SKCT/ME/E05
SRI KRISHNA COLLEGE OF TECHNOLOGY
KOVAIPUDUR, COIMBATORE-641042
COURSE INFORMATION
1. Academic Year : 2016-17 (ODD SEMESTER)
2. Name of faculty : Mr. S.Ram Kumar, Mr.V.Vadivel Vivek, Mr.Thiyagu
3. Department : Mechanical Engineering
4. Programme : B.E., Mechanical Engineering
5. Class and semester : IV year and Seventh Semester
6. Course code and title : 13ME006 - UNCONVENTIONAL MACHINING PROCESSES
7. Regulations : R2013
8. Core / Elective : Elective
9. Contact hours : 45
10. Type of course : Theory
11. Number of credits :3
12. Course pre-requisites:
(i) 13ME203 Manufacturing Processes
(ii) 13ME304 Manufacturing Technology
(iii) 13ME405 Engineering Materials and Metallurgy
Course learning objectives:
(i) To learn about various unconventional machining processes, the various process
parameters and their influence on performance and their applications.
(ii) To understand the concept and basic mechanics of metal cutting, working of
standard machine tools.
13. Course Syllabus:
UNIT I INTRODUCTION 7
Unconventional machining Process Need, classification, overview of all techniques,
considerations in process selection, materials, applications.
UNIT II MECHANICAL ENERGY BASED PROCESSES 9
Abrasive Jet Machining, Water Jet Machining, Ultrasonic Machining. (AJM, WJM and USM). -
working principles, equipment used, process parameters, MRR, variation in techniques used,
applications.
UNIT III ELECTRICAL ENERGY BASED PROCESSES 9
Electric Discharge Machining (EDM)- working principles, equipments, process parameters,
MRR, electrode / Tool, power circuits, tool wear, dielectric, flushing, wire cut EDM,
applications.
UNIT IV CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES 10
Chemical machining and Electro-Chemical machining (CHM and ECM) etchants, maskant,
techniques of applying maskants, process parameters, MRR, applications. Principles of ECM-
equipments, MRR, electrical circuit, process parameters, ECG and ECH, applications.
UNIT V THERMAL ENERGY BASED PROCESSES 10
Laser beam machining (LBM), Plasma arc machining (PAM) and Electron beam machining
(EBM) principles, equipment, types, beam control techniques, applications.
TOTAL: 45
TEXT BOOK
a. Vijay.K. Jain, Advanced Machining Processes, Allied Publishers Pvt. Ltd., New Delhi (2002)
ISBN 81-7764-294-4.
REFERENCES
a. Benedict. G.F, Nontraditional Manufacturing Processes, Marcel Dekker Inc., New York
(1987).
b. Pandey P.C. and Shan H.S, Modern Machining Processes, Tata McGraw-Hill, New Delhi
(2000).
c. Mc Geough, Advanced Methods of Machining, Springer, (2011).
d. 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.
