UNCONVENTIONAL MACHINING

PROCESSES

Subject code: A70359

Regulations: R15-JNTUH
Class: IV Year B. Tech MECH I Sem

Department of Mechanical Engineering

BHARAT INSTITUTE OF ENGINEERING AND TECHNOLOGY
Ibrahimpatnam - 501 510, Hyderabad
 UNCONVENTIONAL MACHINING PROCESSES ( A70359 )
COURSE PLANNER

I. COURSE OBJECTIVE AND RELEVANCE:

In recent years an increasing demand for the machining of components of complex shapes made
of hard, difficult – to – machine materials with exacting tolerances and surface finish has resulted
in the development of a number of new machining processes. Some of these methods have been
commercially exploited while others are still in their experimental stages. There has been a rapid
growth in the development of harder and difficult to machine metals and alloys during the last
two decades. Conventional edged tool machining is uneconomical for such materials and the
degree of accuracy and surface finish attainable is poor. The advancing strength level would
have a catastrophic effect on the total machining bill if there was no corresponding improvement
in machining technology. In view of this seriousness of this problem, Merchant (1960)
emphasized the need for the development of newer concepts in metal machining. The newer
machining processes, so developed are often called modern machining processes or
unconventional machining methods. Modern machining methods are classified according to the
type of fundamental machining energy employed, for example mechanical, electrochemical,
chemical or thermoelectric.
II. COURSE PURPOSE & OBJECTIVE:
An unconventional machining process is a specialized subject for mechanical engineering
branch. It provides an insight of machines associated with specialized production. The purpose
of this course is also to learn the need for various non–traditional machining methods.
III. COURSE OUTCOMES:
At the end of the course the student will be able to,
S.NO Description Bloom’s Taxonomy level
1 Explain the basic types of machines. Understand (Level 2)
2 Discuss various non-conventional machines and their Understand (Level 2)
applications.
2 Classify different types of unconventional machining Understand (Level 2)
processes
IV. HOW COURSE OUTCOMES ARE ASSESSED
Program Outcomes Level Proficiency assessed
by
PO1
An ability to apply knowledge of mathematics, 3 Assignments, Midterm
science, engineering and computing using modern and University
tools. examinations
PO2 An ability to design and conduct experiments, as well 2 Assignments, Midterm
as to synthesize, analyze and interpret data. and University
examinations
PO3 An ability to design a system, component, or process Assignments, Midterm
to meet desired needs within appropriate constraints 2 and University
 for public Health, safety, cultural, societal and examinations
environmental considerations.

PO4 An ability to function on multidisciplinary teams as a -- --

member and leader.
PO5 An ability to identify, analyze, formulate, and solve
-- --
diverse machining problems
PO6 An understanding of professional, ethical, legal, -- --
security, social issues and responsibilities
PO7 An ability to use communication skills effectively -- --
PO8 The broad education necessary to understand the -- --
local and global impact of engineering solutions in a
economic, environmental, and societal context.
PO9 A Recognition of the need for and an ability to 2 Assignments, Midterm
engage in life-long professional development. and University
examinations

PO10 A knowledge of contemporary issues and -- --

Technology up-gradations.
PO11 An ability to use the current techniques, skills, and -- --
modern machining process for Mechanical
Engineering practice.
PO12 Ability to acquire professional competence for facing - --
competitive examinations for successful employment
in Mechanical Engineering.

