SIR C R REDDY COLLEGE OF ENGINEERING, ELURU
DEPARTMENT OF MECHANICAL ENGINEERING
UNCONVENTIONAL MACHINING PROCESSES
Academic Year: 2023-24
Semester: I
Name of the Program: B. TECH Year: IV Section: A&B
Course Subject: UNCONVENTIONAL MACHINING PROCESSES
Name of the Faculty: CHANDRARAO.CHANDU Department: ME
Designation: Assistant Professor
VISION & MISSION OF THE INSTITUTE
VISION:
“To emerge as a premier institution in the field of technical education and research in
the state and as a home for holistic development of the students and contribute to the
advancement of society and the region.”
MISSION:
M1 To provide high quality technical education through a creative balance of academic and
: industry-oriented learning.
M2
To create an inspiring environment of scholarship and research.
:
M3
To instill high levels of academic and professional discipline.
:
M4 To establish standards that inculcate ethical and moral values that contributes to growth in
: career and development of society in general.
DEPARTMENT OF MECHANICAL ENGINEERING
VISION OF THE DEPARTMENT
To be a center of excellence in the field of Mechanical Engineering in this region
where the best of teaching, learning and research synergize with a broader sense of
social responsibility
MISSION OF THE DEPARTMENT
To become a nerve center for academic excellence in Mechanical Engineering for all-
round development of students by
M1 Creating an environment conducive for high quality teaching and learning.
M2 Enabling the students to meet the challenges of the industry through
research-oriented education and entrepreneurial activities.
M3 Inculcating ethical values and responsibility towards environment and society with
leadership qualities
PROGRAM EDUCATIONAL
OBJECTIVES(PEOS)
PEO No. PEO Description
PEO 1 Excel in professional career through the knowledge in Mathematics, Science and
Engineering principles
PEO 2 Solve real time mechanical engineering problems using knowledge, skills and
modern tools that are economically feasible, as required for the industry
Exhibit professionalism, ethical attitude, team work, multidisciplinary approach
PEO 3 and engage in research and lifelong learning in the mechanical
engineering field
PEO 4 Develop the skill of methodical approach for decision making and designing of
mechanical systems
PEO 5 Create awareness towards social, environmental and energy related issues and
emphasize on effective communication skills and professionalism.
PROGRAM OUTCOMES (POS)
PO1 Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems.
PO2 Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.
PO3 Design/development of solutions: Design solutions for complex engineering problems and
design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
PO4 Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of
the information to provide valid conclusions.
PO5 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.
PO6 The engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice.
PO7 Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need
for sustainable development.
PO8 Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
PO9 Individual and team work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
PO10 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.
PO11 Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member and
leader in a team, to manage projects and in multidisciplinary environments.
PO12 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.
PROGRAM SPECIFIC OUTCOMES (PSOs)
PSO1 Demonstrate proficiency in design and analysis of automobile and aviation parts using
advanced software tools.
PSO2 Acquire skills to automate manufacturing processes.
ACADEMIC CALENDAR
R-20 Syllabus for ME JNTUK w. e.f.2020–21
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA
KAKINADA – 533 003, Andhra Pradesh, India
DEPARTMENT OF MECHANICAL ENGINEERING
IV Year - I Semester L T P C
3 0 0 3
UNCONVENTIONAL MACHINING PROCESSES (PE-3)
Course Objectives:
1. To understand basic concepts of modern machining processes.
2. To explain the principles of ultrasonic machining.
3. To illustrate the elector chemical and chemical machining processes.
4. To apply the principles and procedure of thermal metal removal processes.
5. To illustrate the principles and procedure of electron beam machining, laser beam machining and
plasma machining.
UNIT– I:
INTRODUCTION: Need for non-traditional machining methods-classification of modern machining
processes considerations in process selection, applications.
