A

Micro-Project Report

on

“Types of Lubricating Oils, Oil Filters, Coolants for Petrol

Engines”
Submitted in Fulfillment of the Requirement for the Award of the

Diploma

in

Mechanical Engineering

By

Mohammad Raza Mohammad Ashfaque Shaikh (Roll No. 12)

Khushi Suresh Bhanushali (Roll No. 17)

Pranit Sunil Gurav (Roll No. 40)

Under the Guidance of

Mr. Rupesh R. Pawar

Department of Mechanical Engineering

Smt. Geeta D. Tatkare Polytechnic, Gove-Kolad

2024-2025
 ABSTRACT
Non-traditional manufacturing processes is defined as a group of processes that remove
excess material by various techniques involving Mechanical, Thermal, Electrical or Chemical
energy or combinations of these energies but do not use a sharp cutting tools as it needs to be
used for traditional manufacturing processes.

Extremely hard and brittle materials are difficult to machine by traditional machining
processes such as turning, drilling, shaping and milling. Non-traditional machining processes,
also called advanced manufacturing processes, are employed where traditional machining
processes are not feasible, satisfactory or economical due to special reasons as outlined
below.

 Very hard fragile materials difficult to clamp for traditional machining

 When the work piece is too flexible or slender
 When the shape of the part is too complex
 Several types of non-traditional machining processes have been developed to meet
extra required machining conditions. When these processes are
1.1 Introduction

Material removal processes can be divided into two groups

1. Conventional Machining Processes

2. Unconventional Machining processes or Non-Traditional Manufacturing Processes

Conventional Machining Processes mostly remove material in the form of chips by

applying forces on the work material with a wedge shaped cutting tool that is harder than the
work material under machining condition.

The major characteristics of conventional machining are:

• Generally macroscopic chip formation by shear deformation.

Material removal takes place due to application of cutting forces energy domain can be
classified as mechanical.

Cutting tool is harder than work piece at room temperature as well as under machining
conditions.

Non-conventional manufacturing processes is defined as a group of processes that remove

excess material by various techniques involving Mechanical, Thermal, Electrical or Chemical
energy or combinations of these energies but do not use a sharp cutting tools as it needs to be
used for traditional manufacturing processes.
Material removal may occur with chip formation or even no chip formation may take place.
For example in AJM, chips are of microscopic size and in case of Electrochemical machining
material removal occurs due to electrochemical dissolution at atomic level.

NEED FOR UNCONVENTIONAL MACHINING PROCESSES

i. Extremely hard and brittle materials or Difficult to machine material are difficult
to machine by traditional machining processes.
ii. When the workpiece is too flexible or slender to support the cutting or grinding
forces. When the shape of the part is too complex.

CLASSIFICATION OF NON-CONVENTIONAL MACHINING PROCESSES:

1. Mechanical Processes
• Abrasive Jet Machining (AJM)
• Ultrasonic Machining (USM)
• Water Jet Machining (WJM)
• Abrasive Water Jet Machining (AWJM)

2. Electrochemical Processes
• Electrochemical Machining (ECM)
• Electro Chemical Grinding (ECG)
• Electro Jet Drilling (EJD)
3. Chemical Processes
  Chemical Milling (CHM)
 Photochemical Milling (PCM)

MECHANICAL PROCESSES

ABRASIVE JET MACHINING (AJM)

In Abrasive Jet Machining (AJM), abrasive particles are made to impinge on the work
material at a high velocity. The jet of abrasive particles is carried by carrier gas or air. The
high velocity stream of abrasive is generated by converting the pressure energy of the carrier
gas or air to its kinetic energy and hence high velocity jet. The nozzle directs the abrasive jet
in a controlled manner onto the work material, so that the distance between the nozzle and the
work piece and the impingement angle can be set desirably. The high velocity abrasive
particles remove the material by micro-cutting action as well as brittle fracture of the work
material. Fig. 1.1 schematically shows the material removal process.
In AJM, generally, the abrasive particles of around 50 µm grit size would impinge on the
work material at velocity of 200 m/s from a nozzle of L.D. of 0.5 mm with a standoff
distance of around 2 mm. The kinetic energy of the abrasive particles would be sufficient to
provide material removal due to brittle fracture of the work piece or even micro cutting by the
abrasives.

