This textbook is also useful to most of the students who are preparing for competitive exams. Index terms conventional methods, manufacturing processes, non conventional methods, properties of materials. His second book titled fundamentals of machining processesconventional and nonconventional processes has been appeared in september 2007 by crc, taylor and francis. Types, advantages, limitations, machine tool, cutting tool, chips. Other machining operations shaping and planing a singlepoint tool moves linearly relative to the work part shaping a tool moves planing a workpart moves broaching performed by a multipletooth cutting tool by moving linearly relative to the work in the direction of the tool axis.
Classification of unconventional machining processes. The unconventional machining use for the machine the hard and brittle materials such as carbides, stainless steel, hastelloy, nitralloy, waspalloy, and any other that cannot be machined by a conventional process using the conventional machines such as lathe, milling, shaper, planer etc. Unconventional machining process linkedin slideshare. Pdf selection of nonconventional machining processes. During the electrochemical machining ecm of iron atomic weight 56, valency 2 at current of a with 90% current efficiency, the material removal rate was observed to be 0. This machining process is especially ideal for cutting materials that cannot be cut by laser or thermal cut. 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. Unconventional machining process sasurie college of engineering. These processes are generally used when traditional methods are not technically or economically feasible.
Nontraditional processes ntp nontraditional cutting. What are the design factors to be considered while selecting the machine tool. Fundamentals of machining processes by hassan abdel contains total 16 chapters, such as cutting tools, maintainability, micromachining, high speed machining, abrasives etc. Jain department of mechanical engineering, indian institute of technology kanpur, kanpur208016, india. The classification of unconventional machining processes is given below. The common nontraditional machining processes are described in this section. 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. 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. Nonconventional machining processes selection using multiobjective 1449 journal of engineering science and technology november 2015, vol. A machining process is called nontraditional if its material removal mechanism is basically different than those in the traditional processes, i. A typical nonconventional process is the machining of abrasive discs using diamond adopted in 1955 or synthetic tools cubic boron carbide 1970. 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.
Pdf unconventional machining processes local author by. 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. Unconventional machining processes can be broadly classified into several types based on four main criteria. 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. In cm material is removed from selected areas of workpiece by immersing it in a chemical reagents or etchants. The term metal cutting is used when the material is metallic. Types of unconventional machining process manufacturing. Pdf nonconventional machining processes selection using. Pdf me6004 unconventional machining process researchgate.
Senthil kumar, ars publications the book unconventional machining processes for engineering and technology studies. Unconventional machining process need classification brief overview of all techniques. Conventional and nonconventional processes covers the fundamentals machining by cutting, abrasion, erosion, and combined processes. Page 2 the emerson laboratory what is the emerson laboratory.
Cutting processes remove material from the surface of workpiece by producing chips. The main reasons for choosing nontraditional machining processes are. Unconventional machining processes textbook is one of the famous textbook for engineering students. 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. Removal of unwanted material in the form of chips in order to create a geometric shape market. Simply stated, it is an area where students, faculty, staff, and all other members of the cornell community. Machining operations is viewed as a system consisting of. The basic usm process involves a tool made of a ductile and tough material vibrating with a low amplitude and very high frequency and a continuous flow of an abrasive slurry in the small gap between the tool and the work piece. Unconventional machining process need classification brief overview. In order to realize the manufacturingmachining demands thrived by newer, hard and difficulttomachine materials being utilized in the present day industries, an assortment of nontraditional machining ntm processes has been developed over the past few decades. Please switch to hard cover of fundamentals of machining process. Professor elhofy wrote his first book titled advanced machining processes. This book is mainly useful for mechanical engineering students.