HOW PROGRAM SPECIFIC OUTCOMES ARE ASSESSED

Proficiency
Level
Program Specific Outcomes assessed by
The student will be able to apply the knowledge of Mathematics,
Sciences and engineering fundamentals to formulate, analyse and Lectures,
PSO1: 2
provide solutions the problems related to Mechanical engineering and Assignments
communicate them effectively to the concerned.
Design mechanical systems in various fields such as machine
elements, thermal, manufacturing, industrial and inter-disciplinary Lectures,
PSO2: 1
fields by using various engineering/technological tools to meet the Assignments
mercurial needs of the industry and society at large.
The ability to grasp the latest development, methodologies of
mechanical engineering and possess competent knowledge of design Lectures,
PSO3: 3
process, practical proficiencies, skills and knowledge of programme Assignments
and developing ideas towards research
PREREQUISITES:
1. Knowledge in basic manufacturing processes.
2. Engineering Chemistry
3. Engineering Physics
COURSE SYLLABUS :JNTUH SYLLABUS:
UNIT – I
INTRODUCTION: Need for non-traditional machining methods-Classification of modern
machining processes – considerations in process selection. Materials, Applications.
Ultrasonic machining – Elements of the process, mechanics of metal removal process
parameters, economic considerations, applications and limitations, recent development.
UNIT – II: Abrasive jet machining, Water jet machining and abrasive water jet machine: Basic
principles, equipments, process variables, mechanics of metal removal, MRR, application and
limitations.
ELECTRO – CHEMICAL PROCESSES : 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 - III
THERMAL METAL REMOVAL PROCESSES : General Principle and applications of
Electric Discharge Machining, Electric Discharge Grinding and electric discharge wire cutting
processes – Power circuits for EDM, Mechanics of metal removal in EDM, Process parameters,
selection of tool electrode and dielectric fluids, methods surface finish and machining accuracy,
characteristics of spark eroded surface and machine tool selection. Wire EDM, principle,
applications.
UNIT – IV
Generation and control of electron beam for machining, theory of electron beam machining,
comparison of thermal and non-thermal processes –General Principle and application of laser
beam machining – thermal features, cutting speed and accuracy of cut.
UNIT-V
Application of plasma for machining, metal removal mechanism, process parameters, accuracy
and surface finish and other applications of plasma in manufacturing industries. Chemical
machining-principle- maskants –etchants- applications.
SUGGESTED BOOKS:
TEXT BOOK:
1. Advanced machining processes/ VK Jain/ Allied publishers.
2. Production technology by R.K.Jain/Khanna publishers.
REFERENCES:
3. Modern Machining Process / Pandey P.C. and Shah H.S. / TMH.
4. New Technology / Bhattacharya A/ The Institution of Engineers, India 1984.
5. Modern Production / Operations Management / Baffa & Rakesh Sarin.
GATE SYLLABUS:
E.D.M, EGM & ECM: Applications and Properties
IES SYALLABUS:
NOT APPLICABLE
COURSE PLAN (WEEK-WISE):
 Refe
Wee

