Advances in manufacturing processes

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Arulmigu Meenakshi Amman college of Engineering
Vadamavandal-604410.
Prepared by,
V.Umapathy,
Prof./Mech.
Imortant Questions and Answers
23MFP101- ADVANCES IN MANUFACTURING PROCESSES
Syllabus
1. UNIT-I
ENERGY ASSISTED MANUFACTURING PROCESSES 9
Introduction–mechanism of materials removal and operating parameters of: Plasma Arc
Machining –Laser Beam Machining–Electron Beam Machining–Electrical Discharge
Machining–Ultrasonic Machining –Water Jet Machining – Abrasive water jet Machining –
Abrasive jet Machining – Ion Beam Machining.
2. UNIT-II
PRECISION MACHINING 9
Electro chemical Machining- Ultra Precision turning and grinding- Chemical Mechanical
Polishing (CMP) - ELID process – Partial ductile mode grinding-Ultra precision grinding-
Binderless wheel –Free form optics. aspherical surface generation Grinding wheel- Design
and selection of grinding wheel-High-speed grinding-High-speed milling-Diamond turning.
3. UNIT-III
ADVANCES IN METAL FORMING 9
Orbital forging, Isothermal forging, Warm forging, Overview of Powder Metal techniques–
Hot and Cold isostatic pressing - high speed extrusion, rubber pad forming, Hydroforming,
Superplastic forming, Peen forming-microbblanking–Powder rolling–Tooling and process
parameters.
4. UNIT-IV MICRO MACHININING AND NANO FABRICATION 9
Theory of micro machining – Micro machining Processes – Micro-milling – Micro-drilling –
Micro-turning – Micro-grinding – Micro-polishing – Principle of Micro EDM – Micro wire
EDM – PlanetaryMicro EDM – Reverse Micro EDM– Advantages, Challenges. Nano
fabrication process- Nano machining techniques – Top / Bottom up Nano fabrication
techniques - Sub micron litho graphic technique, conventional film growth technique,

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Chemicaletching, Quantum dot fabrication techniques–MOCVD–Epitaxy techniques.
5. UNIT-V RAPID PROTOTYPING AND SURFACE MODIFICATION TECHNIQUES
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Introduction – Classification – Principle advantages limitations and applications- Rapid
Prototyping –Rapid Manufacturing – Rapid Tooling and Future Rapid Prototyping Processes
–Stereolithography(SLA)– 3D Printing (3DP)– Selective Laser Sintering (SLS) – Laminated
Object Manufacturing(LOM) – Fused Deposition Modelling (FDM) Introduction, Process
descriptions, Materials, process variations, economic considerations, applications, design
aspects and quality issues–CVD –PVD –Electroplating–Hot Dip Coating–Thermal Spraying.
S.No. Description
Unit-I
ENERGY ASSISTED MANUFACTURING PROCESSES
Introduction
1. Introduction- Energy-based: Non-traditional machining
- Use: Hard, complex materials
- Processes:
- Thermal (PAM, LBM, EBM, EDM)
- Mechanical (USM, WJM, AWJM)
- Chemical (IBM)

2. Processes- Plasma Arc Machining (PAM):
- Ionized gas → heat
- Cutting metals
- Laser Beam Machining (LBM):
- Focused laser → vaporize
- Precision cutting
- Electron Beam Machining (EBM):
- High-speed electrons → heat
- Vacuum
- Electrical Discharge Machining (EDM):
- Spark erosion
- Complex shapes
- Ultrasonic Machining (USM):
- Abrasive slurry + vibration
- Brittle materials
- Water Jet Machining (WJM):
- High-pressure water
- No heat
- Abrasive Water Jet Machining (AWJM):

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- Abrasives + water
- Cutting hard materials
- Abrasive Jet Machining (AJM):
- Abrasives + gas
- Cutting, cleaning
- Ion Beam Machining (IBM):
- Ion bombardment
- Precision etching

3. Operating Parameters- Process: Power, speed, feed
- Material: Hardness, conductivity
- Output: MRR, surface finish

Tips
- Thermal → cutting.
- Mechanical → abrasive.
- Example: LBM for aerospace
Basic Concepts
1. Introduction
- Energy-based: Non-traditional machining
- Use: Hard, complex materials
- Processes:
- Thermal (PAM, LBM, EBM, EDM)
- Mechanical (USM, WJM, AWJM, AJM)
- Chemical (IBM)

2. Processes & Mechanisms
1. Plasma Arc Machining (PAM)
- Ionized gas (plasma) → heat
- Material removal: Melting, vaporization
2. Laser Beam Machining (LBM)
- Focused laser → heat
- Material removal: Vaporization, ablation
3. Electron Beam Machining (EBM)
- High-speed electrons → heat
- Material removal: Vaporization
- Vacuum required
4. Electrical Discharge Machining (EDM)
- Spark erosion
- Material removal: Melting, vaporization

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5. Ultrasonic Machining (USM)
- Abrasive slurry + vibration
- Material removal: Abrasion
6. Water Jet Machining (WJM)
- High-pressure water
- Material removal: Erosion
7. Abrasive Water Jet Machining (AWJM)
- Abrasives + water
- Material removal: Abrasion
8. Abrasive Jet Machining (AJM)
- Abrasives + gas
- Material removal: Abrasion
9. Ion Beam Machining (IBM)
- Ion bombardment
- Material removal: Sputtering

3. Operating Parameters
- PAM: Current, gas flow, cutting speed
- LBM: Power, pulse duration, frequency
- EBM: Voltage, current, beam diameter
- EDM: Current, voltage, pulse duration
- USM: Frequency, amplitude, abrasive size
- WJM/AWJM: Pressure, abrasive flow, feed rate
- AJM: Abrasive flow, gas pressure, nozzle distance
- IBM: Ion energy, beam current, angle

4. Applications
- PAM: Cutting metals
- LBM: Precision cutting, drilling
- EBM: Micro-machining
- EDM: Complex shapes, molds
- USM: Brittle materials
- WJM/AWJM: Cutting, cleaning
- AJM: Cutting, deburring
- IBM: Precision etching

Tips
- Thermal → heat.
- Mechanical → abrasion.
- Example: LBM for aerospace