ELECTROCHEMICAL MACHINING (ECM)

Electrochemical Machining (ECM) is a non-traditional machining process belonging to

electrochemical category. ECM is opposite of electroplating or galvanic coating.
ECM is a controlled anodic dissolution process at atomic level of the work piece that
is electrically conductive by a shaped tool due to flow of high current at relatively low potential
difference through an electrolyte.
Here a cathode (tool) is advanced into an anode (workpiece). The pressurized electrolyte
is injected to the area being cut. The feed rate is the same as the rate of "liquefication" of the
material. The gap between the tool and the workpiece varies within 80-800 micrometers (.003 in.
and .030 in.). As electrons cross the gap from the tool and they reacts with metal solution and
forms products. Continuous electrolyte flow helps to wash away the reaction products formed
during the electrochemical reactions.
 ELECTRICAL DISCHARGE MACHINE

Electric discharge machining (EDM) is a non-traditional machining processes that

Involved a transient spark discharges Tool steels work pieces using electrical
discharge machining (EDM). Basically, through the fluid due to the potential
difference between the electrode and the work piece. The aim of this project is to
determine the proper electrode material for machining improper choose of
electrode material in EDM machine may result a few problems like the machine
may cause of poor machining performance and it will decrease the accuracy of
the products. This paper presents a fundamental study of characteristic of
electrode discharge machine (EDM)that is electrode wear ratio (EWR) and
material removal rate (MRR) by using different electrode materials in order to
increase the understanding of EDM processes. To archive this project objective,
an experiment will be doing properly.
By following the method, some literature review is going to do first before
preparing the experimental set-up. Then experiment will be runs and the data of
the experiment are taken. This is to make sure the analysis can be done in order
to find the best electrode material. There are three electrodes material should be
compared that are copper, brass and aluminum. Regarding the literature review,
the higher material removal rate in the EDM machine, the better is the machining
performance while the lower electrodes wear ratio in the EDM machine is the
better and accurate performance characteristic. Thus as the expected result for
this experiment, the copper electrode material will be the best electrode among
others electrode for EDM machining process.
 PLASTIC WELDING

Plastic welding and spot welding - both are almost similar to each other.
There is a difference noted. In plastic welding, heat is supplied through
convection of the pincher tips, instead of conduction. The two plastic pieces are
brought together. At the time of welding, a jet of hot air is liberated This melts
the parts to be joined along with the plastic filler rod. As the rod starts melting, it
is forced into the joint and causes the fusion of the parts.
Using plastic welding, two plastics can be welded together. This type of
weld is performed on children's toys, lawn furniture, auto parts and other plastic
equipments which are used daily - both for domestic and commercial purposes. In
order to join the thermoplastics, when they are heated an under a particular
pressure, this type of welding is employed. In normal practice, using filler
material, the pieces are joined together.
 WELDING ROBOTS
Welding being the major asset and salvation for engineering the seminar is all
about the automation of major welding processes used in industries using robots,
which was hitherto done manually under hazardous and perilous working
environs. The seminar dwells two major industrial welding processes namely
continuous arc welding processes and spot welding processes. It also connects
with essential features of the robots used in these welding processes and also the
advantages and disadvantages of these industrial robotic welding processes.
 FIRE SAFETY VALVE
In recent years, many factors have contributed to an increased demand for fire-safe
valves. Engineers and plant managers have faced the rising cost of insurance for
liability and property damage. There has been an across-the-board tightening of
environmental and safety regulations. Also, the cost of replacing damaged property
and the expense of after-fire clean-ups have skyrocketed.
In recent years, specification of fire safe valves has been increasing. Ideally, a
"fire-safe" valve will be leak-free at normal service temperatures and during and
after a fire. Yet, these valves permit small amount of internal and external
leakage, and stem and packing leakage, when subjected to fire. The term "fire-
safe" is ambiguous. Thus, the valve specification engineer must know fire-test
standards, real expectations, ad vantages and disadvantages, and the future
liability associated with fire-safe valves. He must be familiar with the pitfalls of
using them in an application where a standard, non-fire-safe valve
would do better. The engineer should know what steps assure fire safety when a
system really does require fire protection.
 INDUSTRIAL ROBOTS