renc
Lecture Course Learning

Unit
TOPIC

e
No. Outcomes
1. Introduction
2. Need for nontraditional machining
methods
3. Modern machining process
4. 1 Considerations in process selection Understand the what is
5. Materials and applications manufacturing
6. Classification of modern machining processes and need of Book
I process nontraditional No. 1,
7. Modern machining process, applications manufacturing process, 2.
8. 2 Ultrasonic machining and ultrasonic
9. Elements of the process machining process
10. Mechanics of metal removal process
parameters
11. Review of Unit-I
12. 3 Mock Test – I
13.
Abrasive jet machining
14.
Basic principles, equipments
15. Process variables, Mechanics of metal
removal
16.
Applications and limitations Understand the various
4 Tutorial / Bridge Class # 1 nontradational
17. machining processes
Water jet machining Process variables like Abrasive
18. Basic principles, equipments mechanics machining and its
Book
of metal removal applications, water jet
II No. 1,
machining and its
19. 2.
principles , Material
MRR
removal rate and
20. Electro chemical
Applications and limitations grinding ,honning,
5 Tutorial / Bridge Class # 2 deburring
21. Electro chemical process
22. Fundamentals of electro chemical
machining
23. Electro chemical grinding, honing,
deburring process
24. Revision
6 Tutorial / Bridge Class # 3
25. Metal removal rate in ECM Student will be gaining Book
26. 7 Tool design, surface finish knowledge on Electro No. 1,
 27. Accuracy economic aspects of ECM chemical machining 2.
28. Fundamentals of chemical, machining process and constraints
Advantages and applications of the ECM process and
Tutorial / Bridge Class # 4 its applications
29. ECM ,Honing properties
30. Grinding applications
31. Revision
32. Revision
8 Tutorial / Bridge Class # 5
I Mid Examinations (Week 9)
33. General principle and applications of Understand the Electro
electric discharge machining Discharge Machining
34. Electric discharge wire cutting process process and its
35. Power circuits for EDM applications , and gains
36. Mechanics of metal removal in EDM and knowledge on
process parameters mechanics of metal
removal in EDM and its Book
10 Tutorial / Bridge Class # 6 process parameters. No. 1
37. Selection of tool electrode and dielectric
fluids
38. Methods surface finish and machining
accuracy
39. Characteristics of spark eroded surface
and machine tool selection
40. Wire EDM principle and applications
11 Tutorial / Bridge Class # 7
41. Generation and control of electron beam Understand the WEDM
for machining Process and its
42. Theory of electron beam machining Book
applications of the
No. 1,
43. Comparison of thermal and non thermal WEDM Process.
2
processes Thermal processe and
44. General principle and applications of laser bearm
laser beam machining
12 Tutorial / Bridge Class # 8
45. General principle and applications of
laser beam machining
46. Thermal features
47. Cutting speed and accuracy of cut
48. Revision
13 Mock Test - II
49. Applications of plasma for machining Understand the Plasma
Book
50. Metal removal mechanism machining process and
No. 1,
51. Process parameters its metal removal
2.
52. 14 Accuracy and surface finish mechanism,Chemical
 Tutorial / Bridge Class # 9 machining processes,
53. Other applications of plasma in Magnetic abrasive
manufacturing industries machining , Electro
54. Chemical machining principle steam drilling.
55. Chemical machining applications
56. Magnetic abrasive finishing
15 Tutorial / Bridge Class # 10
57. Magnetic abrasive finishing
58. Abrasive flow finishing
59. Electro stream drilling
60. Shaped tube electrolytic machining
16 Tutorial / Bridge Class # 11
61. Revision
62. Revision
63. Revision
64. Revision
17 Tutorial / Bridge Class # 12
II Mid Examinations (Week 18)
DESCRIPTIVE QUESTIONS
(a) JNTUH:
Blooms Taxonomy Course
S. No. Question
Level Outcomes
UNIT-I
1 a) Explain the reasons for the development of Unconventional
Machining Process. Creating,
4,3
b) Discuss about the criteria recommended in selection of these Analyzing
processes.
2 a) List the unconventional machining process, which uses
thermal or heat energy?
Applying,
b) Make a comparison between traditional and unconventional 2,1
Understanding
machinng processes in terms of cost, Application, scope,
Machining time, advantages and limitations.
3 a) List the Unconventional machining process, which uses
Electro chemical energy?
Understanding,
b) Compare the mechanical and electrical energy processes in 2,3
Remembering
terms of physical parameters. Shape capabilities, Process
capability, and Process economy.
4 a) What is a mechanical energy method of unconventional
Evaluating,
machining? 3,4
Understanding
b) What is meant by Unconventional Machining Processes?
5 a) What is meant by Conventional Machining Processes?
Understanding,
b) What are the characteristics of unconventional machining 3,5
Remembering
process?
6 a) Name the unconventional machining process which is Applying, 3,1
used to remove minimum material?b) What is a thermal energy Understanding
method of unconventional machining process?
 a) What is a chemical energy method of unconventional
machining? Applying,
7 1,2
b) List the Unconventional machining process, which uses Understanding
Electro chemical energy?
a) Differentiate between traditional and nontraditional
machining. Evaluating,
8 4,5