Working

In AJM, air is compressed in an air compressor and compressed air at a pressure of around 5.
Bar is used as the carrier gas as shown in Fig. 1.2. Fig. 1.2 Also shows the other major parts
of the AJM system. Gases like CO2, N2 can also be used as carrier gas which may directly be
issued from a gas cylinder. Generally oxygen is not used as a carrier gas.
remove any oil vapour or particulate contaminant the same is passed through a series of
filters. Then the carrier gas enters a closed chamber known as the mixing chamber. The
abrasive particles enter the chamber from a hopper through a metallic sieve. The sieve is
constantly vibrated by an electromagnetic shaker. The mass flow rate of abrasive (15
gm/min) entering the chamber depends on the amplitude of vibration of the sieve and its
frequency. The abrasive particles are then carried by the carrier gas to the machining chamber
via an electromagnetic on-off valve. The machining enclosure is essential to contain the
abrasive and machined particles in a safe and eco-friendly manner. The machining is carried
out as high velocity (200 m’s) abrasive particles are issued from the nozzle onto a work piece
traversing under the jet.
ABRASIVE WATER-JET MACHINING (AWJM)

Abrasive water jet cutting is an extended version of water jet cuting; in which the water jet
contains abrasive particles such as silicon carbide or aluminium oxide in order to increase the
material removal rate above that of water jet machining. Almost any type of material ranging
from hard brittle materials such as ceramics, metals and glass to extremely soft materials such
as foam and rubbers can be cut by abrasive water jet cutting. The narrow cutting stream and
computer controlled movement enables this process to produce parts accurately and
efficiently. This machining process is especially ideal for cutting materials that cannot be cut
by laser or thermal cut. Metallic, non-metallic and advanced composite materials of various
thicknesses can be cut by this process. This process is particularly suitable for heat sensitive
materials that cannot be machined by processes that produce heat while machining.

The schematic of abrasive water jet cutting is shown in Figure 15 which is similar to water jet
cutting apart from some more features underneath the jewel, namely abrasive, guard and
mixing tube. In this process, high velocity water exiting the jewel creates a vacuan which
sucks abrasive from the abrasive line, which mixes with the water in the mixing tube to form
a high velocity beam of abrasives.

Ultrasonic Machining (USM)

USM is mechanical material removal process or an abrasive process used to erode holes or
cavities on hard or brittle workpiece by using shaped tools, high frequency mechanical
motion and an abrasive slurry. USM offers a solution to the expanding need for machining
brittle materials such as single crystals, glasses and polycrystalline ceramics, and increasing
complex operations to provide intricate shapes and workpiece profiles. It is therefore used
extensively in machining hard and brittle materials that are difficult to machine by traditional
manufacturing processes. The hard particles in slurry are accelerated toward the surface of
the workpiece by a tool oscillating at a frequency up to 100 KHz-through repeated abrasions,
the tool machines a cavity of a cross section identical to its own. A schematic representation
of USM is shown in Figure.
In ultrasonic machining, a tool of desired shape vibrates at an ultrasonic frequency (19~25
kHz) with an amplitude of around 15-50 µm over the workpiece. Generally the tool is pressed
downward with a feed force, F. Between the tool and workpiece, the machining zone is
flooded with hard abrasive particles generally in the form of a water based slurry. As the tool
vibrates over the workpiece, the abrasive particles act as the indenters and indent both the
work material and the tool. The abrasive particles, as they indent, the work material, would
remove the same, particularly if the work material is brittle, due to crack initiation,
propagation and brittle fracture of the material Hence, USM is mainly used for machining
brittle materials (which are poor conductors of electricity and thus cannot be processed by
Electrochemical and Electro- discharge machining (ECM and ED)).

USM is primarily targeted for the machining of hard and brittle materials (dielectric or
conductive) such as boron carbide, ceramics, titanium carbides, rubies, quartz etc. USM is a
versatile machining process as far as properties of materials are concerned. This process is
able to effectively machine all materials whether they are electrically conductive or insulator.