ABRASIVE JET MACHINING: Abrasive Jet machining, Water jet machining and abrasive water
jet machining: Basic principles, equipment’s, process variables, mechanics of material removal, MRR,
application and limitations, process capabilities, magnetic abrasive finishing, abrasive flow
finishing.
UNIT– II:
ULTRASONIC MACHINING – Elements of the process, mechanics of material removal, effect of
process parameters, tool feed mechanisms, economic considerations, recent developments,
applications and limitations.
UNIT– III:
ELECTRO–CHEMICAL MACHINING: Fundamentals of electro chemical machining,
electrochemical grinding, electro chemical honing and deburring process, metal removal rate in ECM,
Tool design, Surface finish and accuracy, economic aspects of ECM – Simple problems for estimation
of metal removal rate, Electro-stream drilling, shaped tube electrolytic machining. Fundamentals of
chemical machining, advantages and applications.
UNIT– IV:
THERMAL METAL REMOVAL PROCESSES: General principle and applications of Electric
Discharge Machining, Electric Discharge Grinding and wire EDM – Power circuits for EDM,
Mechanics of metal removal in EDM, Process parameters, selection of tool electrode and dielectric
fluids, surface finish and machining accuracy, characteristics of spark eroded surface.
UNIT– V:
ELECTRON BEAM MACHINING, LASER BEAM MACHINING - Basic principle and theory,
mechanics of material removal, process parameters, efficiency & accuracy, applications
PLASMA ARC MACHINING: Application of plasma for machining, metal removal mechanism,
process parameters, accuracy and surface finish and other applications of plasma in manufacturing
industries.
TEXT BOOKS:
1. Fundamentals of Machining Processes-Conventional and non – conventional
processes/Hassan Abdel – Gawad El-Hafy/CRCPress-2016.
2. Rapid prototyping: Principles and Applications /Chua C.K., Leong K.F. and LIM
C.S/World Scientific publications
REFERENCES:
1. Modern Machining Process / Pandey P.C. and Shah H.S./TMH.
2. New Technology / Bhattacharya A/ the Institution of Engineers, India1984.
3. Non-Traditional Manufacturing Processes / Benedict
Course Outcomes: At the end of the course, student will be able to
CO1: Understand the concepts of modern machining processes. .
CO2: Learn the principles of ultrasonic machining.
CO3: Apply the principles and procedure of electro chemical and chemical machining processes.
CO4: Apply the principles and procedure of thermal metal removal processes
CO5: Illustrate the principles and procedure of electron beam machining, laser beam machining and
plasma machining.
WEB SOURCE REFERENCES:
W1 https://onlinecourses.nptel.ac.in/noc21_me115/preview
W2 https://youtu.be/dVazABNeR3E
TOPIC BEYOND THE SYLLABUS:
PROPOSED
S. NO. GAP PROPOSED ACTIONS
RESOURCE
1 Modern instruments
computer aided inspection,3D Metrology Self-delivery
Usage in industry
INSTRUCTIONAL METHODOLOGIES:
WEB LCD/SMART
x CHALK & TALK x ASSIGNMENT x x
RESOURCES BOARDS
ANY OTHER
SEMINARS ADD-ON COURSES
(SPECIFY)
PEDAGOGICAL INITIATIVES:
MODEL REAL WORLD
x USE OF ICT x QUIZ x
DEMONSTRATION EXAMPLES
COLLABORATIVE POSTER
LEARNING PRESENTATION
ANY OTHER
CO-PO ASSESSMENT METHODOLOGIES-DIRECT
INTERNAL MINI/MAJOR
x x ASSIGNMENTS x ONLINE QUIZ
EXAMINATION PROJECT
INTERNALLY LABORATORY ANY OTHER
DEVELOPED EXAMS TESTS (SPECIFY)
CO-PO ASSESSMENT METHODOLOGIES-INDIRECT
x COURSE END SURVEY CO-CURRICULAR EXTRA CURRICULAR
ACTIVITIES ACTIVITIES
SIR C R REDDY COLLEGE OF ENGINEERING, ELURU
DEPARTMENT OF MECHANICAL ENGINNEERING
LESSON PLAN
Academic Year: 2023-24
Semester: I
Name of the Program: IV B. Tech Year: IV Section: A&B
Course/Subject: UCMP (PE-3) Course Code: R164103C
Name of the Faculty: Chandra Rao. Chandu Department: ME
Designation: Assistant Professor
S. No. of Teaching
Topic(s) planned CO
No. Hrs. Methodology
UNIT-I: Introduction to UCMP Chalk & Talk, PPT
1 1 CO1 Presentation
Need for non-traditional machining methods,
Classification of modern machining processes Chalk & Talk, PPT
2 Presentation
1 considerations in process selection, CO1 Chalk & Talk, PPT
3 Presentation
applications.