b) What are the industrial needs for unconventional Applying
machining processes?
a) Name the unconventional machining processes which are
used to remove maximum material? Understanding,
9 1,2
b) Classify the modern machining processes in detail. Justify Evaluating
for its economic aspects.
a) List the unconventional machining process which uses
mechanical energy?
Remembering,
10 b) Compare and contrast the various unconventional machining 1,2
Applying
process on the basis of the type of energy employed, material
removal rate, transfer media and economical aspects.
UNIT – II
1 a) Define the functions of transducers in ultrasonic machining.
Analyzing,
b) What are the major elements of ultrasonic machining 2,3
Evaluating
equipment?
2 a) Give the range of frequency required for ultrasonic
machining. Understanding,
3,5
b) Explain the principles, equipment’s, transducer, of Evaluating
Ultrasonic Machining.
3 a) What are the process criteria of USM?
Analyzing,
b) What are the various process parameters that govern the 2,5
Evaluating
process criteria?
4 a) What are the actions do the ultrasonic vibrations imparted to
Analyzing,
the fluid medium surrounding the tool have? 1,3
Applying
b) What are the applications of Ultrasonic Machining?
5 a) Briefly discuss about the mechanisms involved in material
Evaluating,
removal by USM.
Remembering 5,2
b) Draw the schematic set-up of Ultrasonic Machine and
indicate its various parts.
6 a) Mention the salient features of Ultrasonic Machining. Evaluating,
1,2
b) Explain the principle of USM with neat diagram. Understanding.
7 a) List the commonly used abrasive powder for the tooling of
Applying,
USM and their properties. 2,3
Remembering
b) What are the limitations of USM?
8 a) Discuss in detail about the methods of generating the
ultrasonic, characteristics of the various types of tool holder
Evaluating,
and tool feed mechanisms in USM. 1,2
Understanding
b) Define “Ultrasonic” and describe the process in which these
are used to machine the material.
9 a) Calculate the depth of indentation produced on a glass surface
in ultrasonic machining by throwing action of abrasive grain of Analyzing,
2,3
100 µm diameter. The following data are given. Amplitude of Evaluating
vibration = 0.1 mm, Frequency = 20kc/s. Abrasive density = 3.0
 Kg/m3, Yield strength of glass = 4.0 × 1011 N/m2.
b) outline a method by which the volume rate of material
removal could be computed.
10 a) Describe the design procedure for the Horn (Velocity
trasnformer) used in Ultrasonic Machining process. Evaluating,
1,5
b) Describe the entire range of applications of Ultrasonic Applying
machining where it can be used economically.
UNIT – III
1 a) State the working principle of Abrasive Jet Machining with a
Understanding,
neat sketch? 1,2
Applying
b) List the advantages of AJM process?
2 a) What are the factors that affect the material removal rate in
Analyzing,
AJM process? 2,5
Applying
b) What are the applications of AJM process?
3 a) State the working principles of WJM process? Understanding,
b) List the unique benefits offered by WJM process? 3,5
Remembering
4 a) Discuss in detail about the AJM process variables that
influence the rate of material removal and accuracy in the Evaluating,
2,4
machining. Analyzing
b) Mention the limitations of AJM.
5 a) Explain the process parameters that influence WJM. Understanding,
2,5
b) Briefly discuss the limitation of WJM. Remembering
6 a) Explain the principles, equipment’s, of Abrasive Jet
Understanding,
Machining. 1,5
Evaluating
b) Explain mechanics of metal removal, MRR of AJM.
7 a) Describe the variables that affect the metal removal rate in
AJM. Analyzing,
5
b) How the restriction offered bypass way governs MRR and Evaluating
quality of surface produced in AFM?
8 a) What are the advantages of water jet machining? Applying,
1,3
b) Describe the practical applications of water jet machining? Remembering
9 a) Explain the affect of following parameters on the metal
removal rate in AJM. Analyzing,
1,5
i) Velocity of fluid. ii) Design of nozzle. iii) Gas pressure. Understanding
b) Describe the operation of AJM in detail.
10 a) Discuss why the AJM technique, when applied to ductile
Evaluating,
materials, leads to a low rate of metal removal. 1,5
Understanding
b) What are the applications of Abrasive Jet Machining?
UNIT – IV
1 a) State the principle of chemical machining process. Understanding,
1,2
b) Explain the principle of ECM process with a neat sketch. Remembering
2 a) What are the requirements of tool materials in ECM process?
Evaluating,
b) What are the factors to be considered while designing the 2,5
Remembering
tool?
3 a) State the function of electrolyte used in ECM process?
Analyzing,
b) What are essential characteristics of an electrolyte used in 2,3
Remembering
ECM process?
4 a) List the applications of ECM process? Applying,
1,2
b) What are the limitations of ECM process? Understanding
 5 a) What is the difference between ECG and conventional Evaluating,
1,3
grinding? Understanding
Blooms Taxonomy Course
S. No. Question
Level Outcomes
b) List the disadvantages of ECG process?
6 a) List the advantages of (ECG) process. Analyzing,
2,5
b) Describe the chemistry involved in ECM process. Understanding
7 a) Describe the chemistry involved in ECM process.
b) Briefly discuss about the effect of high temp and pressure of Understanding,
1,5
electrolyte on the ECM process. Analyzing

