Advanced Machining Processes

By Prof. Shantanu Bhattacharya | IIT Kanpur

Learners enrolled: 3500 | Exam registration: 952

ABOUT THE COURSE:
This is graduate level course on advanced machining processes which delves into the non-conventional manufacturing practices carried across the industries. The course involves graduate level modeling, basic concepts related to these processes and general problem solving. So, students who can be in final year undergraduates interested to know about specialized learning or professionals from industry as well as graduate students.

INTENDED AUDIENCE: Post Graduate Students, Final year Undergraduate students, Industry Professionals, Researchers working in domain related to Advanced Machining processes

PRE-REQUISITES: Should have undertaken UG level training in primary, secondary manufacturing processes

INDUSTRY SUPPORT: Machining Industries, Aerospace and Automotive Industries, Sensor development Industries, National Labs

Summary

Course Status :	Completed
Course Type :	Core
Language for course content :	English
Duration :	12 weeks
Category :	Mechanical Engineering
Credit Points :	3
Level :	Undergraduate
Start Date :	22 Jan 2024
End Date :	12 Apr 2024
Enrollment Ends :	05 Feb 2024
Exam Registration Ends :	16 Feb 2024
Exam Date :	28 Apr 2024 IST

Note: This exam date is subject to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1 : Introduction to Advanced Manufacturing Processes:

Overview of non-conventional machining processes with (USM, AJM/AWJM, ECM, EDM, EBM, LBM etc.).

Mechanical Material Removal Processes (USM, AJM)

Ultrasonic Machining (USM):

Basics of USM processes, Mechanics of USM. Process parameters of USM, Shaw’s model of USM mechanics, Compressed grain modelling and direct throw modelling and comparison

Week 2 : Dependence of process parameters in estimation of MRR, Numerical approach to USM, Ultrasonic machining setup, Design of acoustic ultrasonic head and feed mechanism in USM.

Week 3 : Introduction to abrasive jet machining (AJM), Mechanics of AJM, AJM process parameters, Components of AJM (Abrasive, Gas, Setup), Mixing and Mass ratio and Material removal rate, Numerical approach to AJM, Modelling of Material Removal Rate (MRR).

AJMM, Mask materials of AJMM and applications.

Basics of Electro-chemical Machining: Electrochemistry basics, Debye Huckel theory of Ion transport,

Week 4 : Electrochemical Machining Process (ECM)

Finding out of potential on the electrode surface, Basic Principle of Electrochemical Machining, Estimation of MRR in ECM, Electrode potential in ECM, MRR in multiphase alloys,

Week 5 : Modelling of Kinematics and Dynamics for ECM process, Numerical approach to ECM, Tool shape determination in ECM, Design for electrolyte flow velocity, Electrolyte flow dynamics and design of electrode for electrolyte flow, Insulation design in ECM,

Week 6 : Defects in ECM and reasons, Basics of Electrochemical drilling, Basics of Electrochemical Grinding, Basics of Electro stream drilling, Process parameters from Electro stream drilling and Electrochemical Grinding

Week 7 : Applications of Machining (miscellaneous), Thermal Material Removal Processes (EDM, EBM, LBM)

Electro-discharge machining: Electro-discharge machining (EDM), Process parameters of EDM, Mechanics of EDM, Theoretical estimation of MRR in EDM, Heat source modelling of spark in EDM, Mathematical modelling of depth of melting temperature, Calculation of crater volume in EDM, Role of cavitation in material removal in EDM, Role of melting temperature of the work-piece material, EDM circuits and operating principles,

Week 8 : Mathematical modelling of the resistance-capacitance relaxation circuit, Numerical modelling of MRR from RC relaxation circuit output, Process parameters of RC relaxation circuit and MRR variation with different parameters, Rotary impulse generator and control pulse circuit for process modelling of MRR in EDM, Surface finishing and machining accuracy in EDM, Taper and overcut in EDM, Effect of EDM on surface hardness, Electrode and dielectric fluid.