1 Abrasive Jet machining Basic principles, CO1 Chalk & Talk, PPT
4 Presentation
equipment’s, process variables.
5 1 Mechanics of material removal, MRR CO1 Chalk & Talk, PPT
Presentation
6 1 application and limitations. process capabilities CO1 Chalk & Talk, PPT
Presentation
1 Water jet machining Basic principles, CO1 Chalk & Talk, PPT
7 Presentation
equipment’s, process variables.
1 Mechanics of material removal, MRR CO1 Chalk & Talk, PPT
8 Presentation
9 1 application and limitations, process capabilities CO1 Chalk & Talk, PPT
Presentation
1 abrasive water jet machining: Basic principles, Chalk & Talk, PPT
10 CO1 Presentation
equipment’s, process variables.
11 1 Mechanics of material removal, MRR CO1 Chalk & Talk, PPT
Presentation
12 1 application and limitations, process capabilities CO1 Chalk & Talk, PPT
Presentation
1 magnetic abrasive finishing, abrasive flow CO1 Chalk & Talk, PPT
13 Presentation
finishing.
14 1 UNIT-II: ULTRASONIC MACHINING – CO2 Chalk & Talk, PPT
Elements of the process Presentation
15 1 Mechanics of material removal, CO2 Chalk & Talk, PPT
Presentation
16 1 Simple problems CO2 Chalk & Talk, PPT
Presentation
17 1 Effect of process parameters CO2 PPT Presentation
1 Tool feed mechanisms, Economic CO2 Chalk & Talk, PPT
18 Presentation
considerations
1 Recent developments, Applications and Chalk & Talk, PPT
19 CO2 Presentation
limitations
1 UNIT-III: ELECTRO–CHEMICAL CO3
Chalk & Talk, PPT
20 MACHINING: Fundamentals of electro Presentation
chemical machining.
21 1 Metal removal rate in ECM CO3 Chalk & Talk, PPT
Presentation
22 1 Tool design, Surface finish and accuracy CO3 Chalk & Talk, PPT
Presentation
1 Economic aspects of ECM – Simple problems CO3 Chalk & Talk, PPT
23 Presentation
for estimation of metal removal rate
24 1 Problems continuation CO3 Chalk & Talk, PPT
Presentation
25 1 Electrochemical grinding, CO3 Chalk & Talk, PPT
Presentation
26 1 Electro chemical honing and deburring process CO3 Chalk & Talk, PPT
Presentation
27 1 Electro-stream drilling CO3 Chalk & Talk, PPT
Presentation
28 1 shaped tube electrolytic machining CO3 Chalk & Talk, PPT
Presentation
1 Fundamentals of chemical machining, CO3 Chalk & Talk, PPT
29 Presentation
advantages and applications
1 UNIT-IV: THERMAL METAL REMOVAL CO4 Chalk & Talk, PPT
30 Presentation
PROCESSES: General principle of EDM,
1 Electric Discharge Grinding and wire EDM – CO4 Chalk & Talk, PPT
31 Presentation
1 Power circuits for EDM, CO4 Chalk & Talk, PPT
32 Presentation
33 1 Mechanics of metal removal in EDM CO4 Chalk & Talk, PPT
Presentation
34 1 Simple problems CO4 Chalk & Talk, PPT
Presentation
35 1 Process parameters CO4
36 1 applications of Electric Discharge Machining CO4 Chalk & Talk, PPT
Presentation
1 selection of tool electrode and dielectric CO4 Chalk & Talk, PPT