8 a) Describe the working principle and elements of chemical

machining. Analyzing,
1,3
b) What are the factors on which the selection of a resist for use Evaluating
in chemical machining?
9 a) What are the specific advantages of using chemical
machining over electro chemical machining? Applying,
2,3
b) Give some of the practical applications of chemical Remembering
machining process.
10 a) Discuss about the electrochemical honing and
electrochemical grinding. Understanding,
1,2
b) Give some of the practical applications of chemical Applying
machining process.
UNIT – V
1 a) Explain the mechanism of material removal in EDM with the
Understanding,
help of a neat sketch. 1,5
Applying
b) What are the advantages and applications of EDM?
2 a) Discuss the nature of inaccuracies of machining surface
obtained by EDM and WEDM process and mention the methods Evaluating,
2,3
of reducing their effects? Remembering
b) Explain types of flushing used in EDM.
3 a) Explain the effect of various process parameters of EDM? Analyzing,
1,2
b) Describe with a neat sketch the working of Wire EDM? Remembering
4 a) Sketch the rotary pulse generator used in EDM process and
Remembering,
mention its advantages over relaxation circuit. 1,3
Understanding
b) What is flushing and why is it required in EDM?
5 a) Explain the effect of following parameters in MRR during
EDM.
Evaluating,
i) Resistance ii) Magnitude of current iii) Capacitance. 2,5
Analyzing
b) Differentiate between electro discharge grinding and wire
EDM process.
6 a) Sketch the rotary pulse generator used in EDM process and
mention its advantages over Relaxation circuit.
Understanding,
b) Describe about the importance of supply voltage, break down 2,5
Remembering
voltage, charging resistance, gap setting and die electric strength
of gap in EDM.
7 a) Explain the various Thermal metal removal process and
differentiate between them. Analyzing,
1,5
b) For a relaxation circuit used in EDM process prove that Ve = Evaluating
Vo (1-e-t/RC).
 8 a) Explain the closed loop hydraulic circuit used in EDM
process with a neat sketch. Remembering,
2,3
b) Describe with a neat sketch the electro mechanical servo Understanding
control unit to maintain the correct gap in EDM?
9 a) Develop an expression for the MRR in EDM? Evaluating,
2,5
b) What are the various process parameters to be considered in Understanding
10 a) Explain the principles, equipments, dielectric system,
electrode, tools, process capabilities, applications and
advantages of Electro Discharge Machining. Evaluating,
2,5
b) Explain the principles, equipments, positioning system, wire Analyzing
drive system, process capabilities applications and advantages
of Electro Discharge Wire cutting.
a) Explain the construction and working of Electron beam
machining process with a neat sketch. Understanding,
1 1,2
b) Describe the suitability of LBM and its machining Applying
performance, and industrial applications?
a) What are the various LASERS used in practice for machining
and explain the requirements of “LASERS”? Understanding,
2 2,5
b) Compare EBM and LBM on the following aspects: Evaluating
i) Machining rate ii) Tool wear rate iii) Accuracy.
a) How does vacuum and heating of cathode help the
performance of electron beam? Analyzing,
3 1.5
b) Describe the thermal features of melting and evaporation Evaluating
process in LBM?
a) Explain the working of CO2 laser with neat sketch. Understanding,
4 2,5
b) Explain the production of laser beam with a neat sketch. Remembering
a) Write an equation to compute specific energy of vaporization
and mention the applications of EBM. Evaluating,
5 3,5
b) Explain the working of electron gun used in EBM with a neat Analyzing
sketch.
a) Describe the construction and working of “Micro-Drilling”
by LASER? Evaluating,
6 1,2
b) What is the need of doping of LASER and mention various Understanding
doping materials and their relative advantages?
a) Differentiate between EBM and LBM considering atleast five
aspects? Evaluating,
7 1,2
b) Compare the edge production in EBM and LBM. What are Analyzing
the factors influencing edge for maintain in both the processes?
a) Explain variation of temperature with distance from the
surface for various pulse durations in EBM.
Analyzing,
8 b) Describe the principles, equipments, solid state laser, gas 2,5
Applying
laser, thermal features applications and advantages of Laser
Beam Machining.
a) What is the function of electron beam gun?
Understanding,
9 b) Derive an expression for the dimensionless analysis to 1,5
Evaluating
establish correlation between EBM parameters.
a) Explain the principle and elements of EBM, also how the
work table is protected from getting damaged by electron beam. Understanding,
10 2,3
b) What is laser? Explain how it is used to machine the Remembering
materials.
 1 a) What are the various Etchants used in chemical machining?
Mention their characteristics? Evaluating,
1,2
b) Explain the advantages of dual gas and water injected plasma Applying
torch.

