638072660177837967AMT Week-1

Department of Collegiate and Technical Education
ADVANCED MANUFACTURING AND TECHNOLOGIES

(20ME53I - Vth Sem.)
WEEK-1, SESSION/DAY- 1
INTRODUCTION TO ADVANCED MATERIALs AND
NON CONVENTIONAL MACHINING
MECHANICAL ENGINEERING PROGRAMME
Presented By
WAJID
Lecturer Government
Polytechnic,Bidar Mechanical Engineering Program – 20ME53I
Expected Course Outcome
 On successful completion of this session students can be able to understand the
difference between Conventional and Non conventional manufacturing process.
 Understand the operation manufacturing flow starting to finished product.
 By watching numbers of modern manufacturing video to understand the needs of
advanced Manufacturing Technologies.
 To know the materials used for makings the parts of Aircraft and Automobile
industries.
 Understand the Non conventional manufacturing process and their applications.
Table of Contents
 Overview on Conventional Manufacturing Process.
 Flow chart of manufacturing process.
 Introduction to Advanced Materials.
 Non Conventional Machining.
 Difference between Conventional and Nonconventional manufacturing Process
 Needs of Advanced Manufacturing Technologies.
 Types of Nonconventional Machining Process.
 Ultrasonic Machining (USM)

Overview on Conventional Manufacturing Process
 In Conventional machining process, the material is removed by the direct

contact between tool and work piece.
 Conventional machining is the process of removing material from a work

piece to create the desired shape. This is done by using a variety of
tools such as drills, milling cutters, and lathes to remove the material.
 Conventional machining can only be used on materials that are strong

enough to withstand the force of the cutting tool.
Process Flow chart of manufacturing process.
Introduction to Advanced materials.
 Advanced materials are new materials with enhanced properties that are intentionally
designed for superior performance.
 It’s generally used to refer to new materials, with high-tech applications, that were
developed during the last few decades.
 Research and development of new advanced materials for industrial applications is multi-
disciplinary and can draw on expertise in the fields of chemistry, physics, nanotechnology,
ceramics, metallurgy, and biomaterials for example Plastic, wood, Glass, Ceramic, Paper
etc.
 The general benefits of advanced industrial materials are straightforward. They
have the potential to bring us cheaper, more sophisticated, and more user-friendly
products. Household items, personal vehicles, and consumer durables are already
improving our quality of life, saving labor, and enhancing recreation.
Non conventional Machining
 Non conventional machining process is a very special type of machining
process because in this process there is no direct contact between the tool and
the work piece.
 Non conventional machining processes are widely used where a lot of hard
and brittle materials are found such as tungsten carbide, high speed steels,
stainless steels, ceramics, etc. Which can not be processed by the
conventional machining process.
 Advantages of Non conventional machining process: It has good accuracy,
It provides a good surface, Complex shapes can be made easily, It has longer
tool life and The rate of metal removal is high.
 Disadvantage of unconventional machining process : The cost of
this process is high, It requires skilled operators and Its setup is difficult
Difference between Conventional and Non conventional
Machining Process
Needs of Advanced Manufacturing Technologies.
 Need to machine newly developed metals and non-metals with special
properties that make them difficult or impossible to machine by conventional
methods
 Need for unusual and/or complex part geometries that cannot easily be
accomplished by conventional machining
 Need to avoid surface damage that often accompanies conventional machining
 Advanced-manufacturing technologies can boost innovation by allowing
manufacturers to create new kinds of products that can’t be made cost
effectively with conventional processes.
 Therefore, there is a vital need to have more efforts to continuously advance
manufacturing technology for a better-off and more stable future.
Types of Nonconventional Machining Process.
Some of the common types of unconventional machining processes are

discussed which are used for machining using different energy sources:
•Abrasive Jet Machining (AJM)

•Ultrasonic Machining (USM)
•Electrochemical Machining (ECM)
•Electrical Discharge Machining (EDM)
•Electron Beam Machining (EBM)
•Laser Beam Machining (LBM)
•Electrochemical Grinding (ECG)
Ultrasonic Machining (USM)
 Ultrasonic machining is a Non process that removes material from the surface

of a part through high frequency, low amplitude vibrations of a tool against the
material surface in the presence of fine abrasive particles.
 Principle of USM : In this machining method, a slurry of small abrasive
particles are forced against the work piece by means of a vibrating tool and it
causes the removal of metal from the work piece in the form of extremely small
chips.
Construction and Working :
 It consists of abrasive slurry, work piece, fixture, table, cutting tool, circulating
pump, reservoir, ultrasonic oscillator, leads, excitation coil, feed mechanism,
ultrasonic transducer, transducer cone, connecting body and tool holder.
 The ultrasonic oscillator and amplifier also known as generator is used to convert
the applied electrical energy at low frequency to high frequency.
 The function of the transducer is to convert the electrical energy into mechanical
energy.
 Generally tough and ductile tool material is used in this process. Low carbon steels
and stainless steels are commonly used as tool materials.
 Electric power is given to ultrasonic oscillator and this oscillator converts the
electrical energy at low frequency to high frequency (20 kHz).
 High frequency power (20 kHz) from oscillator is supplied to the transducer
 The function of the transducer is to convert the electrical energy into mechanical
vibrations. The transducer is made up of magnetostrictive material, which is excited
by flowing high frequency electric current and this results in the generation of
mechanical vibrations. The vibrations are generated in the transducer of the order of
20 kHz to 30 kHz and hence ultrasonic waves are produced.
 These vibrations are then transmitted to the cutting tool through transducer cone,
connecting body and tool holder. This makes the tool to vibrate in a longitudinal
direction as shown in Fig
 Abrasive slurry is pumped from the reservoir and it is made to flow under pressure
through the gap between tool and work piece.
 In an abrasive slurry, when the cutting tool vibrates at high frequency, it leads in the
removal of metal from the work piece.
 The impact force arises out from the vibration of tool end and the flow of slurry
through the work piece tool gap causes thousands of microscopic grains to remove
the work piece material by abrasion.
 A refrigerated cooling system is used to cool the abrasive slurry to a temperature of
5 to 6°C.
 The ultrasonic machining process is a copying process in which the shape of the
cutting tool is same as that of the cavity produced.

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Department of Collegiate and Technical Education

ADVANCED MANUFACTURING AND TECHNOLOGIES

 Flow chart of manufacturing process.

 Introduction to Advanced Materials.

 Non Conventional Machining.

 Difference between Conventional and Nonconventional manufacturing Process

 Needs of Advanced Manufacturing Technologies.

 Types of Nonconventional Machining Process.

 Ultrasonic Machining (USM)

 In Conventional machining process, the material is removed by the direct

 Conventional machining is the process of removing material from a work

 Conventional machining can only be used on materials that are strong

Some of the common types of unconventional machining processes are

•Abrasive Jet Machining (AJM)

 Ultrasonic machining is a Non process that removes material from the surface

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