37 Presentation
fluids
38 1 surface finish and machining accuracy CO4 PPT Presentation
39 1 characteristics of spark eroded surface. CO4 Chalk & Talk, PPT
Presentation
1 UNIT -V: ELECTRON BEAM CO5
Chalk & Talk, PPT
40 MACHINING- Basic principle and Presentation
Theory. mechanics of material removal
41 1 Process parameters, CO5 PPT Presentation
42 1 efficiency & accuracy, applications CO5 Chalk & Talk, PPT
Presentation
1 LASER BEAM MACHINING: Basic CO5 Chalk & Talk, PPT
43 Presentation
principle and theory,
44 1 Mechanics of material removal CO5 Chalk & Talk, PPT
Presentation
45 1 Process parameters, CO5 Chalk & Talk, PPT
Presentation
46 1 efficiency & accuracy, applications CO5 Chalk & Talk, PPT
Presentation
1 PLASMA ARC MACHINING: Application CO5 Chalk & Talk, PPT
47 Presentation
of plasma for machining,
1 Metal removal mechanism CO5 Chalk & Talk, PPT
48 Presentation
49 1 process parameters, accuracy and surface finish CO5 Chalk & Talk, PPT
Presentation
1 other applications of plasma in manufacturing CO5 Chalk & Talk, PPT
50 Presentation
industries.
COURSE OUTCOMES:
CO No. DESCRIPTION BLOOMS’
TAXONOMY
C4103C. Understand the concepts of modern machining processes. 1
1
C4103C. Learn the principles of ultrasonic machining. 1
2
C4103C. Apply the principles and procedure of electro chemical and 3
3 chemical machining processes.
C4103C. Apply the principles and procedure of thermal metal removal 3
4 processes.
C4103C. Illustrate the principles and procedure of electron beam 2
5 machining, laser beam machining and
plasma machining.
POs & PSOs REFERENCE:
Engineering
PO1 PO6 Engineer & Society PO11 Project Mgt. & Finance
Knowledge
Environment &
PO2 Problem Analysis PO7 PO12 Life Long Learning
Sustainability
Design &
PO3 PO8 Ethics PSO1 Design Skill
Development
Individual & Team
PO4 Investigations PO9 PSO2 Manufacturing Skill
Work
PO5 Modern Tools PO10 Communication Skills
CO-PO MAPPING (HIGH:3; MEDIUM:2; LOW:1):
PO PO PO PO PO PO PO PO PO PO PO PO PO PSO PSO
CO 1 2 3 4 5 6 7 8 9 10 11 12 1 2
C4103C.1 2 1 - - - 2 2 - - 2 - 2 - -
C4103C.2 2 1 - - - 2 2 - - 2 - 2 - -
C4103C.3 2 2 - - - 2 3 - - 2 - 3 - 3
C4103C.4 2 2 - - - 2 3 - - 2 - 3 - 3
C4103C.5 2 1 - - - 2 3 - - 2 2 - -
JUSTIFICATION FOR CO-PO MAPPING:
CO PO RELEVANCE
Apply the knowledge of mathematics, science, engineering
PO1 fundamentals to Understand the concepts of modern machining
processes.
Demonstrate the knowledge of modern machining processes using first
PO2
principles of mathematics, natural sciences and engineering sciences.
Apply reasoning informed by the concepts of modern machining
processes to assess societal, health, safety, legal and cultural issues and
PO6 the consequent responsibilities relevant to the professional engineering
C4103C.1 practice.
