Machining of brittle materials and hard materials using unconventional machining and to
attain good surface finish.
3.
To machine hard materials and brittle materials without using any tools those are used in
traditional machining.
4.
Usage of electric diodes for the electric discharge during machining process.
5.
Attaining better surface finish using chemical etchants, electrochemical machining.
6.
7.
Techniques of learning metal removal by thermal energy and using various thermal energy
processes.
Utilization of laser beam technology for metal removal process.
8.
Achievement of metal removal of brittle materials by plasma arc welding techniques
Signature of Faculty
Date:
Department of
II/ME/2015
OUTCOMES
Page 4
Signature of HOD
Date:

On completion of this Subject / Course the Student shall be able to:
1. Understand the concept of unconventional machining process and the difference
between the traditional and non-traditional machining.
2. know the working principle and machining of the hard materials using ultrasonic
machining process
3. Classify of unconventional machining process based up on the utilization of energies
in their direct form
4. Understand the working of ultrasonic machining process and water jet machining,
abrasive water jet machining.
5. have the knowledge of machining of materials with help of chemicals and thermo
electric methods.
6. Explain Machining of hard and soft materials by using laser beam technology and
acquire knowledge of laser beam technology
7. Explain Working and Applications of plasma arc welding process for machining of
metals
Signature of the Faculty

Date:
Department of
II/ME/2015
Signature of the HOD

Date:
Objectives Outcomes Relationship

Page 5

Programme
objectives
Matrix
1
2
3
4
5
6
7
8
(Indicate the relationship by X mark)

Date:
Department of
II/ME/2015

Date:
LESSON PLAN
Page 6
Semester : B-Tech (II I)

Subject
Topics / Sub-Topics
Unit
II
Date
Cumulative
periods
Expected
Need for non traditional machining

methods.
Classification of modern machining
process
Considerations in process selection
30/06/2015
3/07/2015
4/07/2015
Materials
06/07/2015
Applications
07/07/2015
Ultrasonic machining
10/07/2015
Elements of the process
13/07/2015
Mechanics of metal removal process

parameters,
Economic considerations
10
14/07/2015
11
16/07/2015
Applications and limitations
12
17/07/2015
Recent development
13
20/07/2015
14
21/07/2015
15
24/07/2015
16
25/07/2015
17
27/07/2015
18
28/07/2015
19
31/07/2015
20
01/08/2015
21
03/08/2015
Abrasive jet machining

Water jet machining
Basic principles
Equipments
III
No. of
Periods
Process variables
Mechanics of metal removal
MRR
II/ME/2015
1
1
1
1
1
1
1
1
Page 7
Actual

IV
VI
Fundamentals of electro chemical

machining
Electrochemical grinding
22
04/08/2015
23
07/08/2015
Electro chemical honing and deburring

process
Metal removal rate in ECM
24
10/08/2015
25
11/08/2015
Tool design
26
14/08/2015
Surface finish and accuracy
27
17/08/2015
Economic aspects of ECM
28
18/08/2015
Simple problems for estimation of metal

removal rate
Fundamentals of chemical machining
29
20/08/2015
30
21/08/2015
Advantages and applications.
31
22/08/2015
General Principle and applications of

EDM
Electric Discharge Grinding
32
29/08/2015
33
31/08/2015
Electric discharge wire cutting processes
34
01/09/2015
Power circuits for EDM
35
04/09/2015
Mechanics of metal removal in EDM
36
07/09/2015
Process parameters
37
08/09/2015
Selection of tool electrode and dielectric

fluids
Surface finish and machining accuracy
38
11/09/2015
39
14/09/2015
Characteristics of spark eroded surface
40
15/09/2015
Machine tool selection, Applications
41
18/09/2015
Generation and control of EBM
42
19/09/2015
Theory of electron beam machining
43
21/09/2015
II/ME/2015
Page 8

VII
VIII
Comparison of thermal and non-thermal

processes
General Principle and application of
LBM
Thermal features
44
22/09/2015
45
25/09/2015
46
26/09/2015
Cutting speed and accuracy of cut.
47
28/09/2015
Application of plasma for machining
48
29/09/2015
Metal removal mechanism
49
03/10/2015
Process parameters
50
05/10/2015
Accuracy and surface finish
51
06/10/2015
Applications of plasma in
manufacturing industries
Chemical machining-Principle
52
07/08/2015
53
08/10/2015
Maskants
54
09/10/2015
Etchants
55
12/10/2015
Applications
56
13/10/2015
Magnetic abrasive finishing
57
14/10/2015
Abrasive flow finishing
58
15/10/2015
Electrostream drilling
59
16/10/2015
Shaped tube electrolytic machining
60
17/10/2015

