In the electron beam machining process, a high velocity focused beam of electrons are used to remove the metal from the workpiece. Reference books fundamental of modern manufacturing. The spdt manufacturing process produces a relatively high percentage of defective parts, which must be discarded. Manufacturing technology 1 notes pdf mt 1 pdf notes book starts with the topics joining processes,classification of welding process,fusion welding,plastic welding,gas welding technique,oxyacetylene welding,friction welding,friction stir welding,brazing methods.
Advanced machining processes nptel online videos, courses. Abrasive flow machining afm, also known as abrasive flow deburring or extrude honing, is an interior surface finishing process characterized by flowing an. When no filler metal is used, that fusion welding operation is referred to as autogenous weld. The noteworthy feature of electrolysis is that electrical energy is used to produce a chemical reaction, therefore, the machining process based on this principle is known as electrochemical machining ecm.
The introduction of abrasives to the fluid jet enhances the machining efficiency and is known as abrasive water jet machining. Jagadeesha t, assistant professor, national institute of technology, calicut. Oct 11, 2020 micromilling is a precision manufacturing process with broad applications across the biomedical, electronics, aerospace, and aeronautical industries owing to its versatility, capability, economy. Develop an understanding of the capabilities and limitations of the unit processes in terms of quality and productivity emphasis on understanding the physical principles underlying these processes apply this knowledge to manufacturing process. Turning a machining process in which a singlepoint tool remove material from the surface of a rotating work piece. These manufacturing process som study notes will help you to get conceptual deeply knowledge about it. Machining is a metal removal process, which can be accomplished by applying force on raw material by means of a cutting tool.
A machining process is called nontraditional if its material removal mechanism is basically different than those in the traditional processes, i. It covers a wide spectrum of manufacturing activities such as machining, sheet metal working, welding, fabricating, scheduling and assembly. Mechanical engineering advanced machining processes nptel. Arc welding it is a fusion welding process in which the melting and joining of metals is done by the heat energy generated by the arc between the work and electrode. Nontraditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as outlined below. Part 2 deals with thermal machining processes for example, electric discharge machining, laser beam machining, electron beam machining, etc. Very hard fragile materials difficult to clamp for. Enjoy the videos and music you love, upload original content, and share it all with friends, family, and the world on youtube. A flexible manufacturing system fms has four or more processing workstations connected mechanically by a common part handling system and electronically by a distributed computer system. The process of metal removal by electro chemical dissolution was known as long back as 1780 ad but it is only over the last couple of decades that this. In the electrical beam machining, electrical energy is used to generate the electrons with high energy. A detail classification f the machining process based on the type of energy used, the mechanism of. Cutting,mechanism of oblique cutting, practical machining.
The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process. In this subject we will be talking about the different aspects related. We are here to provides you the best study notes from best coaching like made easy, ace academy etc and lecture notes from best institutions like mit open course, iit nptel, crec tirupati, washington, middle east technical university etc. Machining processes provide desired shape with good accuracy and precision but tend to waste material in the generation of removed portions. Turning, shaping and planning, slab milling, drilling. A poorly designed process results in overuse of manufacturing resources men and machines. For most enterprises, the long term goal is to stay in business, grow and make profits. Independent variables include workpiece material, specific machining processes, and tool materials and geometry. Minimum number of castings for profitable use of a permanent mold is dependent on the complexity of its shape. Dfm is the method of design for ease of manufacturing of the collection of parts that will form the product after assembly. These are casting, machining, joining welding, mechanical fastners, epoxy, etc.
Modern manufacturing processes are classified according to the type of fundamental machining energy employed. Machining, machining process, tool geometry, mechanics of metal cutting, friction in metal. Nptel mechanical engineering advanced machining processes. Advanced manufacturing process for micro system fabrication.
This is particularly true for manufacturing enterprises, which must understand the dynamic changes that are taking place in business environment and are flexible enough. Machining of thin sectioned hard and brittle materials is possible. Singhmelkotecolton cos sin cos sin tan s c t n t c s f f f f f f f. There is a need for machine tools and processes which can accurately and easily machine the most difficultto machine materials and. Lecture series on manufacturing processes ii by prof. Classification of metal removal processes and machine tools. Please submit your suggestions and detected errors to jeetender singh kushawaha 9450935651 k. Module 3 selection of manufacturing processes lecture 6 design for powder metallurgy instructional objectives by the end of this lecture, the student will learn the basic principles of powder metallurgy processes and the critical issues to be considered during design of parts to be manufactured using powder metallurgy processes. Generally, process improvements are made regularly with new efficiencies embedded within the process. Fundamentals of manufacturing processes course nptel. This process works on the principle of of faradays laws of electrolysis. As the metal enters the mold, the polystyrene foam is vaporized ahead of the advancing liquid. Nptel mechanical engineering manufacturing processes ii. Mechanical micro machining is capable to machine metals, polymers, and ceramics in very less time as compared to lithographic processes and other micro machining processes such as edm, ecm, lbm, etc.