Understand the impact of modern machining processes in societal
and environmental contexts, and demonstrate the knowledge of,
PO7
and need for sustainable development.
Communicate effectively on concepts of modern machining
P10 processes with the engineering community.
Recognize the need for, concepts of modern machining processes and
P12 have the preparation and ability to engage in independent and life-long
learning in the broadest context of technological change
C4103C.2 Apply the knowledge of mathematics, science, engineering
PO1 fundamentals, and an engineering specialization to learn the principles
of ultrasonic machining.
analyze complex engineering problems reaching substantiated
PO2 conclusions using principles of ultrasonic machining.
Apply reasoning informed by the ultrasonic machining to assess
PO6 societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.
PO7 Understand the impact of the ultrasonic machining in societal
and environmental contexts, and demonstrate the knowledge of,
and need for sustainable development.
Communicate effectively on ultrasonic machining with the
P10 engineering community.
Recognize the need for, ultrasonic machining and have the preparation
P12 and ability to engage in independent and life-long learning in the
broadest context of technological change.
Apply the principles and procedure of electro chemical and chemical
PO1
machining to the solution of complex engineering problems.
Analyze complex engineering problems reaching substantiated
PO2 conclusions using the principles and procedure of electro chemical and
chemical machining processes.
Apply principles and procedure of electro chemical and chemical
machining processes.to assess societal, health, safety, legal and cultural
PO6
issues and the consequent responsibilities relevant to the professional
engineering practice
Understand the impact of the principles and procedure of electro
chemical and chemical machining processes. societal and
C4103C.3 PO7 environmental contexts, and demonstrate the knowledge of, and
need for sustainable development.
Communicate effectively on principles and procedure of electro
chemical and chemical machining processes. with the
PO10
engineering community.
Recognize the need for, electro chemical and chemical machining
processes. and have the preparation and ability to engage in
PO12
independent and life-long learning in the broadest context of
technological change
Acquire skills to automate electro chemical and chemical machining
PSO2
processes.
C4103C.4
Apply the principles and procedure of thermal metal removal processes
PO1
to the solution of complex engineering problems.
Analyze complex engineering problems reaching substantiated
PO2 conclusions using the principles and procedure of electro thermal metal
removal processes.
Apply principles and procedure of thermal metal removal processes to
assess societal, health, safety, legal and cultural issues and the
PO6
consequent responsibilities relevant to the professional engineering
practice
Understand the impact of the principles and procedure of thermal
metal removal processes societal and environmental contexts,
PO7 and demonstrate the knowledge of, and need for sustainable
development.
PO10 Communicate effectively on principles and procedure of
thermal metal removal processes with the engineering
community.
Recognize the need for, thermal metal removal processes and have the
PO12 preparation and ability to engage in independent and life-long learning
in the broadest context of technological change
PSO2 Acquire skills to automate thermal metal removal processes.
Apply the knowledge of mathematics, science, engineering
fundamentals to illustrate electron beam machining, laser beam
PO1
machining and
plasma machining.
Demonstrate the knowledge of principles and procedure of electron
beam machining, laser beam machining and plasma machining. using
PO2
first principles of mathematics, natural sciences and engineering
sciences.
Apply reasoning informed by the concepts of principles and procedure
of electron beam machining, laser beam machining and
plasma machining to assess societal, health, safety, legal and cultural
PO6
issues and the consequent responsibilities relevant to the professional
engineering practice.
C4103C.5
Understand the impact of principles and procedure of electron
beam machining, laser beam machining and plasma machining.in
PO7 societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development.
Communicate effectively on concepts of principles and procedure of
PO10 electron beam machining, laser beam machining and plasma
machining. with the engineering community
Recognize the need for electron beam machining, laser beam
machining and plasma machining and have the preparation and ability
PO12
to engage in independent and life-long learning in the broadest context
of technological change.
Sri Ch. Chandra Rao Module Coordinator
Course Handler
H.O.D