Date:
Department of

Date:
COURSE SCHEDULE
(Expected)
Semester : B-Tech (II I)

Expected date of completion of the whole Subject / Course and remarks, if any:
II/ME/2015
Page 9

S.No
Unit No
Description
Duration (Dates)
From
To
Total
No. Periods
1.
Introducing processestion to
unconventional machining
process
29/06/2015
07/07/2015
2.
II
10/07/2015
20/07/2015
3.
III
Abrasive jet machining, Water

jet machining
21/07/2015
03/08/2015
4.
IV
Fundamentals of electro
chemical machining
04/08/2015
22/08/2015
10
5.
General Principle and

applications of EDM
29/08/2015
18/09/2015
10
6.
VI
Generation and control of EBM
19/09/2015
28/09/2015
7.
VII
Application of plasma for

machining Metal removal
mechanism
29/09/2015
13/10/2015
8.
VIII
14/10/2015
17/10/2015
Remarks (if any):
Date:
Department of
Signature of HOD
Date:
SCHEDULE OF INSTRUCTIONS Academic Year:2015-16
Semester: B-Tech (II I)
UNIT NO: I
II/ME/2015
Expected date of completion:

Actual date of completion:
Page 10

Objective
s&
Outcome
Nos.
Date
Subject
Topics / Sub-Topics
S. No
No. of
Periods
Expected
1
2
3
4
5
Actual
Need for non traditional

machining methods.
Classification of modern
machining process
Considerations in process
selection
Materials
30/06/2015
3/07/2015
4/07/2015
06/07/2015
Applications
07/07/2015
Objectives and
Outcomes achieved
Total Number of periods
Date:
Department of
Advanced
Machining
ProcessesV K Jain
Unconventional
machining by P
K Mishra

Date:
SCHEDULE OF INSTRUCTIONS
UNIT NO: II
II/ME/2015
Referenc
es
Text
Books
Journals
Websites

Page 11

S.
No
Subject
Topics / Sub-Topics
No. of
Period
s
Date
Expected
Actual
10/07/2015
Elements of the process
13/07/2015

process parameters,
14/07/2015
Economic considerations
16/07/2015
Applications and limitations
17/07/2015
Recent development
20/07/2015
Objectives and
Outcomes
achieved
4
5
6
Date:
Department of
Advanced
Machining
ProcessesV K Jain
Unconventional
machining by P K
Mishra
Signature of HOD
Date:
UNIT NO: III
II/ME/2015
Objective
s&
Outcome
Nos.
Reference
s
Text
Books
Journals
Websites

Page 12

S.
No
1
2
3
4
5
6
7
No.
of
Perio
E
ds
Subject
Topics / Sub-Topics
Abrasive jet machining
Water jet machining
Basic principles
Equipments
Process variables

MRR

8
Date:
Department of
1
8
Date
Expected
References
Text Books
Journals
Websites
21/07/2015
24/07/2015
Advanced
Machining
ProcessesV K Jain
25/07/2015
27/07/2015
Unconventional
machining by P
K Mishra
28/07/2015
31/07/2015
01/08/2015
03/08/2015
Objectives and
Outcomes achieved
Signature of HOD
Date:
SCHEDULE OF INSTRUCTIONS Academic Year:2015-16
UNIT NO: IV
II/ME/2015
Actual
Objectives
&
Outcome
Nos.

Page 13

S.
No
Subject
Topics / Sub-Topics
No.
of
Peri
ods
1
04/08/2015
Expected
Fundamentals of electro
chemical machining
Electrochemical grinding
07/08/2015
Electro chemical honing and

deburring process
10/08/2015
Metal removal rate in ECM
11/08/2015
Tool design
14/08/2015
5
6
7
8
9
10
Surface finish and accuracy
17/08/2015
Economic aspects of ECM
18/08/2015
Simple problems for

estimation of metal removal
rate
Fundamentals of chemical
machining
20/08/2015
21/08/2015
Advantages and applications.
22/08/2015
10
Actual
Unconventional
machining by P K
Mishra
Objectives and
Outcomes achieved
Signature of HOD
Date:
UNIT NO: V
II/ME/2015
References
Text Books
Journals
Websites
Advanced
Machining
ProcessesV K Jain
Date:
Department of
Objectives
&
Outcome
Nos.
Date

Page 14

No. of
Period
s
Expected

applications of EDM
Electric Discharge Grinding
29/08/2015
31/08/2015
Electric discharge wire

cutting processes
Power circuits for EDM
01/09/2015
04/09/2015

in EDM
07/09/2015
Process parameters
08/09/2015
Selection of tool electrode

and dielectric fluids
Surface finish and
machining accuracy
Characteristics of spark
eroded surface
Machine tool selection,
Applications
11/09/2015
14/09/2015
15/09/2015
18/09/2015
S.
No
1
2
3
4
7
8
9
10
Subject
Topics / Sub-Topics
10
Date
Actual
Unconventiona
l machining by
P K Mishra
Objectives and
Outcomes achieved
Signature of HOD
Date:
UNIT NO: VI
II/ME/2015
References
Text Books
Journals
Websites
Advanced
Machining
ProcessesV K Jain
Date:
Department of
Objectives
&
Outcome
Nos.

