Nontraditional Manufacturing Processes: Mf30604: Aknath Lecture No.-1 Introduction To Ntmps
Nontraditional Manufacturing Processes: Mf30604: Aknath Lecture No.-1 Introduction To Ntmps
Nontraditional Manufacturing Processes: Mf30604: Aknath Lecture No.-1 Introduction To Ntmps
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Conventional Machining Processes (Material Removal): Primarily rely on electrical motors and hard tool materials to perform tasks e.g. Turning, Drilling, Boring, Milling, Shaping, Sawing, Slotting, & Grinding etc.
Main Characteristics of Conventional Machining: * Material removal by chip formation * Material removal by mechanical force * Cutting tool harder than work piece under machining condition * Direct mechanical contact - residual mechanical & thermal stress.
Other requirements of the New Manufacturing Process Low machining cost * Automated processing, Fast production Rapid change of Product design * Elimination of Traditional tooling to reduce time & cost Less Temperature rise or residual stresses
Photochemical Machining
Electro-Discharge Machining
* Mechanical NTM Processes( Plastic deformation / Abrasive Erosion) - Abrasive Jet Machining (AJM)
- Ultrasonic Machining (USM) - Water Jet Machining (WJM) - Abrasive Water Jet Machining (AWJM)
Characteristics of Modern / Non Traditional Machining (NTM) Processes: Mostly NTM processes do not use mechanical energy for material removal. They use different forms of energy for machining. Example, USM, AJM, WJM - Mechanical energy ECM- Electrochemical dissolution Laser, EDM, EB - Thermal Material removal with chip formation or even without chip formation Example: AJM - Microscopic size chips ECM - Electrochemical dissolution at atomic level In NTM, Physical tool may or may not be present. Example: Laser beam machining- No tool, Electrochemical Machining- Physical tool needed In NTM, Tool need not be harder than the work piece material. Example: EDM, copper tool to machine hardened steels. Nontraditional media for energy transfer: EDM: Dielectric fluid, Laser: Coherent photon beam
Perform operation not feasible by traditional Manufacturing Processes, Example drilling holes of very high depth to width aspect ratio, 100:1 Easy automation, On-line Process Monitoring & Control: Increased reliability, repeatability; reduced human involvement Versatile & Virtually unlimited Capability: Ex.- Laser can cut most materials of any hardness: diamond, metals, concrete, glass, plastics, textiles, wood etc. Drill holes of any diameter
Course Outline by Topical Areas: Introduction to Nontraditional Manufacturing Processes Thermal Processing: Laser Beam Machining (LBM): Fundamentals of Materials Processing- (Laser cutting, drilling, welding, surface modification- hardening, alloying, cladding; marking, micro-machining, laser rapid prototyping & manufacturing) Equipment for Laser Beam Processing Electron Beam Machining (EBM) Fundamentals of Materials Processing (Ebeam machining, welding, lithography) Plasma Arc Machining (PAM): Cutting, Welding & Plasma Spraying Ion-Beam Machining (IBM): Ion Beam removal, deposition, surface treatment Mechanical NTM Processes( Plastic deformation / Abrasive Erosion) - Abrasive Jet Machining (AJM) - Ultrasonic Machining (USM) - Water Jet Machining (WJM) - Abrasive Water Jet Machining (AWJM)
Abrasive Machining
Laser Cutting
Course Materials : Lecture Notes Reference Books : 1. Nontraditional Manufacturing Processes Gary F. Benedict, Marcel Dekker,Inc 2. Modern Machining Processes P C Pandey & H S Shan, Tata McGraw-Hill 3. Nonconventional Machining P K Mishra, Narosa Publishing House 4. Manufacturing Science Amitabha Ghosh & A K Mallik, Affiliated East-West Press 5. www.nptel.iitm.ac.in National Programme on Technology Enhanced Learning (NPTEL) Course- IIT Kharagpur- Manufacturing-Module 9 (on NTM) Lessons 35-40. 6. Laser Material Processing, by W M Steen