DOC/LP/01/28.02.

02

LESSON PLAN

LP-MR ME2026
LP Rev. No: 00

Sub Code & Name : ME2026 UNCONVENTIONAL MACHINING

PROCESS
Unit: 01

Branch: Mechanical Engg

Date: 15.12. 10
Page 01 of 06

Semester : VI

Unit syllabus: INTRODUCTION

Unconventional machining Process Need classification Brief overview of all
techniques
Objective:
To make the students familiar with the needs and the different types of unconventional
machining processes.
Session
No

1
2
3
4
5

Topics to be covered

Introduction to unconventional machining

processes, their needs and classification
Brief introduction to the type of energy source
employed in AJM, USM , WJM
Brief introduction to the type of energy source
employed in EDM, ECM, ECG
Brief introduction to the type of energy source
employed in EDM, ECM, ECG
Brief introduction to the type of energy source
employed in LBM, PAM,EBM

Time

Ref

Teaching
Aids

50 min

BB/OHP

50 min

1,2,3,
4
1,2,3

50 min

1,2,3

BB/OHP

50 min

1,2,3

BB/OHP

50 min

1,3,4

BB/OHP

BB/OHP

DOC/LP/01/28.02.02

LESSON PLAN

LP-MR ME2026
LP Rev. No: 00
Date: 15.12. 10

Sub Code & Name : ME2026 UNCONVENTIONAL MACHINING

PROCESS
Unit: 02

Branch: Mechanical Engg

Page 02 of 06

Semester : VI

Unit syllabus: MECHANICAL ENERGY BASED PROCESSES

Abrasive Jet Machining Water Jet Machining Ultrasonic Machining. (AJM, WJM
and USM). Working Principles equipment used Process parameters MRR-Variation
in techniques used Applications.
.
Objective:
To make the students familiar with the principles, process parameters, applications, and
recent trends of AJM, WJM and USM.
Session
No

06
07
08
09
10
11
12
13
14
15
16

Topics to be covered

Time

Ref

Teaching
Aids

Abrasive Jet Machining, Working Principle

equipment used
Abrasive Jet Machining ,Process parameters

50 min 1,3,4

BB/OHP

50 min 1,2

BB/OHP

Abrasive Jet Machining, MRR-Variation in

techniques used, Applications
Water Jet Machining, Working Principle
equipment used
Water Jet Machining- Process parameters

50 min 1,3

BB

50 min 1,3,4

BB

50 min 1,3,5

BB

Water Jet Machining ,MRR-Variation in

techniques used, Applications
Ultrasonic Machining, Working Principle
equipment used
Ultrasonic Machining ,Process parameters

50 min 1,3

BB/OHP

50 min 1,3,5

BB/OHP

50 min 1,3

BB/OHP

Ultrasonic Machining, MRR-Variation in

techniques used, Applications
Comparison of process capabilities and
parametric analysis
CAT - I

50 min 1,3

BB/OHP

50 min 1,3,5

BB/OHP

DOC/LP/01/28.02.02

LESSON PLAN

LP-MR ME2026
LP Rev. No: 00
Date: 15.12.10

Sub Code & Name : ME2026 UNCONVENTIONAL MACHINING

PROCESS
Unit: 03

Branch: Mechanical Engg

Page 03 of 06

Semester : VI

Unit syllabus: ELECTRICAL ENERGY BASED PROCESSES

Electric Discharge Machining (EDM)- working Principles-equipments-Process
Parameters-MRR- electrode / Tool Power Circuits-Tool Wear Dielectric Flushing
Wire cut EDM Applications.
Objective:
At the end of this unit the student would have learnt about the principles, process
parameters, applications, and recent trends of EDM.
Session
No

Topics to be covered

Time

Ref

Teaching
Aids

17

Electric Discharge Machining (EDM)- working

Principle

50 min 1,2,4,

BB/OHP

18

Electric Discharge Machining (EDM)

equipments-Process Parameters
MRR- electrode / Tool Power Circuits
Characteristic of the Electric Discharge
Machining process
Dielectric, Flushing

50 min 1,2,4,
5
50 min 1,2,4,
50 min 1,2,4,

BB/OHP

50 min 1,2,4,
5
50 min 1,2,4,
50 min 1,2,4,
50 min 1,2,4,

BB/OHP

19
20
21
22
23
24

Wire cut EDM working Principles

Process Parameters, equipments
Characteristic of Machining process,
Applications.

