Lecture: 1
Material Removal Processes
1. Why are the nontraditional material removal
processes important?
2. There are four categories of nontraditional machining
processes, based on principal energy form.
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Lecture: 2
Ultrasonic Machining
1. Illustrate with sketch the principle of work of USM.
2. What are the main components of ultrasonic
machining system? Briefly discuss each component.
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3. What are the parameters that affect on the
performance of USM?
4. What are advantages and disadvantages of
ultrasonic machining?
Advantages
Disadvantages
5. State some of ultrasonic machining applications.
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Lecture: 3
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Abrasive Jet Machining (AJM)
1. Illustrate with sketch the principle of work of AJM.
2. What are the main components of AJM system?
Briefly discuss each component.
3. What are the parameters that affect on the
performance of AJM?
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4. What are advantages and disadvantages of AJM?
Advantages
Disadvantages
5. State some of AJM applications.
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Lecture: 4
Water Jet Machining (WJM)
1. Illustrate with sketch the principle of work of WJM.
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2. What are the main components of WJM system?
Briefly discuss each component.
3. What are the parameters that affect on the
performance of WJM?
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4. What are advantages and disadvantages of WJM?
Advantages
Disadvantages
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5. State some of WJM applications.
Lecture: 5
Electro-discharge machining (EDM)
1. Illustrate with sketch the principle of work of EDM.
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2. What are the process parameters for EDM?
3. What are the characteristics of the dielectric fluid in
EDM?
4. What are the main Functions of dielectric fluid?
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5. What are advantages and disadvantages of EDM?
Advantages
Disadvantages
6. State some of EDM applications.
Lecture: 6
Laser Beam Machining (LBM)
1. Illustrate with sketch the principle of Laser Beam
Machining (LBM).
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2. What are Laser Beam Machining (LBM)Applications
3. Illustrate with sketch the principle of work Plasma Arc
Cutting (PAC).
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4. What are applications of Plasma Arc Cutting?
5. What is the difference between Water Jet, Laser,
Plasma? Respect to Materials, Cost, Quality,
Productivity.
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Lecture: 7
Electrochemical Machining (ECM)
1. Describe with sketch the three types of
electrochemical machining (ECM).
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Lecture: 8
Friction Stir Welding
1. Illustrate with sketch the principle of work of FSW.
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2. What are the parameters that affect on the
performance of FSW?
3. Show with sketch What are Zones of Friction Stir
Welds.
4. What is Friction Stir Welding Positions?
5. What are advantages and disadvantages of FSW?
Advantages
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Disadvantages
6. State some of FSW applications.
Lecture: 9
Thermit Welding (TW)
1. Describe the exothermic reaction (in which heat is
produced) of the thermit welding.
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2. Illustrate with sketch the principle of Electron Beam
Welding.
3. What are Electron Beam Welding Applications
4. Illustrate with sketch the principle of PAW.
5. How does the PAW process work?
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6. What are Wire PAW Applications?
7. What are difference between Transferred arc mode
and Non-transferred mode?
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8. State Shielding gases used in PAW.
Lecture: 10
MEASUREMENT OF SURFACE FINISH
1. What are the factors affecting surface roughness?
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2. What are the reasons for controlling Surface
Roughness?
3. State some types of Lay
4. Describe the three statistical criteria are used for
average roughness.
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5. Describe the Symbol to designate surface finish on
drawing
1. A square through hole of 5 mm x 5 mm has to
be drilled in a 10 mm thick tungsten carbide
plate. The slurry is made of 1 part of abrasive to
1 part of water. The abrasive grains are of 0.02
mm diameter. The feed force is 5 N. The tool
oscillates at an amplitude of 0.02 mm and
frequency of 20 KHZ. Assuming that only 20% of
pulses are effective, calculate the time required
to complete the job (λ=5, μ=1, Hw =6900
N/mm2).
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2. In an electrochemical machining operation, the
frontal working area of the electrode is 2.5 in2.
The applied current = 1500 A and the voltage =
12 V. The material being cut is pure aluminium,
the specific removal rate is 1.26 x 10-4 in3/A.
Min. a) If the ECM process is 90% efficient,
determine the rate of the metal removal in in3 /
hr . b) If the resistivity of the electrolyte = 6.2
Ω.in , determine the working gab.
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3. A square hole is to be machined through a 1-
in plate of pure copper (valence = 1) using ECM.
The hole is 1.0 in on each side, but the electrode
that is used to cut the hole is slightly less than 1
in on its sides to allow for overcut, and its shape
includes a hole in its centre to permit the flow of
electrolyte and to reduce the area of the cut. This
tool design results in a frontal area of 0.3 in2.
The applied current = 1000 A-using an efficiency
of 95%, determine how long it will take to cut the
hole?
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4. A round hole of 90 mm diameter is being cut
by (ECM) into iron plate 50 mm thick. The
electrode tool has a central hole of 75 mm, which
would produce a center core that can be
removed after ECM operation. The operation is
carried at a current = 2000 A. Efficiency is
expected to be 90% and c = 3 x 10-5 cm3/A.sec.
Determine the time required to cut the hole.
Compare this time with that required for a
traditional drilling hole in the plate having same
diameter, if drill speed is 300 rpm and feed is
0.15 mm/rev.
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5. A metal removed rate 0.01 in3/min is achieved
in a certain in a certain EDM operation on a pure
iron work part. What metal removal rate would
be achieved on aluminum in this EDM operation if
the same discharge current were used
(Tiron=2900 k , Tal=1220 k)?
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6. A Wire EDM operation is used to cut a steel
plate of 30 mm thick and length of 50 cm. A
brass wire electrode of 0.2 mm diameter is used
in EDM machine. It is expected that overcut
would be 0.03 mm using a discharge current=10
A and constant (k=39.86), steel melting point is
1537°C. What are the kerf width and the feed
rate?
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7. A wire EDM operation is to be performed on
Nickel slab 20 mm thick using Brase wire
electrode that is 0.125 mm diameter. It is
expected that overcut will be 0.025 mm. Using a
discharge current = 10 A, what is the allowable
material removal rate of the operation. Estimate
the cutting time if the length to be cut = 50 mm.
Melting point of Nickel = 1455 °C (K=39.86 in SI
units).
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8. A wire EDM operation is used to cut a steel
plate of 3 cm thick and length of 60 cm. A brass
wire electrode of 0.2 mm diameter is used in
EDM machine. It is expected that overcut would
be 0.03 mm. Using a discharge current =20 A
and constant (C=39.86). Steel melting point is
1539 °C. What are the kerf width, feed rate and
cutting time?
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9. In a chemical milling operation on a flat, mild
steel plate, it is desired to cut a round pocket to a
depth of 15 mm. The outside diameter of this
pocket is 400 mm. A solution of hydrochloric and
nitric acids was used as an etchant solution, their
penetration rate is 0.03 mm/min. The etch factor
is 0.2. Determine i) Metal removal rate ii) Milling
time iii) Opening diameter in cut and peel
maskant.
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