WORKING

The basic mechanical structure of an USM is very similar to a drill press. However, it has
additional features to carry out USM of brittle work material. The workpiece is mounted on a
vice, which can be located at the desired position under the tool using a 2 axis table. The table
can further be lowered or raised to accommodate work of different thickness. The typical
elements of an USM are,

1. Slurry delivery and return system

2. Feed mechanism to provide a downward feed force on the tool during machining
3. The transducer, which generates the ultrasonic vibration
4. The horn or concentrator, which mechanically amplifies the vibration to the required
amplitude of 15-50 um and accommodates the tool at its tip.
The ultrasonic vibrations are produced by the transducer. The transducer is driven by suitable
signal generator followed by power amplifier. The transducer for USM works on the
following principle

1. Piezoelectric effect
2. Electrostrictive effect
3. Magnetostrictive effect

Magnetostrictive transducers are most popular and robust amongst all Fig. 7 shows a typical
magnetostrictive transducer along with horn. The horn or concentrator is a wave-guide, which

amplifies and concentrates the vibration to the tool from the transducer.
Process Parameters and their Effects.

During discussion and analysis as presented in the previous section, the process parameters
which govern the ultrasonic machining process have been identified and the same are listed
below along with material parameters

Amplitude of vibration (ao)15-50 µm

Flow strength of the tool material

• Frequency of vibration (f)19-25 kHz

Contact area of the tool – A

Feed force (F)-related to tool dimensions

Volume concentration of abrasive in water

Feed pressure (p)

Slurry-C

Abrasive size 15 µm-150 µm

The machining tool must be selected to be highly wear resistant, such as high-carbon steels.

Abrasive material AbO, SIC, BC,

Boronsilicarbide, Diamond
Flow strength of work material

The abrasives (25-60 µm in dia.) in the (water-based, up to 40% solid volume) slurry
includes:

Boron carbide, silicon carbide and aluminum oxide.

ELECTRICAL ENERGY BASED PROCESSES

1. Electrical discharge machining (EDM)

Electrical discharge machining is one of the most widely used non-traditional machining
processes. The main attraction of EDM over traditional machining processes such as metal
cutting using different tools and grinding is that this technique utilises thermoelectric process
to erode undesired materials from the workpiece by a series of discrete electrical sparks
between the workpiece and the electrode. A picture of EDM machine in operation.

The traditional machining processes rely on harder tool or abrasive material to remove the
soffer material whereas non-traditional machining processes such as EDM uses electrical
spark or thermal energy to erode unwanted material in order to create desired shape. So, the
hardness of the material is no longer a dominating factor for EDM process. A schematic of an
EDM process is shown in Figure 2, where the tool and the workpiece are immersed in a
dielectric fluid.

EDM removes material by discharging an electrical current, normally stored in a capacitor

bank, across a small gap between the tool (cathode) and the workpiece (anode) typically in
order.
Working principle of EDM

As shown in Figure 1, at the beginning of EDM operation, a high voltage is applied across
the narrow gap between the electrode and the workpiece. This high voltage induces an
electric field in the insulating dielectric that is present in narrow gap between electrode and
workpiece.

This cause conducting particles suspended in the dielectric to concentrate at the points ..
strongest electrical field. When the potential difference between the electrode and the
workpiece is sufficiently high, the dielectric breaks down and a transient spark discharges
through the dielectric fluid, removing small amount of material from the workpiece surface.
The volume of the material removed per spark discharge is typically in the range of 10-6 to
10- 6m * m ^ 3

The material removal rate, MRR, in EDM is calculated by the following foumula: MRR =
40I / T * m 1.23 (c * m ^ 3 / m * in)

Where,

I is the current amp,

Tm is the melting temperature of workpiece in ^ C .

Process Parameters

The process parameters in EDM are mainly related to the waveform characteristics. Fig 11
shows a general waveform used in EDM.

The waveform is characterised by the

 The open circuit voltage Vo

 The working voltage Vw
 The maximum current lo
 The pulse on time the duration for which the voltage pulse is applied ton
 The pulse off time-toff
 CONCLUSION
In this micro project we studied about non traditional manufacturing processes. We also had
an overview on Conventional Machine Process. Most importantly, in this micro project, we
learnt about Non-Conventional manufacturing processes, need of this processes, it’s
classification and brief explanation of some of the types of Non-Conventional manufacturing
processes with figures.