14. Course plan:
S. Cum
Name of the topic Hour Reference
No Hour
Unit: 1 INTRODUCTION
1 Need of Unconventional machining Process 1 1
2 Classification of Unconventional machining Process 1 2
3 Overview of Unconventional machining Process techniques 1 3
4 Considerations of Unconventional machining Process selection 1 4
5 Materials used in Unconventional machining Process 1 5
6 Application of Unconventional machining process 1 6
7 Application of Unconventional machining process 1 7
Unit : 2 MECHANICAL ENERGY BASED PROCESSES
Abrasive Jet Machining Process (AJM)- working principle,
8 1 8
equipment used
Abrasive Jet Machining Process (AJM)- process parameters, MRR,
9 1 9
variation in techniques used
10 Abrasive Jet Machining Process (AJM)- applications 1 10
Water Jet Machining Process (WJM)- working principles,
11 1 11
equipment used
12 Water Jet Machining Process (WJM)-process parameters, MRR, 1 12
variation in techniques used
13 Water Jet Machining Process (WJM)- applications 1 13
Ultrasonic Machining Process (USM)- working principles,
14 14
equipment used
Ultrasonic Machining Process (USM)- process parameters, MRR,
15 1 15
variation in techniques used
16 Ultrasonic Machining Process (USM)- applications 1 16
UNIT: 3 ELECTRICAL ENERGY BASED PROCESSES
17 Electric Discharge Machining (EDM)- working principles 1 17
18 Electric Discharge Machining (EDM)-equipment used 1 18
Electric Discharge Machining (EDM)- process parameters, MRR,
19 1 19
electrode / Tool
20 Electric Discharge Machining (EDM)- power circuits 1 20
21 Electric Discharge Machining (EDM)- tool wear 1 21
22 Electric Discharge Machining (EDM)- dielectric, flushing 1 22
wire cut EDM - working principles, - process parameters, MRR,
23 1 23
electrode / Tool, power circuits, tool wear
24 wire cut EDM - equipment used 1 24
25 wire cut EDM - applications 1 25
UNIT: 4 CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
26 Chemical machining process (CHM) 1 26
27 Principles of Electro-Chemical machining (ECM) 1 27
28 Etchants used in CHM 1 28
29 techniques of applying maskants in CHM 1 29
30 process parameters, MRR of CHM 1 30
31 Applications of CHM 1 31
32 Equipments, MRR of CHM 1 32
33 Electrical circuit of ECM 1 33
34 Process parameters of ECG and ECH 1 34
35 Applications of ECG and ECH 1 35
UNIT:5 THERMAL ENERGY BASED PROCESSES
36 Laser beam machining (LBM)- Working principle 1 36
Laser beam machining (LBM)- equipment, types, beam control
37 1 37
techniques
38 Laser beam machining (LBM)- applications 1 38
39 Plasma arc machining (PAM)- Working principle 1 39
Plasma arc machining (PAM)- equipment, types, beam control
40 1 40
techniques
41 Plasma arc machining (PAM)- applications 1 41
42 Electron beam machining (EBM) - Working principle 1 42
Electron beam machining (EBM))- equipment, types, beam
43 1 43
control techniques
44 Electron beam machining (EBM)- applications 1 44
45 Case studies 1 45
Total No. of lecture hours: 45
15. Weightage of unit contents:
Factors considered
F1 Number of hours allotted for the units
F2 Usefulness of content with respect to students work [0-5 scale: 0-not useful and 5-highly
important]
F3 usefulness of content with respect to other units of same subject [0-5 scale: 0-not useful
and 5-highly important]
F4 usefulness of content with respect to other subjects for the same Programme [0-5 scale:
0-not useful and 5-highly important]
Topic F1 F2 F3 F4 A2
A1
UNIT 1 INTRODUCTION (%)
Need of Unconventional machining Process 5 5 5
Classification of Unconventional machining Process 5 4 3
Overview of Unconventional machining Process techniques 5 3 2
Considerations of Unconventional machining Process 7 5 4 3 85 17
selection