B) OBJECTIVE QUESTIONS:
JNTUH:
UNIT 1
1. One of the following is not the part of Mechanical Machining Processes.
a. Abrasive Jet Machining b. Water jet machining
c. Laser machining d. Ultrasonic Machining
2. In _____________ Kinetic energy of either abrasive particle is used to remove.
a. USM b. Plasma c. EDM d. EDM
3. Parametric Analysis depends on the following:
a. Abrasive size b. Dielectric strength c. Standoff distance d. Frequency of vibration
4. SOD stand for _______________.
a. Separation of Distance
b. Standoff Distance
c. Surface of Dimension
5. Gear shaving is a ________________ machining process.
a. Conventional b. Unconventional
6. Purpose of Concentrator in USM is ________________.
a. Generate low frequency electrical signals
b. Prevent cavitations erosion
c. Remove material from cavitations erosion
d. None of the above
7. Piezoelectric crystals generate __________________.
a) Generate Ultrasonic waves
b) Small electric Current
c) Reduce Tool wear
d) None of the above
8. Criteria for selecting abrasive grains used in USM are:
a. Hardness b. Particle size c. Usable lifetime d. All of the above
9. One of the following is not a commonly used Abrasive in USM.
a. AL2O3 b. SiC c. Boron Carbide d. Copper alloy
10. Magneto-strictive Transducer is a ________________.
a. A control valve b. Pipe carrying slurry
c. type of tool d. Device that converts frequencies
UNIT-2
1. Cost of surface finish increases sharply for a roughness value of less that ____ micron. a. 1
b. 5 c. 25 d. 50
2. AFM stands for ______________.
a. Abrasive finishes machining b. Abrasive fundamental machining
c. Absolute forever molding d. Abrasive Flow Machining
3. Bore of a Shaft is __________________.
a. External surface b. Internal surface c surface roughness d. Weight of the shaft
4. The stiffest media is used for ____ hole, while soft media is used for small holes.
5. Airfoil surface refers to a marching surface of the part found in _____________.
a. Boilers b. Multi-storied building c. Lathe machine d. Turbines and Compressors
6. Electrical energy is transported through metals by _________conduction of electric charges
from one place to another.
a. Conduction b. Convection c. Radiation d. None of these
7. ECM stands for ___________________.
a) Electrochemical machining b) Electronic Constituent Machinery
c) Energy Consumed Materially d) Electrochemical Moulding
8. What is the expansion for IEG _____________ .
9. It is very essential that in the process in ECM, to pump the electrolyte at very _____
pressure.
a. Low b. high c. very low d. moderate
10. ______________ is popularly used as Electrolytes in ECM.
a. Alkali’s b. Pure water c. basic salts d. magnetic slurry
UNIT- 3
1. EDM is a ________________ process.
a. Thermodynamic b. Gravimetric c .Thermodynamic d. Thermoelectric
2. Crater refers to _________ removed from the work piece
3. Debris refers to particles eroded from the _______________.
a. Wok piece b. electrodes c .dielectric solution concentration d. None of the above
4. Purpose of Servo system is to maintain between tool and work piece.
a. Maintain correct gap between tool and work piece
b. save the tool surface
c prevent the machine from burnout
d none of the above
5. The most labor intensive uncontrollable area in the manufacture of ______ parts involve
final machining operations.
UNIT-4
1. MASER stands for ________.
2. LASER stands for _____________.
3. Stimulated emission is _________________.
4. _______ light is monochromatic and its wavelength occupies a very narrow portion of the
spectrum.
 5. Electrical energy is transported through metals by _________conduction of electric charges
from one place to another.
a. Conduction b Convection c Radiation d None of these
UNIT -5
1. Abrasive Finishing process can produce _____ as good as 50 nm.
2. _______ act as cutting tools, hence it is multipoint cutting process.
3. The most labor intensive uncontrollable area in the manufacture of _____ involves final machining
operations.
4. Magneto-strictive Transducer is a ________________.
5. Purpose of ______ is to maintain between tool and work piece.