Module 3 selection of manufacturing processes nptel figure 3. Machining parameters, force magnitudes, power consumption, material removal rate, time per pass. Oct 22, 2008 lecture series on manufacturing processes ii by prof. In fusionwelding processes, heat is applied to melt the base metals. Machining is a manufacturing process of making useful product by the removal of the material. The life of the grinding wheel is described as the time period between two successive dressings. Machining awjm through the ieg in amperes, t is time of current flow or ecm, e.
Develop an understanding of the capabilities and limitations of the unit processes in terms of quality and productivity emphasis on understanding the physical principles underlying these processes apply this knowledge to manufacturing process selection, part. Module 3 selection of manufacturing processes nptel. Jain, department of mechanical engineering, iit kanpur. Manufacturing process study notes handwritten free pdf. The electron beam polishing equipment technology is brought forward and its characteristic is explained because general processing method cant obtain preferable machining efficiency and product. Building of machines, structures, or process equipment by cutting, shaping and assembling components made from raw materials. Nptel provides elearning through online web and video courses various streams. Joining processes permit complex shapes to be constructed from simpler components and have a wide domain of applications. Contents laser beam machining laser type of laser laser application parameters affecting lbm advantage disadvantage references 2 3. Dec 23, 2018 this process is known as dressing of grinding wheel and the whole process takes 15 to 20 minutes to operate. In many fusion welding processes, a filler metal is added to the molten pool during welding to facilitate the process and provide strength to the welded joint. Basic working principle, configuration, specification.
Introduction to machining processes machining handbooks. Electron beam machining is a thermal process used for metal removal during the machining process. Fundamental of modern manufacturing materials, processes and systems, 4ed. How the various surfaces are obtained in machining, advantages, disadvantages. Electron beam machining ebm diagram, working, advantages. Optimization of the manufacturing process dfa is a tool used to select the most cost effective material and process to be used in the production in the early stages of product. Machining a material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. Materials and processes in manufacturing, prentice hall of india, 1997.
Manufacturing processes, kalpakjian and schmid, pearson 4. The planning department processes the data and produces slides that serve as the template for manufacturing the parts. Share your videos with friends, family, and the world. This is an introductory level course in manufacturing systems technology and management. The grinding wheel rotates at 3600 rpm, has a diameter d of 150 mm, thickness b of 25 mm, and c 5 grains per mm2. Axially loaded members, cantilever beam, rings and octagon, dynamometer requirements. Pm is therefore becoming increasingly competitive with conventional manufacturing processes like forging, casting, and machining. Instructional objectives i manufacturing process ii. Casting process exploit the fluidity of a metal in liquid state as it takes shape and solidifies in a mold. Grinding operation is one of the machining processes which consume the highest specific cutting energy with very less material removal rate. Manufacturing metal mold is much more expensive than manufacturing sand molds or investment casting process mold.
Toolchip interface decomposition of resultant force. Groover, fundamentals of modern manufacturing 2e figure 11. His research areas include advanced finishing and nanofinishing processes, magnetorheological finishing mrf process, advancednontraditional machining processes, micromachining processes. Cutting force and power, surface finish, and tool wear and failure are some dependent variables discussed. Introduction to mechanical micro machining course nptel. Lecture 1 fundamentals of metal forming there are four basic production processes for producing desired shape of a product. The common nontraditional machining processes are described in this section. Ferrous and noferrous metals and alloys are cast by the permanent mold casting process. Non traditional machining processes s5me complied by. S kalpakkajian, s r schmid, manufacturing engineering and technology, pearson 2000degarmo et al.
Mechanical engineering manufacturing processes ii nptel. The article also describes the relations between the input variables and process. Paul,department of mechanical engineering, iit kharagpur. Machining processes provide desired shape with good. The article also describes the relations between the input variables and process behavior. R s parmar, welding process and technology, khanna publisher, new delhi 2004. Brujos y guerreros steve jackson pdf machijability shear zone, chip formation, chip thickness measurements, machining mechanics of ductile and brittle materials. As a result, it has found strong base in a wide array of practical applications. Powder metallurgy pdf nptel by the end of this lecture, the student will learn the phq 9 pdf pfizer basic principles of powder metallurgy processes and the critical issues to be. Machining is the manufacturing process by which parts can be produced to the desired dimensions and surface finish from a blank by gradual removal of the. Continuous process improvement is a critical part of lean manufacturing.
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