BB/OHP
BB/OHP

BB/OHP
BB/OHP
BB/OHP

DOC/LP/01/28.02.02

LESSON PLAN

LP-MR ME2026
LP Rev. No: 00
Date: 15.12.10

Sub Code & Name : ME2026 UNCONVENTIONAL MACHINING

PROCESS
Unit: 04

Branch: Mechanical Engg

Page 04 of 06

Semester : VI

Unit syllabus: CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES

Chemical machining and Electro-Chemical machining (CHM and ECM)- Etchantsmaskant- techniques of applying maskants-Process Parameters MRR-Applications.
Principles of ECM-equipments-MRR-Electrical circuit-Process Parameters-ECG and
ECH Applications.
Objective:
At the end of this unit the student would have learnt about the chemical and electrochemical energy based processes
Session
No

Topics to be covered

Time

Ref

Teaching
Aids

25
26
27
28
29

Chemical machining, working Principle

Etchants, Maskant,
Techniques of applying maskants
Process Parameters MRRPrinciples of ECM, Electrolysis, Functions of
Electrolyte and its importance
ECM machine tool, equipments
CAT - II
Electrical circuit, MRR
Process Parameters of ECM, parametric analysis
Principles of ECG, ECG Machine Tool
Equipments, Process Parameters
Electrical circuit, MRR
Process Parameters ,Process characteristics

50 min
50 min
50 min
50 min
50 min

1,2,4
2,3,4
1,4
2,3
1,2,3

BB/OHP
BB
BB/OHP
BB/OHP
BB

50 min
50 min
50 min
50 min
50 min
50 min
50 min

2,4,5
1,4
1,4
1,4,5
2,3,4
2,3,4
2,3,4

BB
BB/OHP
BB
BB
BB/OHP
BB/OHP
BB/OHP

30
31
32
33
34
35
36
37

DOC/LP/01/28.02.02

LESSON PLAN

LP-MR ME2026
LP Rev. No: 00
Date: 15.12.10

Sub Code & Name : ME2026 UNCONVENTIONAL MACHINING

PROCESS
Unit: 05

Branch: Mechanical Engg

Page 05 of 06

Semester : VI

Unit syllabus: THERMAL ENERGY BASED PROCESSES

Laser Beam machining (LBM), plasma Arc machining (PAM) and Electron Beam
Machining (EBM). Principles-Equipment- Types-Beam control techniques
Applications.
Objective:
At the end of this unit the student would have learnt about the thermal energy based
processes
Session
No

Topics to be covered

Time

Ref

Teaching
Aids

38
39
40
41
42
43
44

Laser Beam machining ,LBM -working Principle

Types of laser, Equipments
Process Parameters ,Process characteristics
plasma Arc machining (PAM) working Principle
plasma Arc cutting system, Equipments
Process Parameters ,Process characteristics
Electron Beam Machining (EBM)- working
Principle
Electron Beam machining system, Equipments
Process Parameters ,Process characteristics
Beam control techniques Comparison of
process capabilities, Applications.

50 min
50 min
50 min
50 min
50 min
50 min
50 min

1,3,5
1,4,5
1,2,4
1,2
1,3,4
1,3,4
1,4,5

BB/OHP
BB
BB
BB
BB/OHP
BB/OHP
BB/OHP

50 min 1,4,5
50 min 1,4
50 min 1,4

BB/OHP
BB/OHP
BB/OHP

CAT - III

45
46
47
48

DOC/LP/01/28.02.02

LESSON PLAN

LP-MR ME2026
LP Rev. No: 00

Sub Code & Name : ME2026 UNCONVENTIONAL MACHINING

PROCESS
Unit: ---

Branch: Mechanical Engg

Date: 15.12. 10
Page 06 of 06

Semester : VI

Course Delivery Plan:

Week

10

11

12

13

14

15

I II

I II

I II

I II

I II

I II

I II

I II

I II

I II

I II

I II

I II

I II

I II

Units

Text Books and References:

1.
2.
3.
4.
5.