Materials used in Unconventional machining Process 3 3 3
Application of Unconventional machining process 5 4 1
Application of Unconventional machining process 5 4 1
UNIT 2 MECHANICAL ENERGY BASED PROCESSES
Abrasive Jet Machining Process (AJM)- working principle, 4 4 3
equipment used
Abrasive Jet Machining Process (AJM)- process parameters, 3 3 3
MRR, variation in techniques used
Abrasive Jet Machining Process (AJM)- applications 5 4 4
Water Jet Machining Process (WJM)- working principles, 4 3 3
equipment used 98 20
Water Jet Machining Process (WJM)-process parameters, 4 4 5
MRR, variation in techniques used 9
Water Jet Machining Process (WJM)- applications 4 3 3
Ultrasonic Machining Process (USM)- working principles, 3 2 3
equipment used
Ultrasonic Machining Process (USM)- process parameters, 2 1 2
MRR, variation in techniques used
Ultrasonic Machining Process (USM)- applications 5 4 1
UNIT 3 ELECTRICAL ENERGY BASED PROCESSES
Electric Discharge Machining (EDM)- working principles 5 5 4
92 18
Electric Discharge Machining (EDM)-equipment used 9 4 3 2
Electric Discharge Machining (EDM)- process parameters, 4 3 3
MRR, electrode / Tool
Electric Discharge Machining (EDM)- power circuits 4 3 1
Electric Discharge Machining (EDM)- tool wear 3 3 1
Electric Discharge Machining (EDM)- dielectric, flushing 3 3 1
wire cut EDM - working principles, - process parameters, 4 3 2
MRR, electrode / Tool, power circuits, tool wear
wire cut EDM - equipment used 4 3 2
wire cut EDM - applications 5 4 1
UNIT 4 CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
Chemical machining process (CHM) 5 4 4
Principles of Electro-Chemical machining (ECM) 4 3 3
Etchants used in CHM 5 2 4
techniques of applying maskants in CHM 3 1 3
process parameters, MRR of CHM 3 1 2 103 21
10
Applications of CHM 5 4 1
Equipments, MRR of CHM 4 3 2
Electrical circuit of ECM 4 3 1
Process parameters of ECG and ECH 4 3 2
Applications of ECG and ECH 5 4 1
UNIT 5 THERMAL ENERGY BASED PROCESSES
Laser beam machining (LBM)- Working principle 5 4 4
Laser beam machining (LBM)- equipment, types, beam 5 4 5
control techniques
Laser beam machining (LBM)- applications 4 3 3
Plasma arc machining (PAM)- Working principle 4 4 3
Plasma arc machining (PAM)- equipment, types, beam 4 3 2 122 24
control techniques 10
Plasma arc machining (PAM)- applications 5 4 1
Electron beam machining (EBM) - Working principle 5 4 4
Electron beam machining (EBM))- equipment, types, beam 4 3 2
control techniques
Electron beam machining (EBM)- applications 5 4 1
Case studies 5 4 4
Total 500 100
A1 Number of Boxes Filled with numbers
A2 Weightage Assigned to Each Units in terms of Percentage
16. Mapping syllabus with Blooms Taxonomy LOT and HOT:
Lower Order Thinking
Students are expected to Recall the information through Recognizing,
R Remembering
listing, describing, retrieving, naming, finding
Students are expected to Explain an ideas or concepts through
U Understanding
Interpreting, summarizing, paraphrasing, classifying, explaining
Students are expected to Use the information in another familiar
Ap Applying
situation through Implementing, carrying out, using, executing
Higher Order Thinking
Students are expected to Break the information into parts to explore
A Analyzing understandings and relationships through Comparing, organizing,
deconstructing, interrogating, finding
Students are expected to Evaluate the Justifying a decision or course of
E Evaluating
action through Checking, hypothesizing, experimenting, judging
Students are expected to Generate new ideas, products, or ways of
C Creating viewing things through Designing, constructing, planning, producing,
inventing.