GATE & IES:

1. In ECM, the material removal is due to ____.
(a) Corrosion (b) erosion (c) fusion (d) ion displacement
2. The mechanism of material removal in EDM process is ____.
(a) Melting and Evaporation (b) Melting and Corrosion (c) Erosion and Cavitations
3. Arrange the processes in the increasing order of their maximum material removal rate.
Electrochemical Machining (ECM)
Ultrasonic Machining (USM)
Electron Beam Machining (EBM)
Laser Beam Machining (LBM) and
Electric Discharge Machining (EDM)
(A) USM, LBM, EBM, EDM, ECM
(B) EBM, LBM, USM, ECM, EDM
(C) LBM, EBM, USM, ECM, EDM
(D) LBM, EBM, USM, EDM, ECM
4. During the electrochemical machining (ECM) of iron (atomic weight = 56, valency = 2) at current
Of 1000 A with 90% current efficiency, the material removal rate was observed to be 0.26 gm/s. If
Titanium (atomic weight = 48, valency = 3) is machined by the ECM process at the current of
2000 A with 90% current efficiency, the expected material removal rate in gm/s will be
(A) 0.11 (B) 0.23 (C) 0.30 (D) 0.5
5. The primary mechanism of material removal in electrochemical machining (ECM) is ______.
6. The surface irregularities of electrodes used in an electrochemical machining (ECM) process are 3
μm and 6 μm as shown in the figure.

Conductivity of the electrolyte is 0.02 ohm-1mm-1, Over-potential voltage 1.5 V, Density of iron
7860 kg/m3. Atomic weight of iron 55.85 gm. Assume the iron to be dissolved as Fe+2 and the
 Faraday constant to be 96500 Coulomb. If the work-piece is of pure iron and 12V DC is applied
between the electrodes, the largest feed rate is ___________ mm/min.
7. I n a wire-cut EDM process the necessary conditions that have to be met for making a successful
cut are that:
(A) wire and sample are electrically non-conducting
(B) wire and sample are electrically conducting
(C) wire is electrically conducting and sample is electrically non-conducting
(D) sample is electrically conducting and wire is electrically non-conducting

WEBSITES:
1. http://www.nptel.ac.in/downloads/112105127/
2. http://www.nitc.ac.in/dept/me/jagadeesha/mev303/OVERVIEW_OF_NTM_PROCESSES.pdf
3. http://www.slideshare.net/vatsal30/unconventional-machining-process
4. http://www.tandfonline.com/doi/abs/10.1080/21693277.2014.899934
5. http://ymcaust.ac.in/tame2012/cd/production/P-40.pdf

EXPERT DETAILS:
1. Dr. Manzoor Hussain, Professor, JNTU, Hyderabad
2. Dr. Muralidhar, Scientist G, DRDL, Hyderabad
3. Dr. Sai Kumar, Scientist-G, DRDL, Hyderabad
4. Prof. S. Narendranath, Professor, NIT, Suratkal

JOURNALS:
1. The International Journal of Advanced Manufacturing Technology.
2. International Journal of Machine Tools & Manufacture.
3. The "Journal of Manufacturing Technology Research”.
4. International Journal of Materials Forming and Machining Processes.
5. International Journal of Precision Engineering and Manufacturing

LIST OF TOPICS FOR STUDENT SEMINARS:

1. Use of abrasive in non conventional Modeling Process
2. Electro chemical machining
3. Electrical discharge machining
4. Laser beam machining
5. Electron beam machining
6. Plasma machining-process parameters

CASE STUDIES/SMALL PROJECTS:

1. Study and detail the process of magnetic abrasive finishing and make a small presentation about
the practical applications of this technology
2. Study and derails the process of electrical discharge machining and explain the type of finish
components which can be manufactured from this technology
3. List out all the applications of laser manufacturing technology as applied in some of the modern
manufacturing process