Vijay.K. Jain Advanced Machining Processes Allied Publishers Pvt. Ltd., New Delhi (2002)
ISBN 81-7764-294-4.
Benedict. G.F. Nontraditional Manufacturing Processes Marcel Dekker Inc., New York (1987).
Pandey P.C. and Shan H.S. Modern Machining Processes Tata McGraw-Hill, New Delhi
(1980).
Mc Geough, Advanced Methods of Machining Chapman and Hall, London (1998).
Paul De Garmo, J.T.Black, and Ronald.A.Kohser, Material and Processes in Manufacturing
Prentice Hall of India Pvt. Ltd., New Delhi (8th Edition) (2001) ISBN 81-203-1243-0.

Prepared by

Approved by

Dr. R. Ramesh
Professor
15.12. 10

Dr.N.Nalluswamy
Professor & Head ME
15.12. 10

Signature
Name
Designation
Date

DOC/LP/01/28.02.02

B.E. /B.TECH DEGREE EXAMINATION, APRIL/MAY 2008.

Sixth Semester
(Regulation 2004)
Mechanical Engineering
ME1001 UNCONVENTIONAL MACHINING PROCESS
Time: Three hours Maximum: 100 marks
PART A - (102 = 20 MARKS)
1. Enlist the requirement that demands the use of advanced machining process.
2. Why unconventional mechanical machining process is not so effective on soft metals like
aluminium?
3. Mention the application of catcher in water jet machining.
4. What are the characteristics of a good suspension media of the USM process?
5. What do you mean by recast layer with reference to the EDM?
6. What are the functions of adaptive control used for EDM?
7. What is the self adjusting feature in ECM?
8. What do you understand by Etch Factor?
9. What is the function of water muffler in PAM?
10. Can you machine electrically non-conducting materials using EBM process?
PART B - (5*16 = 80 marks)
11. (a) (i) Explain the factors that should be considered during the selection of an appropriate
unconventional machining process for a given job. (8)
(ii) Compare and contrast the various unconventional machining process on the basis of type
of energy employed, material removal rate, transfer media and economical aspects. (8)
OR
(b) (i) Explain the principles and elements of EBM, also how the work table is protected from
getting damaged by electron beam. (8)
(ii) Discuss how the process variables influence MRR, HAZ and pattern generation. (8)
12. (a) (i) Explain the principle of AJM. Mention some of the specific applications. (6)
(ii) Discuss in detail about the AJM process variables that influence the rate of material
removal and accuracy in the machining. (10)
OR
(b) (i) Discuss in detail about the methods of generating the ultrasonic characteristics of the

DOC/LP/01/28.02.02

various types of tool holder and tool feed mechanisms in USM. (10)
(ii) Briefly discuss the mechanisms involved in material removal by USM. (6)
13. (a) (i) Explain the classification and characteristics of various spark erosion generators. (8)
(ii) With help of neat sketch describe the mechanism of material removal in EDM. (8)
OR
(b) (i) Explain the working principle, elements and characteristics of wire EDM. (10)
(ii) Explain how the stratified wire works. Also discuss about the recent developments in wire
EDM. (6)
14. (a) (i) Describe the chemistry involved in ECM process. (8)
(ii) Briefly discuss about the effect of high temperature and pressure of electrolyte on the ECM
process. (4)
(iii) Discuss about the economics of ECM. (4)
OR
(b) (i) Describe the working principle and elements of chemical machining. What are the
factors on which the selection of a resist for use in chemical machining? (10)
(ii) What are the specific advantages of using chemical machining over electro chemical
machining? Give some of the practical applications of chemical machining process. (6)
15. (a) (i) What is non transferred and transferred mode of plasma arc? Explain the
mechanism of material removal in PAM. (8)
(ii) Discuss the factors that influence the quality of the cut in PAM. (8)
OR
(b) (i) What is laser? Explain how it is used to machine the materials. (6)
(ii) Discuss in detail the thermal features and analysis of laser beam machining. (10)
------THE END------