Page 15

S.
No
1
2
3
4
5
6
Subject
Topics / Sub-Topics
Generation and control of
EBM
Theory of electron beam
machining
Comparison of thermal and
non-thermal processes
application of LBM
Thermal features
Cutting speed and accuracy
of cut.
No.
of
Peri
ods
1
Date
Expected
21/09/2015
22/09/2015
25/09/2015
26/09/2015
28/09/2015
Advanced
Machining
ProcessesV K Jain
Unconventiona
l machining by
P K Mishra
Objectives and
Outcomes achieved
Date:
Department of
Signature of HOD
Date:
UNIT NO: VII
II/ME/2015
References
Text Books
Journals
Websites
19/09/2015
Actual
Objectives
&
Outcome
Nos.

Page 16

S.
No
1
Subject
Topics / Sub-Topics
Application of plasma for
machining
Metal removal mechanism
No.
of
Peri
ods
1
Date
Expected
03/10/2015
Process parameters
05/10/2015
Accuracy and surface finish
06/10/2015
07/08/2015
08/10/2015
Applications of plasma in
manufacturing industries
Chemical machiningPrinciple
Maskants
09/10/2015
Etchants
12/10/2015
Applications
13/10/2015
3
4
5
6
Advanced
Machining
ProcessesV K Jain
Unconventiona
l machining by
P K Mishra
Objectives and
Outcomes achieved
Date:
Department of
Signature of HOD
Date:
UNIT NO: VIII
II/ME/2015
References
Text Books
Journals
Websites
29/09/2015
Actual
Objectives
&
Outcome
Nos.

Page 17

S.
No
1
2
3
4
No.
of
Peri
ods
1
Abrasive flow finishing
15/10/2015
Electrostream drilling
16/10/2015
Shaped tube electrolytic

machining
17/10/2015
Objectives and
Outcomes achieved
Subject
Topics / Sub-Topics
Date:
Department of
Date
Expected
Actual
14/10/2015
References
Text Books
Journals
Websites
Advanced
Machining
ProcessesV K Jain
Unconventiona
l machining by
P K Mishra
Signature of HOD
Date:
COURSE COMPLETION STATUS
Actual Date of Completion & Remarks, if any:
II/ME/2015
Objectives
&
Outcome
Nos.
Page 18

Unit
No
Expected Date of Completion
1.
07/07/2015
2.
II
20/07/2015
3.
III
03/08/2015
4.
IV
22/08/2015
5.
18/09/2015
6.
VI
28/09/2015
7.
VII
13/10/2015
8.
VIII
17/10/2015
S.No
Actual date of completion
Date:
Department of
LEARNING OBJECTIVES
Unit-I
Student will be able to
II/ME/2015
Page 19
Remarks by
HOD
Signature of HOD
Date:

Give the need for non-traditional machining methods.
Classify modern machining process
List out material applications.
Unit-II
List the ultrasonic machining elements of the process.
Explain mechanics of metal removal process parameters for ultrasonic machining.
List out the economic considerations, Applications and limitations of ultrasonic
machining..
Unit-III
Explain the principle of Abrasive jet machining, Water jet machining
List out the Equipments of Abrasive jet machining, Water jet machining
Analyze Process variables, Mechanics of metal removal, MRR of Abrasive jet
machining, Water jet machining
Gives the Application and limitationsAbrasive jet machining, Water jet machining
Unit-IV
Explain the principles of electro chemical machining, Electrochemical grinding,
Electro- chemical honing and Deburring process.
Analyze Metal removal rate in ECM,
Evaluate the economic aspects of ECM
Solve Simple problems for estimation of metal removal rate.
List out the Fundamentals of chemical machining,
Explains the advantages and applications ECM & ECG.
Unit-V
Explain the General Principle and applications of EDM
Illustrate about Electric Discharge Grinding Electric discharge wire cutting processes
Analyze the Mechanics of metal removal in EDM, & Process parameters
Select tool electrode and dielectric fluids for EDM
II/ME/2015
Page 20