Changes in todays manufacturing environment allow tedious, fatiguing and

repetitive tasks to be mechanically performed by robots, as manually
controlled work is transition to auto-cycle control equipment. Such changes
tend to take advantage of, and expand upon, an operators process
knowledge. As this trend continuous, the operators contribution becomes
more technically oriented and less physically oriented with significantly greater
product output being released.

A robot is a reprogrammable multifunctional manipulator designed to

move materials , parts , tools or specialized devices through variable
programmed motions for the performance of variety of tasks.
A robot may include a feedback-driven connection between sense and
action, not under direct human control, although it may have a human
override function. The action may take the form of electro-magnetic
motors or actuators (also called effectors) that move an arm, open and
close grips, or propel the robot. The step by step control and feedback is
provided by a computer program run on either an external or embedded
computer or a microcontroller. By this definition, a robot may include
nearly all automated devices.

In industries the robots are widely used for developing and improving the
productivity and quality of product . The industrial robots are used in various
fields applicable in following categories .
 ESCALATOR

An escalator is a moving staircase conveyor transport device for carrying

people between floors of a building. The device consists of a motor-driven chain
of individual, linked steps that move up or down on tracks, allowing the step
treads to remain horizontal.

Escalators are used around the world to move pedestrian traffic in places
where elevators would be impractical. Principal areas of usage include
department stores, shopping malls, airports, transit systems, convention centers,
hotels, and public buildings. The benefits of escalators are many. They have the
capacity to move large numbers of people, and they can be placed in the same
physical space as one might install a staircase. They have no waiting interval
(except during very heavy traffic), they can be used to guide people toward main
exits or special exhibits, and they may be weatherproofed for outdoor use.
Escalators are one of the largest, most expensive machines people use on a
regular basis, but they're also one of the simplest. At its most basic level, an
escalator is just a simple variation on the conveyer belt. A pair of rotating chain
loops pull a series of stairs in a constant cycle, moving a lot of people a short
distance at a good speed. In this article, we'll look inside an escalator to find out
exactly how these elements fit together. While it is exceedingly simple, the
system that keeps all the steps moving in perfect synchrony is really quite
brilliant.
 FUEL ENERGISER

In this era of increasing fuel prices, here a device called FUEL ENERGIZER
help us to Reduce Petrol /Diesel /Cooking gas consumption up to 28%, or in other
words this would equal to buying the fuel up to 28% cheaper prices.
When fuel flow through powerful magnetic field created by Magnetizer
Fuel Energizer, The hydrocarbons change their orientation and molecules in them
change their configuration. Result: Molecules get realigned, and actively into
locked with oxygen during combustion to produce a near complete burning of
fuel in combustion chamber.
 TUNNEL BORING MACHINE

Tunnel boring machines (TBM) are used to excavate tunnels with a circular
cross section through a variety of geologies. They can be used to bore through hard
rock or sand and almost anything in between. Tunnel diameters can range from a
metre (done with micro-TBMs) to 15 metres. The two biggest were built in 2005 to
dig two tunnels for the same urban project in Madrid (Spain). Dulcinea and Tizona,
as they were called, have diameters of 15 metres. Tunnels of less than a metre or so
in diameter are more typically done by horizontal directional drilling rather than by
TBMs. Tunnel boring machines are used as an alternative to drilling and blasting
(D&B) methods. A TBM has the advantages of not disturbing surrounding soil and
producing a smooth tunnel wall. This significantly reduces the cost of lining the
tunnel, and makes them suitable to use in built-up areas. The key disadvantage is
cost. TBMs are expensive to construct, difficult to transport and require significant
infrastructure.