The introduction of abrasives to the fluid jet enhances the machining efficiency and is known as abrasive water jet machining. Unconventional machining processes introduction and. The applicable processes differ in the spectrum of machinable geometry, removal rate. An introduction to machining practices cornell university. An unconventional machining process or nontraditional machining process is a special type of machining process in which there is no direct contact between the tool and the workpiece. In some applications these processes replaced almost completely the aluminium oxide processes 1893 and the green silicon carbide processes 1891. Mechanical energy based unconventional machining processes e. Advancedunconventionalnon traditional machining process an. Conventional and nonconventional processes written by hassan abdel gawad elhofy covers the fundamentals machining by cutting, abrasion, erosion and combined processes. Advanced processes include electrical and chemical means of material removal, as well as the use of abrasive jets, water. Machining material removal by a sharp cutting tool, e. Nielsen book data summary completely revised and updated, this second edition of fundamentals of machining processes. Most machining has very low setup cost compared to forming, molding, and casting processes.
Ajm characteristics work material hard and brittle materials abrasive al 2 o 3, sic, glass powder size of abrasive around 25 microns flow rate 2 to 20 gmin medium n 2, co 2 or air velocity 125 to 300ms pressure 2 to 8 kgcentimetre square nozzle material tungsten carbide or synthetic sapphire. The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process. 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. Traditional machining processes consist of turning, boring, drilling, reaming, threading, milling, shaping, planing, and broaching, as well as abrasive processes such as grinding, ultrasonic machining, lapping, and honing. Analysis of part drawing and assembly drawing this is the basis of the machining. Nontraditional machining processes are widely used to manufacture geometrically complex and precision parts for aerospace, electronics and automotive.
In many cases, the engineering materials cannot be machined by traditional machining processes because of their shape and material type and other effective factors 3. Hence the machining process which utilizes other machining methods are termed as unconventional machining or nontraditional machining or advanced machining processes or modern machining processes. This book is written to serve the needs of under graduate students embarking introductory course in unconventional machining processes. Unconventional machining processes textbook pdf free download unconventional machining processes textbook pdf free download. It is a process in which a piece of raw material is cut into a desired shape and size by means of sharp cutting tools called a machining process. 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 gms will be. The removal of material can be achieved by cutting, abrasion, and erosion. 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. Conventional machining uses tools, such as lathes, milling machines, boring machines, drill presses, or. Tools that belongs to reaming and tapping processes are tend to breakage so machinists should behave carefully not to break tapers and reamers pieces in the hole. Metallic, nonmetallic and advanced composite materials of various thicknesses can be cut by this process. The former onesprovide basic shape and size to the material as per designers requirement. 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. Manufacturing processes can be broadly divided into two groups and they are primarymanufacturing processes and secondary manufacturing processes.
Machining can be defined as the process of removing material from a workpiece in the form of chips. Introduction to nontraditional machining iit kanpur. Unconventional machining processes textbook pdf free. Nontraditional 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. In terms of annual dollars spent, machining is the most important of the manufacturing processes. Chemical machining cm is the controlled dissolution of workpiece material etching by means of a strong chemical reagent etchant. While making a part from raw material, one may require bulk removal of material, forming cavitiesholes and finally finishing as per the parts requirements. There is a large number of machining processes available for making precise mold inserts for e. 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. The aim of the mtcs nonconventional machining ncm theme is to provide efficient, costeffective solutions for the manufacture of traditionally difficult to machine materials using stateoftheart spark erosion and laser technologies. 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. Examples of conventional machining processes are turning, boring, milling, shaping, broaching, slotting, grinding etc. Selection of nonconventional machining processes using the ocra method article pdf available in serbian journal of management 101 september 2014 with 1,732 reads how we measure reads. Introduction we all know that the term machinability refers to the case with which a metal can be machined to an acceptable surface finish.
There are 10 steps to draw up machining process flow chart. Regarding these, nontraditional machining ntm processes have been developed since the world war ii largely in response. 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. Turning operation is a machining process and is used to produce. In unconventional machining, a form of energy is used to remove unwanted material from a given workpiece. A new nontraditional machining method using cavitation.
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