Summarize the Wire EDM, Principle, applications.
Unit-VI
Explain Generation and control of EBM
Compare thermal and non-thermal processes
Explain General Principle and application of LBM,
Analyze Thermal features, Cutting speed and accuracy of cut.
Unit-VII
Give the Application of plasma for machining
Analyze Metal removal mechanism, Process parameters, Accuracy and surface finish
of plasma machining
Give the Applications of plasma in manufacturing industries.
Explain Chemical machining- Principle.
List out the Maskants etchants, Applications for chemical machining.
Unit VIII
Explain Magnetic abrasive finishing
Illustrate Abrasive flow finishing,
Explain Electrostream drilling, Shaped tube electrolytic machining.
Department of
II/ME/2015
Question Bank
Page 21

1. (i) Explain the factors that should be considered during the selection of an appropriate
unconventional machining process for a given job. (8)
2. Compare and contrast the various unconventional machining process on the basis of type
of energy employed, material removal rate, transfer media and economical aspects. (8)
3. Explain the principle of AJM. Mention some of the specific applications. (6)
4. Discuss in detail about the AJM process variables that influence the rate of material
removal and accuracy in the machining. (10)
5. (i) Explain the method of AJM with help of schematic diagram.(10)
6. Mention the advantages and limitations of AJM.(6)
7. Explain the process parameters in WJM processs.(16)
8. With neat sketch explain the process of AJM .List its application and limitations.(16)
9. Explain the process parameters that influence WJM.List the applications and limitations
of WJM(10)
10. Briefly discuss the application and limitation of WJM.(6)
11. Explain the USM machine setup an discuss various feed mechanisms.(16)
12. Discuss the influence of process parameters and applications of USM (10)
13. Give a note o the various types of transducers.(6)
14. Explain the process of electrical discharge machining, its process parameters and
applications.
15. Describe the wire cut EDM equipment, its working, applications and advantages
16. With the help of neat sketch, Describe the EDM process.(12)
17. Explain briefly advantages of wire EDM process.(4)
18. Explain the classification and characteristics of various spark erosion generators. (8)
19. With help of neat sketch, describe the mechanism of material removal in EDM. (8)
20. Explain the working principle, elements and characteristics of wire EDM. (10)
21. Explain how the stratified wire works. Also, discuss about the recent developments in
wire EDM. (6)
22. Describe the chemistry involved in ECM process. (8)
23. Briefly discuss about the effect of high temperature and pressure of electrolyte on the
ECM process. (4)
24. Discuss about the economics of ECM. (4)
25. Describe the working principle and elements of chemical machining. What are the
factors on which the selection of a resist for use in chemical machining? (10)
II/ME/2015
Page 22

26. What are the specific advantages of using chemical machining over electro chemical
machining? Give some of the practical applications of chemical machining process. (6)
27. Explain the principle of ECG with sketch. (8)
28. List out the advantage of EGC over conventional grinding.(4)
29. Mention the product application of ECG.(4)
30. Explain the process of LBM and PAM with a neat sketchs.
31. Discuss the process parameters of EBM and their influence on machining quality.(8)
32. Explain the process capabilities of EBM and PAM..(8)
33. Explain the principle of LBM with neat sketch.(10)
34. Explain the principle of PAM with sketch (10)
35. List out the advantage and limitation of LBM process.(6)
36. Mention the application of EBM.(4)
37. What is EBM? Sketch its set up an indicate its main parts and explain the priciple of
operation.(12)
38. Explain the principles and elements of EBM, also how the worktable is protected from
being damaged by electron beam. (8)
39. Discuss how the process variables influence MRR, HAZ and pattern generation. (8)
40. Explain the principle of LBM with neat sketch.(10)
41. Explain the principle of PAM with sketch (10)
42. List out the advantage and limitation of LBM process.(6)
Department of
TUTORIAL QUESTIONS/
ASSIGNMENT QUESTIONS
UNIT-I
Essay Questions:
II/ME/2015
Page 23

