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NON TRADITIONAL MACHINING Semester IV

Course Code BME405A CIE Marks 50
Teaching Hours/Week (L: T:P: S) 3:0:0:0 SEE Marks 50
Total Hours of Pedagogy 40 Total Marks 100
Credits 03 Exam Hours 03
Examination nature (SEE) Theory/practical/Viva-Voce /Term-work/Others
Course Objectives:
• To learn various concepts related to modern machining processes & their applications.
• To appreciate the differences between conventional and non-conventional machining
processes.
• To acquire a functional understanding of non-traditional manufacturing equipment.
• To know about various process parameters and their influence on performance and their
applications.
• To impart knowledge on various types of energy involved in non-traditional machining
processes.
Teaching-Learning Process (General Instructions)
These are sample Strategies, which teachers can use to accelerate the attainment of the various course
outcomes.
• Adopt different types of teaching methods to develop the outcomes through
PowerPoint presentations and Video demonstrations or Simulations.
• Chalk and Talk method for Problem Solving.
• Adopt flipped classroom teaching method.
• Adopt collaborative (Group Learning) learning in the class.
• Adopt Problem Based Learning (PBL), which fosters students’ analytical skills and
develops thinking skills such as evaluating, generalizing, and analyzing information.
Module-1
Introduction to Non-traditional machining
Introduction to Non-traditional machining, Need for Non-traditional machining process, Comparison
between traditional and non-traditional machining, general classification Non-traditional machining
processes, classification based on nature of energy employed in machining, selection of non-traditional
machining processes, Specific advantages, limitations and applications of non-traditional machining
processes.
Module-2
Ultrasonic Machining (USM):
Introduction, Equipment and material process, Effect of process parameters: Effect of amplitude and
frequency, Effect of abrasive grain diameter, effect of slurry, tool & work material. Process characteristics:
Material removal rate, tool wear, accuracy, surface finish, applications, advantages & limitations of USM.
Abrasive Jet Machining (AJM):
Introduction, Equipment and process of material removal, process variables: carrier gas, type of abrasive,
work material, stand-off distance (SOD). Process characteristics-Material removal rate, Nozzle wear,
accuracy & surface finish. Applications, advantages & limitations of AJM.
Module-3
Electrochemical machining (ECM):
Introduction, Principle of electro chemical machining, ECM equipment, elements of ECM operation,
Chemistry of ECM. ECM Process characteristics: Material removal rate, accuracy, surface finish. Process
parameters: Current density, Tool feed rate, Gap between tool & work piece, velocity of electrolyte flow,
type of electrolyte, its concentration temperature, and choice of electrolytes. ECM Tooling: ECM tooling
technique & example, Tool & insulation materials. Applications ECM: Electrochemical grinding and
electrochemical honing process. Advantages, disadvantages and application of ECG, ECH.
Chemical Machining (CHM):
Elements of the process, Resists (maskants), Etchants. Types of chemical machining process-chemical

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blanking process, chemical milling process. Process characteristics of CHM: material removal rate, accuracy,
surface finish, advantages, limitations and applications of chemical machining process.
Module-4
Electrical Discharge Machining (EDM):
Introduction, mechanism of metal removal, EDM equipment: spark erosion generator (relaxation type),
dielectric medium-its functions & desirable properties, electrode feed control system. Flushing types;
pressure flushing, suction flushing, side flushing, pulsed flushing. EDM process parameters: Spark frequency,
current & spark gap, surface finish, Heat Affected Zone. Advantages, limitations & applications of EDM,
Electrical discharge grinding, Traveling wire EDM.
Plasma Arc Machining (PAM):
Introduction, non-thermal generation of plasma, equipment mechanism of metal removal, Plasma torch,
process parameters, process characteristics. Safety precautions. Safety precautions, applications, advantages
and limitations.
Module-5
Laser Beam Machining (LBM):
Introduction, generation of LASER, Equipment and mechanism of metal removal, LBM parameters and
characteristics, Applications, Advantages & limitations.
Electron Beam Machining (EBM):
Introduction, Principle, equipment and mechanism of metal removal, applications, advantages and
limitations.
Course outcome (Course Skill Set)
At the end of the course, the student will be able to :
CO1: Describe non-traditional machining process and compare with Traditional machining
process. Recognize the need for Non-traditional machining process.
CO2: Describe the constructional features, performance parameters, process characteristics,
applications, advantages, and limitations of USM, AJM and WJM.
CO3: Characterize the need of Chemical and electro-chemical machining process along with the
constructional features, process parameters, process characteristics, applications,
advantages, and limitations.
CO4: Illustrate the constructional feature of the equipment, process parameters, process
characteristics, applications, advantages and limitations EDM & PAM

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Assessment Details (both CIE and SEE)

The weightage of Continuous Internal Evaluation (CIE) is 50% and for Semester End Exam (SEE) is
50%. The minimum passing mark for the CIE is 40% of the maximum marks (20 marks out of 50)
and for the SEE minimum passing mark is 35% of the maximum marks (18 out of 50 marks). A
student shall be deemed to have satisfied the academic requirements and earned the credits allotted
to each subject/ course if the student secures a minimum of 40% (40 marks out of 100) in the sum
total of the CIE (Continuous Internal Evaluation) and SEE (Semester End Examination) taken
together.

Continuous Internal Evaluation:

• For the Assignment component of the CIE, there are 25 marks and for the Internal Assessment
Test component, there are 25 marks.
• The first test will be administered after 40-50% of the syllabus has been covered, and the
second test will be administered after 85-90% of the syllabus has been covered
• Any two assignment methods mentioned in the 22OB2.4, if an assignment is project-based then
only one assignment for the course shall be planned. The teacher should not conduct two
assignments at the end of the semester if two assignments are planned.
• For the course, CIE marks will be based on a scaled-down sum of two tests and other methods of
assessment.
Internal Assessment Test question paper is designed to attain the different levels of Bloom’s taxonomy
as per the outcome defined for the course.

Semester-End Examination:
Theory SEE will be conducted by University as per the scheduled timetable, with common question papers for
the course (duration 03 hours).
1. The question paper will have ten questions. Each question is set for 20 marks.
2. There will be 2 questions from each module. Each of the two questions under a module (with a maximum
of 3 sub-questions), should have a mix of topics under that module.
3. The students have to answer 5 full questions, selecting one full question from each module.
4. Marks scored shall be proportionally reduced to 50 marks.

Suggested Learning Resources:

Books
TEXT BOOKS:
1. Modern Machining Process by P.C Pandey and H S Shah, McGraw Hill Education India Pvt. Ltd.
2000
2. Wellar, E.J. "Non-Traditional Machining Processes", Society of Manufacturing Engineers
Publications, 2nd Edition, Michigan, 1984.
3. Non Traditional Manufacturing Processes, by Gary F Benedict, Taylor & Francis

REFERENCE BOOKS:
1. Production technology, HMT, McGraw Hill Education India Pvt. Ltd. 2001
2. New Technology, Dr. Amitabha Bhattacharyya, The Institute of Engineers (India), 2000
3. Modern Machining process, Aditya, 2002.
4. Non-Conventional Machining, P.K.Mishra, The Institution of Engineers (India) Test book series,
Narosa Publishing House – 2005.
5. Metals Handbook: Machining Volume 16, Joseph R. Davis (Editor), American Society of Metals (ASM)
6. Gary F. Benedict, ―Nontraditional manufacturing processes‖, Marcel Dekker, Inc. 1987.

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Web links and Video Lectures (e-Resources):

• https://nptel.ac.in/courses/112105127

Activity Based Learning (Suggested Activities in Class)/ Practical Based learning

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