UNIT I INTRODUCTION (Weightage 17%)
Sl.No Name of the Topic Process verb Types of thinking
1. Define Remembering
Need of Unconventional machining Process
Interpret Understanding
2. Classification of Unconventional machining Define Remembering
Process Interpret Understanding
Define Remembering
3. Overview of Unconventional machining
Interpret Understanding
Process techniques
Implementing Applying
4. Considerations of Unconventional Define Remembering
machining Process selection Interpret Understanding
5. Materials used in Unconventional
Examine Analyzing
machining Process
6. Application of Unconventional machining Examine Analyzing
process Designing Creating
7. Application of Unconventional machining Define Remembering
process Interpret Understanding
R U Ap A C E Total
Type of thinking in Nos 5 5 1 2 1 0 14
Weightage,% 6.0 6.0 1.2 2.4 1.2 0 17
UNIT II UNIT 2 MECHANICAL ENERGY BASED PROCESSES (Weightage 20%)
8. Abrasive Jet Machining Process (AJM)- Define Remembering
working principle, equipment used Interpret Understanding
Abrasive Jet Machining Process (AJM)-
9. Define Remembering
process parameters, MRR, variation in
Implementing Applying
techniques used
Define Remembering
10. Abrasive Jet Machining Process (AJM)-
Interpret Understanding
applications
Determine Evaluating
11. Water Jet Machining Process (WJM)- Define Remembering
working principles, equipment used Interpret Understanding
Water Jet Machining Process (WJM)-process
12. Implementing Applying
parameters, MRR, variation in techniques
Examine Analyzing
used
13. Water Jet Machining Process (WJM)- Implementing Applying
applications Examine Analyzing
14. Ultrasonic Machining Process (USM)- Examine Analyzing
working principles, equipment used Determine Evaluating
Ultrasonic Machining Process (USM)-
15. Interpret Understanding
process parameters, MRR, variation in
Implementing Applying
techniques used
16. Ultrasonic Machining Process (USM)- Define Remembering
applications Interpret Understanding
R U Ap A C E Total
Type of thinking in Nos 5 5 4 3 0 2 19
Weightage,% 5.3 5.3 4.2 3.1 0 2.1 20
UNIT III ELECTRICAL ENERGY BASED PROCESSES (Weightage 18%)
Implementing Applying
17. Electric Discharge Machining (EDM)-
Determine Evaluating
working principles
Designing Creating
18. Electric Discharge Machining (EDM)- Implementing Applying
equipment used Examine Analyzing
Define Remembering
19. Electric Discharge Machining (EDM)-
Interpret Understanding
process parameters, MRR, electrode / Tool
Designing Creating
Define Remembering
20. Electric Discharge Machining (EDM)- power
Interpret Understanding
circuits
Implementing Applying
21. Electric Discharge Machining (EDM)- tool Examine Analyzing
wear Determine Evaluating
Define Remembering
22. Electric Discharge Machining (EDM)-
Interpret Understanding
dielectric, flushing
Designing Creating
23. wire cut EDM - working principles, - process Define Remembering
parameters, MRR, electrode / Tool, power Interpret Understanding
circuits, tool wear Designing Creating
24. Implementing Applying
wire cut EDM - equipment used
Examine Analyzing
25. Define Remembering
wire cut EDM - applications
Interpret Understanding
R U Ap A C E Total
Type of thinking in Nos 5 5 4 3 4 2 23
Weightage,% 3.9 3.9 3.1 2.3 3.1 1.6 18
UNIT IV CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES (Weightage 21%)
Define Remembering
26. Chemical machining process (CHM)
Interpret Understanding
Principles of Electro-Chemical machining Define Remembering
27.
(ECM) Interpret Understanding
Define Remembering
28. Etchants used in CHM Interpret Understanding
Implementing Applying
Define Remembering
29. techniques of applying maskants in CHM Interpret Understanding
Implementing Applying
Define Remembering
30. process parameters, MRR of CHM Interpret Understanding
Implementing Applying
Define Remembering
31. Applications of CHM
Interpret Understanding
Implementing Applying
32. Equipments, MRR of CHM Examine Analyzing
Determine Evaluating
Define Remembering
33. Electrical circuit of ECM Interpret Understanding
Implementing Applying
Define Remembering
34. Process parameters of ECG and ECH Interpret Understanding
Implementing Applying
Define Remembering
35. Applications of ECG and ECH
Interpret Understanding
R U Ap A C E Total
Type of thinking in Nos 9 9 6 1 0 1 26
Weightage,% 6.6 6.6 4.4 0.7 0 0.7 19
Unit- V THERMAL ENERGY BASED PROCESSES (Weightage 24%)
Define Remembering
Laser beam machining (LBM)- Working
36. Interpret Understanding
principle
Implementing Applying
Laser beam machining (LBM)- equipment, Implementing Applying
37.
