Figure 2 schematically illustrates a convenient classification for the different levels of control that one might encounter in a controller for a machining process. Turning operation is a machining process and is used to produce. Professor elhofy wrote his first book titled advanced machining processes. It is the material removal process where the material is removed or machined by the impact. This book is written to serve the needs of under graduate students embarking introductory course in unconventional machining processes. The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process. Book download link provided by engineering study material esm. This is used for removing a layer of metal material, either shallow or deep, by means of etching using chemical compounds, like acids, bases, etc.
The removal of material can be achieved by cutting, abrasion, and erosion. After achieving the merits of nonconventional machining methods, efforts are being made for crossprocess innovations to improve the machining characteristics. The answers will fall into place as experience is gained. This is a comparatively old process and it has several options. Nontraditional machining processes are widely used to manufacture geometrically complex and precision parts for aerospace, electronics and automotive. The usm is effective and particular for all brittle materials 11, 5.
Nonconventional machining processes selection using multiobjective 1449 journal of engineering science and technology november 2015, vol. Nontraditional processes ntp nontraditional cutting. Need for development of nontraditional machining processes. Machining cutting action involves shear deformation of work material to form a chip as chip is removed, a new surface is exposed figure 21. However, machining processes inevitably waste material in the form of chips, production rates may be low, and unless carried out properly, the processes can have detrimental effects on the surface properties and performance of parts. Unconventional machining processes textbook pdf free download unconventional machining processes textbook pdf free download. Advanced machining processes by hassan abdelgaward elhofy. Download me6004 unconventional machining processes lecture notes, books, syllabus parta 2 marks with answers me6004 unconventional machining processes important partb 16 marks questions, pdf books, question bank with answers key. A new nontraditional machining method using cavitation. Reamer is a metalworking tool used to create an accurate sized hole. Nonconventional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal.
Nontraditional and hybrid processes which has been published by mcgraw hill co in march 1, 2005. In 1927, emil lerp invented a saw that works with using oil in germany. Features such as smooth shiny surfaces, smalldiameter deep holes in a part, threaded section, and threaded holes all require further manufacturing operations. Conventional machining uses tools, such as lathes, milling machines, boring machines, drill presses, or. Conventional machining processes and machine tools module. All questions carry equal marks 1 a classify unconventional machining processes based on basic mehanism involved in the process and medium for tranfer of enrgies and type of energy. Selectthe best process from the remaining processes under consideration by optimizing process performance criteria. Unconventional machining processes textbook is one of the famous textbook for engineering students.
In electric discharge machining process an arc is produced when two currentcarrying wires are shortcircuited. Please switch to hard cover of fundamentals of machining process. Pdf nonconventional machining processes selection using. Note that there is an optimum cutting speed for both cost and time, respectively. Download me6004 unconventional machining processes ump books lecture notes syllabus part a 2 marks with answers me6004 unconventional machining processes ump important part b 16 marks questions, pdf books, question bank with answers key, me6004. Unconventional 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. Nontraditional manufacturing processes or unconventional machining 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. Gear technology, the journal of gear manufacturing issn 07436858 is published bimonthly by randall publishing, inc.
Unconventional machining processes textbook pdf free. Unconventional machining process linkedin slideshare. Machining processes produce finished products with a high degree of accuracy and surface quality. His second book titled fundamentals of machining processesconventional and nonconventional processes has been appeared in september 2007 by crc, taylor and francis. If you cannot answer all of these questions, do not get frustrated since some of them are open ended. Hence the machining process which utilizes other machining methods are termed as unconventional. Machining processes produce finished parts, ready for use or assembly, at high degree of accuracy and surface quality by removing a certain machining allowance from the workpiece material. Machining process flow chart is an important document to guide machining, while also ensuring the quality of processing, based on the machining process allows higher productivity and lower cost. Otherwise, precision grinding and polishing are limited in contrast to e.