1.
What is necessity for unconventional machining processes?
2.
How non-traditional machining processes are classified?
3.
Enlist the requirement that demands the use of advanced machining process.
4.
Why unconventional mechanical machining process is not so effective on soft

metals like aluminum?
5.
Define MRR.
6.
Explain the factors that should be considered during the selection of an appropriate
Unconventional machining process for a given job.
7.
Compare and contrast the various unconventional machining processes based on type
of energy employed, material removal rate, transfer media and economical aspects.
Objective Questions:
1.
Conventional machining usually involves using a ---------------- made of a harder

material
2.
Conventional machining can be defined as a process using ----------------energy.
3.
--------------------- machining utilises other forms of energy.
4.
The three main forms of energy used in non-conventional machining processes are
--------------
5.
Concentrating heat onto any material greatly affects its -----------------------
6.
The chemicals used in AM are ------------ than other nonconventional machining

processes
7.
Extremely hard and brittle materials are difficult to machine by ----------------processes.
8.
Non-traditional machining processes, also called -----------------
9.
The machining characteristics are -------------------
Key:
1)
Cutting tool
2)
mechanical
4)
Thermal, Chemical, and Electrical
7)
Traditional machining
9)
MRR, Tolerance, Surface finish, Depth of surface damage, Power required
8)
3)
Non - conventional
5)
microstructure
advanced manufacturing processes
UNIT-II
Essay Questions:
1.
What is ultrasonic machining?
2.
What are the advantages of USM?
II/ME/2015
6)less
Page 24

3.
What are the Disadvantages of USM?
4.
What are the applications of USM?
5.
What are the components of USM?
6.
What is ultrasonic transducer?
7.
What is abrasive Slurry?
8.
What are the different types of concentrators?
9.
What are the characteristics of carrier fluid?
10.
What are the elements of Carrier Fluid?
11.
What are the types of feed mechanisms used in USM?
12.
Explain the USM machine setup and discuss various feed Mechanisms.
13.
Discuss the influence process parameters and applications of USM.
1)
The ----------------- can even be sea water, in AM.
2)
The removal of material in mechanical process is -------------work.
3)
An ultrasonic frequency used in usm -------------------
4)
An amplitude of too used in usm is about ------------------
5)
USM is mainly used for machining --------------------- and which are poor --------
6)
Ultrasonic machining is used for machining profiles like ---------------------
7)
---------------- is used as the dielectric medium.
Key:
1)
Electrolyte
2)
erosion
3)
4)
15 50
5)
Brittle materials, conductors of electricity
6)
Round, square, irregular shaped holes and surface impressions
7)
Kerosene or deionised water.
UNIT-III
Essay Questions:
1.
Define AJM?
II/ME/2015
Page 25
25 kHz

2.
How does AJM differ from conventional sand blasting process?
3.
What are the advantages of AJM process?
4.
What are the applications of AJM?
5.
Write the Disadvantages of AJM process?
6.
Give the formula for find the material remove rate for brittle metal?
7.
Give a summary of the abrasive of their application for different operation?
8.
Write the formula for find the MRR for ductile materials?
9.
What are the Process parameters affecting the MRR in AJM?
10.
What are the disadvantages of using abrasives again and again?
11.
What are the different types of nozzles heads used in AJM?
12.
Why oxygen should not be used in AJM?
13.
What are the different types abrasives used in AJM?
14.
What are the properties of water jet machining about effect cutting action?
15.
What are the types of units and its purpose used in water jet cutting system?
16.
Why we are using the diamond nozzle?
17.
(i) Explain the principle of AJM. Mention some of the specific applications.
(ii) Discuss in detail about the AJM process variables that influence the rate of
material removal and accuracy in the machining.
18.
(i) Explain the method of AJM with help of schematic diagram.

(ii) Mention the advantages and limitations of AJM.
19.
With neat sketch explain the process of AJM. List its application and limitations.
20.
Explain the process parameters in WJM processes.
21.
What are the advantages of WJC over conventional cutting methods?
22.
What are the applications of WJM?
23.
What are the commonly used additives in WJM?
24.
What is optical tracing system?
25.
What is the principle of WJM?
26.
(i) Explain the process parameters that influence WJM. List the applications and
limitations of WJM
(ii) Briefly discuss the application and limitation of WJM.
1.
The machining zone is flooded with hard ---------------------
2.
As the tool vibrates over the work piece, the abrasive particles act as the ---------
3.
Abrasive material used in ultrasonic machining process are----------------
II/ME/2015
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4.
In Abrasive Jet Machining (AJM), abrasive particles are made to impinge on the
work material at a------------------.
5.
The jet of abrasive particles is carried by carrier ----------------
6.
Convert the pressure energy of the carrier gas or air in to -----------------
7.
The high velocity abrasive particles remove the material by -------------------
8.
The abrasive particles would impinge on the work material at velocity of ---------
9.
The size of the Nozzle in the abrasive jet is ---------------
10.
In AJM, air is compressed to a pressure of around ----------------
11.
Gases --------------can also be used as carrier gas
12.
Oxygen is not used as a -------------------
13.
The wheel is metal bonded with-------------------.
14.
Plasma arc cutting was primarily employed to -----------------
15.
The heat produced is sufficient to raise the work piece temperature above its ----
Key:
1) Abrasive particles
2) Indenters
3) Al2O3,SiC, B4C,Diamond
4) High velocity
5) gas or air
6) kinetic energy
7) micro-cutting action
8) 200m/s
9) 0.5 mm
10) 5 bar
11)like CO2; N2
12) carrier gas
13) diamond or Al oxide abrasives
14) cut metals
15) melting point
UNIT-IV
Essay Questions:
1.
Define ECM?
II/ME/2015
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2.
Write the Faradays first law of electrolysis?
3.
Write the Faradays second law of electrolysis?
4.
Write Ohms law?
5.
What are the factors that influence oxidation in ECM?
6.
What are the materials used to make the tool electrode?
7.
What are the main functions of electrolysis in the ECM?
8.
What are the properties are expected from the electrolysis used in the ECM?
9.
What are the electrolysis commonly used in ECM?
10.
What are the results which are in improper selection of electrolyte in ECM?
11.
What are the methods generally used to filter the electrolyte?
12.
What are the characteristics of a good ECM tool?
13.
What are the parameters that affect the MRR?
14.
How the current densities affect the MRR?
15.
What are the advantages of ECM?
16.
What are the limitations of ECM?
17.
What are the applications of ECM?
18.
(i) Describe the chemistry involved in ECM process.