Electron Beam Machining (EBM): Introduction to electron beam machining.

Week 9 : Comparison of E-beam machining with other thermal processes, Setup for EBM, Power requirement in E-Beam, Mechanics of EBM process, Numerical model for heat transfer in EBM and estimation of MRR, Derivation of functional characteristics in EBM by using Buckingham’s Pie theorem, Comparison of outcome of functional characteristics with empirical model, Power requirements for different work-piece materials in EBM

Laser Beam Machining (LBM): Introduction to Lasers and Laser beam machining, Types of lasers and feedback mechanisms in Lasers, Mechanics of material removal in Laser machining, Heat conduction model and temperature rise in LBM, Numerical modelling of LBM on semi-infinite surface and LBM with circular beams, Numerical estimation of time of machining in both the semi-infinite and circular beam cases, Steady state hole penetration model in LBM, Dependence of heat input in cutting speed of laser beam, Introduction to Plasma Arc Machining.

Week 10 : Overview of micro-fabrication (Silicon/ glass processes). Overview of soft lithography processes for polymer micro-fabrication Introduction to use of non-conventional processes for micromachining.

Week 11 : Advanced Finishing Processes:

Basics of Abrasive flow finishing (AFF) and Magneto-rheological abrasive flow finishing processes (MRAF), Physics of MRAF, Process parameters of AFF and MRAF. Lab sessions: WAJM, EDM

Week 12 : Lab sessions: EDM, Photolithography

Books and references

1. Ghosh, A., Mallik, A.K., Manufacturing Science (2ndedition), EastWest Press, 2010.
2. M.P. Groover, Fundamentals of Modern Manufacturing, John Wiley& Sons Inc., 2010.
3. V.K. Jain, Advanced Machining Processes, Allied Publishers Private Limited, 2004.
4. Advanced manufacturing processes, Hassan Abdel, Gabad El Hoffy, McGraw Hill, 2005.
5.The Science and Engineering of Micro-fabrication (2ndedition),Stephen P.Campbell, Oxford university press,2001.
6. Fundamentals of Stereolithography (1stEdition), Paul F. Jacobs, Society of manufacturing engineers, 2000.
7. GHOSHDASTIDAR, P. "Ghoshdastidar, PS Ghoshdastidar-heat Transfer-oxford University Press (2012).

Instructor bio

Prof. Shantanu Bhattacharya

IIT Kanpur

Prof. Shantanu Bhattacharya is an Abdul Kalam Technology Innovation National (INAE) Fellow and currently working as Dr. Gurumukh D. Mehta and Veena M. Mehta Chair, Professor at the Department of Mechanical Engineering at the Indian Institute of technology (IIT) Kanpur. He also performed the duties as Head of the Design Programme from 2017-2020 at IIT Kanpur. Prior to joining the Department of Mechanical Engineering at IIT Kanpur, he has been associated at a senior management level at Suzuki Motors and has over 6 years of experience in various production capacities and positions. His research includes Micro-system design and fabrication, Bio Micro Electromechanical Systems, Nano Technology, Lab on Chip, Nano energetics, Water remediation, Energy storage devices and Microfluidics. He currently heads Microsystems Fabrication Laboratory and worked as a coordinator of the 4-I laboratory and associated with the TA202 laboratory as coordinator between 2012-2015 at IIT Kanpur. Both these laboratories are very high end in terms of offering manufacturing training programs. He has 19 international and national patents, 100 international journals and numerous national and international conferences to his name and recipient of many awards and honours - NASI Reliance Platinum Jubilee Award – 2019, Er. M.P. Baya National Award from IEI for 2019; Senior Member, IEEE, 2019; Fellow of the International Society of Energy, Environment and Sustainability (ISEES), 2018 to name a few.

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.

The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).

Date and Time of Exams: 28 April 2024 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.

Registration url: Announcements will be made when the registration form is open for registrations.

The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.

Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 8 assignments out of the total 12 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Kanpur .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team

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