Conventional machining process metal is removed by means of tool which is harder than work piece and they both are in contact with each other demerits of conventional machining process disposal and recycling of the chips are difficult and tedious process large cutting forces are involved in this process. The former onesprovide basic shape and size to the material as per designers requirement. Chemical machining cm photochemical machining pcm 2. Introduction to nontraditional machining iit kanpur. Traditional machining processes consist of turning, boring, drilling. Edm machining process is also known as spark erosion machining. The machining can be performed on various components in the form of either conventional or unconventional processes. Examples of conventional machining processes are turning, boring, milling, shaping, broaching, slotting, grinding etc. In 1926, the first saw which worked with electricity was invented by andreas stihl. In unconventional machining, a form of energy is used to remove unwanted material from a. The two key materials used in chemical milling process are etchant and maskant. This is due to material removal rate mrr decreases with increased hardness of the work material. Unconventional machining process sasurie college of engineering. The wire edm process can cut intricate components for the electric and aerospace industries.
Electrochemical machining ecm electro chemical grinding ecg 3. In 1950, he invented first portable saw which has a motor. Removal of unwanted material in the form of chips in order to create a geometric shape market. The machining can be performed on a lathe machine, milling machine, ultrasonic machining, etc.
During this machining process, a small portion of metals is also eroded away, leaving a small cater. Materials are removed by traversing in a direction parallel to the axis of rotation of axis or along a specified path to form a complex rotational shape. Chemical machining is oldest of nontraditional machining processes employed as micromachining process to produce micronsize components. Manufacturing processes can be broadly divided into two groups and they are primarymanufacturing processes and secondary manufacturing processes. In chemical milling, shallow cavities are produced on plates, sheets, forgings and extrusions. This book is mainly useful for mechanical engineering students. Nontraditional and hybrid machining processes by hassan abdelgaward elhofy book is a good reference for both nontraditional and hybrid machining processes. Pdf unconventional machining process radhika talupula. Until at least the mid19th century, saws were made laboriously by hand. Advancedunconventionalnon traditional machining process an. The lowest level is servo control, where the motion of the cutting tool relative to the workpiece is controlled. Pdf unconventional machining processes local author by. The applications of machining process are as follows.
Material removal processes machining is the broad term used to describe removal of material from a workpiece includes cutting, abrasive processes grinding, advanced machining processes electrical, chemical, thermal, hydrodynamic, lasers automation began when lathes were introduced in 1700s. List down various mechanical energy based unconventional machining processes the various. The difficulty to cut materials encouraged efforts that led to the introduction of the unconventional machining. Machining a material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. There are 10 steps to draw up machining process flow chart. Senthil kumar, ars publications the book unconventional machining processes for engineering and technology studies. Introduction as a result of the advances in machine tools and cutting tool technology in recent decades, many of the conventional machining processes such as turning, milling and drilling have become costeffective, flexible and highthroughput manufacturing processes for producing high precision and high. This textbook is also useful to most of the students who are preparing for competitive exams. Conventional machining processes and machine tools moduleiv turning turning operation is a machining process and is used to produce round parts in shape by a single point cutting tool. Classification of unconventional machining processes was mainly on the basis of the nature of energy employed in machining process. Its materialremoval mechanism includes impacting and hammering. Conventional machining utilizes cutting tools that must be harder than workpiece material. Nontraditional machining processes covers recent research and development in techniques and processes which focus on achieving high accuracies and good surface finishes, parts machined without burrs or residual stresses especially with materials that cannot be machined by conventional methods. The advent of hard materials for aerospace applications have made the machining process by conventional methods very difficult and time consuming.
In this ebook you will find covering the both electrical discharge machining and electrochemical machining. Fundamentals of machining processes by hassan abdel contains total 16 chapters, such as cutting tools, maintainability, micromachining, high speed machining, abrasives etc. Pdf me6004 unconventional machining process researchgate. History the early ancestors of modern humans, likely first used a jawbone of bovid animals as a saw. Unconventional machining process need classification brief overview. Multisetup planning is typically used in the machinery industry where the main limitation is the capabilities of the machine. Machining is a processes in which a piece of raw material is cut into a desired final shape and size by a controlled materialremoval process. Pdf me6004 unconventional machining processes lecture. To learn about various unconventional machining processes, the various process parameters and their influence on performance and their applications.
Analysis of part drawing and assembly drawing this is the basis of the machining. The usm process is effectively used to machining conductive and nonconductive materials. By conventional machining the mrr reduces with an increase in the work material hardness. Introduction we all know that the term machinability refers to the case with which a metal can be machined to an acceptable surface finish. Read through this list and familiarize yourself with these.
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