types, beam control techniques Examine Analyzing
Determine Evaluating
Implementing Applying
38. Laser beam machining (LBM)- applications
Examine Analyzing
Define Remembering
Plasma arc machining (PAM)- Working
39. Interpret Understanding
principle
Implementing Applying
Implementing Applying
Plasma arc machining (PAM)- equipment,
40. Examine Analyzing
types, beam control techniques
Determine Evaluating
Define Remembering
41. Plasma arc machining (PAM)- applications
Interpret Understanding
Electron beam machining (EBM) - Working Define Remembering
42. principle Interpret Understanding
Implementing Applying
Electron beam machining (EBM))- Implementing Applying
43. equipment, types, beam control techniques Examine Analyzing
Determine Evaluating
Electron beam machining (EBM)- Define Remembering
44.
applications Interpret Understanding
Case studies Define Remembering
45.
Interpret Understanding
R U Ap A C E Total
Type of thinking in Nos 6 6 7 4 0 3 26
Weightage,% 5.5 5.5 6.5 3.7 0 2.8 24
R U AP A E C TOTAL
UNIT 1 6.0 6.0 1.2 2.4 1.2 0 17
UNIT 2 5.3 5.3 4.2 3.1 0 2.1 20
UNIT 3 3.9 3.9 3.1 2.3 3.1 1.6 18
UNIT 4 6.6 6.6 4.4 0.7 0 0.7 19
UNIT 5 5.5 5.5 6.5 3.7 0 2.8 24
TOTAL 27.3 27.3 19.4 12.2 4.3 12.6 100
Lower Order Thinking 70.9
Higher Order Thinking 29.1
17. Expected outcome of the course:
Upon successful completion of this course, the student will be able to:
CO1 Familiarize with fundamentals of unconventional machining processes and
thus acquire the capability to apply them.
CO2 Apply the concept of unconventional machining processes in the industries.
18. Mapping course outcome with Blooms Taxonomy LOT and HOT:
R U Ap A E C
CO1
CO2
19. Mapping Course outcome with graduate attributes:
Graduate attributes
Graduate attributes Descriptions
GA1 Engineering Remembering Apply the Remembering of mathematics, science,
engineering fundamentals, and an engineering
specialization to the solution of complex engineering
problems.
GA2 Problem analysis Identify, formulate, research literature, and analyze
complex engineering problems reaching substantiated
conclusions using first principles of mathematics, natural
Sciences, and engineering sciences.
GA3 Design/development of Design solutions for complex engineering problems and
design system components or processes that meet the
solutions
specified needs with appropriate consideration for the
public health and safety, and the cultural, societal, and
environmental considerations.
GA4 Conduct investigations of Use research-based Remembering and research methods
including design of experiments, analysis and
complex problems
interpretation of data, and synthesis of the information to
provide valid conclusions.
GA5 Modern tool usage Create, select, and apply appropriate techniques, resources,
and modern engineering and IT tools including prediction
and modeling to complex engineering activities with an
understanding of the limitations.
GA6 The engineer and society Apply reasoning informed by the contextual Remembering
to assess societal, health, safety, legal and cultural issues
and the consequent responsibilities relevant to the
professional engineering practice
GA7 Environment and Understand the impact of the professional engineering
solutions in societal and environmental contexts, and
sustainability demonstrate the Remembering of, and need for
sustainable development.
GA8 Ethics Apply ethical principles and commit to professional ethics
and responsibilities and norms of the engineering practice.
GA9 Individual and team work Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
GA10 Communication Communicate effectively on complex engineering activities
with the engineering community and with society at large,
such as, being able to comprehend and write effective
reports and design documentation, make effective
presentations, and give and receive clear instructions.
GA11 Project management and Demonstrate Remembering and understanding of the
engineering and management principles and apply these to
finance
ones own work, as a member and leader in a team, to
manage projects and in multidisciplinary environments
GA12 Life-long learning Recognize the need for, and have the preparation and
ability to engage in independent and life-long learning in
the broadest context of technological change.