(ii) Briefly discuss about the effect of high temperature and pressure of
electrolyte
on the ECM process.

(iii) Discuss about the economics of ECM.
19.
(i) Describe the working principle and elements of chemical machining. What
are
the factors on which the selection of a resist for use in chemical machining?
(ii) What are the specific advantages of using chemical machining over
electrochemical machining? Give some of the practical applications of chemical
machining process.
20.
What is the self-adjusting feature in ECM?
21.
(i) Describe the process of electrochemical machining
22.
Explain in detail the ECM process with neat sketch and also mention the advantages
and application
1.
The removal of material in electrical process is ---------------------on the work.
2.
The removal of material in chemical process is --------------------
3.
Material is removed by microscopic --------------------
4.
ECM is --------------- of electrochemical or galvanic coating or deposition process.
II/ME/2015
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5.
Thus ECM can be thought of a controlled -------------------
6.
Electrolyte is water based neutral -----------------
7.
Majority of the metal removal is by ------------------------
8.
Work piece and grinding wheel must be ------------------------
9.
Grinds delicate parts and thin-walled sections without -----------------------
10.
Electro-chemical oxidation produces a ------------------
11.
Abrasives serve as insulator between wheel and ------------------------
12.
A flow of electrolyte is provided for --------------------------
13.
During ECM, there will be reactions occurring at the ---------------------
14.
That voltage or potential difference is around --------------------
15.
ECM is not suitable to produce sharp square ---------------------------
16.
Electrochemical Grinding is a combination of electrochemical machining and
----------------------17.
The tool and the work material are immersed in a ---------------------
Key:
1) Electrochemical
2) reaction
3) electrochemical action
4) Opposite
5) anodic dissolution
6) salt solution
7) Electrolytic action
8) conductive
9) distortion or heat
10) Soft hydroxide
11) Work piece.
12) Electrochemical machining
13)electrodes 2 to 30 V
14)corners or flat bottoms
16)conventional grinding
17)Dielectric medium
UNIT -V
Essay Questions:
1.
Define electrical discharge machining?
II/ME/2015
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2.
What are functions of dielectric fluid used in EDM?
3.
Basic requirement of dielectric fluid used in EDM?
4.
What the dielectric fluids commonly used in EDM?
5.
What are the prime requirements of tool material in EDM?
6.
Name some of the tool material used in EDM?
7.
What is the process parameter efficiency the MRR?
8.
Write the formula for finding the energy discharge in EDM?
9.
What is the effect of capacitance in EDM?
10.
Explain electrode wear?
11.
What are types of power supply circuits used in EDM?
12.
What are the design factors to be considered while selecting the machine tool?
13.
Why the servo controlled system is needed in EDM?
14.
Define wear ratio?
15.
What are the functions of adaptive control used for EDM?
16.
Explain the process of electrical discharge machining, its process parameters and
applications.
17.
Describe the wire cut EDM equipment, its working, applications and advantages
18.
(i) With the help of neat sketch, describe the EDM process.
(ii) Explain briefly advantages of wire EDM process.
19.
(i) Explain the classification and characteristics of various spark erosion
generators.
(ii) With help of neat sketch describe the mechanism of material removal in
EDM.
20.
Explain the working principle, elements and characteristics of wire EDM.