GA1 GA2 GA3 GA4 GA5 GA6 GA7 GA8 GA9 GA10 GA11 GA12
CO1
CO2
Strongly agreed Moderately agreed
20. Mapping course outcome with programme outcomes:
Programme outcomes
(a) An ability to apply Remembering of mathematics, science, and engineering
(b) An ability to design and conduct experiments, as well as to analyze and interpret data
(c) An ability to design a system, component, or process to meet desired needs within realistic
constraints such as economic, environmental, social, political, ethical, health and safety,
manufacturability, and sustainability
(d) An ability to function on multidisciplinary teams
(e) An ability to identify, formulates, and solves engineering problems
(f) An understand the professional and ethical responsibility
(g) An ability to communicate effectively
(h) The broad education necessary to understand the impact of engineering solutions in a
global, economic, environmental, and societal context
(i) A recognition of the need for, and an ability to engage in life- long learning
(j) A Remembering of contemporary issues
(k) An ability to use the techniques, skills, and modern engineering tools necessary for
engineering practice.
[l] An ability to fabricate real time mechanical systems and tests the worthiness
a b c d e f g h i j k l
CO1
CO2
Strongly agreed Moderately agreed
21. Mapping with programme educational objectives:
Programme educational objectives:
1. To provide students with a sound foundation in the mathematical, scientific and
engineering fundamentals necessary to formulate, solve and analyze mechanical
engineering problems.
2. To develop the ability among students to synthesize data and technical concepts for
solving research problems.
3. To provide opportunities for students to work as part of teams on multidisciplinary
projects with good communication and interpersonal skills in the areas like automation,
composite materials, automotive technology, green fuels etc.,.
4. To prepare students for successful careers in industry that meet the needs of Indian and
multinational companies and to inculcate the entrepreneurial skills.
COURSE NAME PEO1 PEO2 PEO3 PEO4
DTS
Strongly agreed Moderately agreed
22. Course assessment methods:
Monthly test: 15 Marks
Objective To Identify What Students Have Learned and also to identify students strength and
weakness
Product Answer scripts
Frequency Monthly
Format Part A 9 x 2 18 marks
Part B 2 x 16 32 marks
Total marks 50
Duration : 1hour and 30 minutes
Evaluation Based on answer given in the scripts
criteria Pass mark 50%
Minimum pass percentage: 75%
If not, remedial action will be taken.
Project: 15 marks
Objective To enhance students understanding of a particular reading / To apply their
knowledge
Product To make a working model/ Desired output in a process
Frequency All working days
Format Application of a specified tool in syllabus
Evaluation Based on power point presentation and output
Criteria No. of Projects : 2
Submit on or before the date of submission.
Marks will be awarded based on the performance of the student.
Seminar: 5 marks
Objective To measure Remembering, abilities, and/or skills.
Product Questions and answers script
Frequency After completing project/tools
Format Application of a specified tool in syllabus
Evaluation Based on answer given by students
Criteria Marks will be awarded based on the performance of the student.
Attendance: 5 marks
Objective To make all students to attend the class throughout the course
Product Record of class work
Frequency All working days
Format Record of class work format
Evaluation Based on attendance earned by the students
Criteria Marks will be awarded according to attendance percentage of students.
Less than 75% 0 Marks
76% to 80% 1 Marks
81% to 85% 2 Marks
86% to 90% 3 Marks
91% to 95% 4 Marks
95% to 100% 5 Marks
End semester exam: 60 marks
Objective To assess the each students Remembering of the course
Product Result analysis
Frequency Semester
Format Part A 10 x 2 20 marks
Part B 5 x 16 80 marks
Total marks 100
Duration : 3hours
Evaluation Based on answer given in the scripts
criteria Minimum pass percentage: 75%
If not, remedial action will be taken.
Faculty HOD-MECH Principal