(ii) Explain how the stratified wire works. Also discuss about the recent
developments in wire EDM.
1.
The methods using electrical energy are -------------------
2.
The other name of EDM often referred to as --------------------.
3.
The EDM has a lower material removal Tool design is more ------------ in EDM
process.
4.
---------------- is one of the most widely used non-traditional machining
5.
In EDM electrical energy is used to generate ----------------------
6.
EDM can be used to machine ----------------------------
7.
Work material to be machined by EDM has to be ---------------------------
II/ME/2015
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processes.

8.
In EDM, a potential difference is applied between the -----------------------
9.
Both the tool and the work material are to be conductors of -----------------
10.
The tool is connected to the negative terminal of the generator and the workpiece is
connected to -----------------Key:
1)
EDM
2)
spark erosion
4)
EDM
5)
electrical spark
6)
difficult
geometries
7)
electrically conductive
8)
tool and
workpiece
9)
electricity
10)
positive
terminal
UNIT-VI
Essay Questions:
LASER BEAM MACHINING
II/ME/2015
Page 31
3)
complex

1.
What is Laser?
2.
What is the principle of LBM?
3.
What are the characteristics of Laser beam?
4.
What are the gases commonly used in LASER?
5.
Explain the process of LBM with a neat sketch
6.
What are the advantages of Laser drilling?
7.
What are the characteristics of Laser used in Laser machining?
8.
What are the fundamentals of photons used in Laser?
9.
What are the emission lines?
10.
How does Laser melting works?
11.
What is solid state Laser?
12.
(i) Explain the principle of LBM with neat sketch.

(ii) List out the advantage and limitation of LBM process.
ELECTRON BEAM MACHINING

1.
(i)Discuss the process parameters of EBM and their influence on machining

quality.
(ii) Explain the process capabilities of EBM
2.
(i)Explain the principle of EBM with sketch

(ii) List out the advantage and limitation of EBM process.
3.
(i)Mention the application of EBM.

(ii) What is EBM? Sketch its set up an indicate its main parts and explain the
principle of operation.
4.
(i)Explain the principles and elements of EBM, also how the work table is protected
from getting damaged by electron beam.
(ii) Discuss how the process variables influence MRR, HAZ and pattern
generation.
1.
The removal of material in thermal process is -------------------
2.
Electron Beam Machining and Laser Beam Machining are -------------------
3.
-------------- stands for Light Amplification by Stimulated Emission of Radiation.
4.
Electron beam is generated in an --------------------
5.
Electron beam gun provides high ---------------
6.
Electron Beam Machining is required to be carried out in -----------------
7.
The actual heating of the gas takes place due to the energy liberated when free
ions and electrons --------------------
II/ME/2015
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8.
The metal removal in PAM is basically due to the ---------------
Key:
1)
Fusion
2)
thermal processes
3)
LASER
4)
Electron beam gun
5)
velocity electrons
6)
Vacuum.
7)
Recombine into atoms
8)
high temperature
UNIT-VII
Essay Questions:
PLASMA ARC MACHINING
II/ME/2015
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1.
Define plasma.
2.
What are the advantages of plasma arc welding?
3.
What are the metals that can't be machined by plasma arc machining?
4.
What is the basic heating phenomenon that takes place in plasma arc welding?
5.
How the basic plasma does is generated?
6.
How the initial ionization is accomplished in plasma arc machining?
7.
Why does gas formed in plasma do in P.A.M?
8.
How another source of heating achieved in P.A.M?
9.
Write the principle of P.A.M
10.
Write the circuitry details in PAM.
11.
Which type of power supply is used in P.A.M?
12.
Which part is constricted by plasma?
13.
Describe the commonly used gas mixture in PAM and their corresponding work
materials
14.
What is the function of water muffler in PAM?
ELECTRO-CHEMICAL GRINDING
1.
Define ECG.
2.
Which material is used to make the grinding wheel?
3.
What are the important functions of abrasive particles used in ECG?
4.
What are the advantages of ECG?
5.
What are the disadvantages of ECG?
6.
What are the limitations of ECG?
7.
What is the application of ECG?
8.
What do you understand by Etch Factor?
9.
(i) Explain the principle of ECG with sketch.

(ii) List out the advantage of EGC over conventional grinding.
(iii) Mention the product application of ECG.
(iv) Discuss about the electrochemical honing and electrochemical grinding
1.
Chemical machining (CM) is the ------------------------- of workpiece material
2.
In CM material is removed from --------------------------
3.
In chemical machining penetration rates of the material removal are --------
4.
In Photochemical blanking the material is removed using ---------------------
5.
Applications of CM are ----------------
II/ME/2015
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6.
The Steps in Chemical Machining are ---------------------
7.
Chemical milling is used in the ----------------------
8.
Material removal mainly occurs due to -------------- of the spark.
Key:
1)controlled dissolution
2)selected areas of work piece
3) 0.00250.1 mm/min
4)photographic techniques
5)electric motor lamination, flat springs, masks for color
television, printed circuit cards etc. 6) Cleaning Masking Etching 7)Aerospace industry
8)thermal energy
UNIT-VIII
Essay Questions:
1.
What are magnetic abrasives and how to use in machining operation?
II/ME/2015
Page 35

2.
What do you mean by electro stream drilling operation?
3.
Explain in detail about shaped tube electrolytic machining process?
1.
The work piece may be made of either ------------------------materials.
2.
Deburring and chamfering are the applications of -------------------------------------
3.
In MAF process, granular magnetic abrasive are used as -----------------------------
4.
The necessary finishing pressure is applied by ----------------------------generated

field.
5.
The magnetic particles are joined to each other magnetically between -------------
6.
The lines of magnetic force form -----------------magnetic abrasive brushes (FMAB).
7.
Surface and edge finishing is performed by the --------------------------
8.
The finishing efficiency and quality are greatly influenced by the ------------------ of
the magnetic abrasive brush.
9.
If the workpiece is of non-magnetic material, then the lines of magnetic field

go---------------------it, and if it is of magnetic material then they ------------------the
workpiece.
10.
Magnitude of Magnetic force between the two poles is affected by the

------------------of the workpiece, and magnetic poles.
11.
The pressure exerted by the magnetic abrasives is -----------------------as the, gap

between the magnetic pole and the workpiece is increased
12.
Any change in the strength of the magnetic field in the direction of the line of
magnetic force near the workpiece surface, will ----------the magnetic abrasive
particles.
13.
In MAF the plane finishing process, magnetic force on the surface and rigidity of the
magnetic abrasive brush are governed mainly by the ------------of magnetic abrasives.
14.
In MAF finishing efficiency can be remarkably improved by mixing small sized

diamond abrasive with -----------------shaped large sized ferromagnetic particles
15.
Magnetic abrasives have been used in the form of either a mixture ----------------- ---of abrasive and ferromagnetic particles
16.
In MAF It was found that--------------- magnetic abrasives yield higher removal rates
17.
In MAF the best surface finish that could be achieved is------------
18.
A better surface finish has been reported in the ---------------of cutting fluid.
19.
In MAF the grinding burrs are -----------------efficiently removed than turning burrs
II/ME/2015
Page 36

Answers:
1) Ferromagnetic or non-ferromagnetic,
2) MAF,
3) cutting tools,
4) electro- magnetically,
5) Magnetic poles,
6) Flexible,
7) magnetic abrasive,
8) rigidity,
9) around, pass through,
10) shape, size,
11) decreased,
12) actuate,
13) grain size,
14) irregular,
15) bonded or unbounded,
16) unbounded,
17) 0.5mm,
18) absence,
19) more

Date:
II/ME/2015

Date:
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SREYAS INSTITUTE OF ENGINEERING &

Name of the Course : B.Tech / M.Tech

Branch/Specialization: Mechanical Engg.

Title of the Subject

: Unconventional Machining Process

Nature of the Subject: Core / Elective / Basic

The model Question papers must be attached to this course file

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Semester: B-Tech (IV I)

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Attaining better surface finish using chemical etchants, electrochemical machining.

Achievement of metal removal of brittle materials by plasma arc welding techniques

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Signature of the Faculty

Signature of the HOD

Objectives Outcomes Relationship

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Semester: B-Tech (IV I)

Signature of the Faculty

Signature of the HOD

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Need for non traditional machining

Elements of the process

Mechanics of metal removal process

Applications and limitations

Abrasive jet machining

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Fundamentals of electro chemical

Electro chemical honing and deburring

Surface finish and accuracy

Economic aspects of ECM

Simple problems for estimation of metal

Advantages and applications.

General Principle and applications of

Electric discharge wire cutting processes

Power circuits for EDM

Mechanics of metal removal in EDM

Selection of tool electrode and dielectric

Characteristics of spark eroded surface

Machine tool selection, Applications

Generation and control of EBM

Theory of electron beam machining

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Comparison of thermal and non-thermal

Cutting speed and accuracy of cut.

Application of plasma for machining

Metal removal mechanism

Accuracy and surface finish

Magnetic abrasive finishing

Abrasive flow finishing

Shaped tube electrolytic machining

Signature of the Faculty

Signature of the HOD

Semester : B-Tech (II I)

SREYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY

Abrasive jet machining, Water

General Principle and

Generation and control of EBM