Course

Advanced Machining Processes

Indian Institute of Technology Kanpur

This course on 'Advanced Machining Processes', also known as "Unconventional Machining Processes", "Modern Machining Processes", and "New Technology", covers the latest advancements in machining techniques. The course is structured into three main parts:

Part 1: Focuses on mechanical advanced machining processes including Ultrasonic machining, Water jet machining, Abrasive water jet machining, and micro-/nano-finishing processes such as Abrasive flow finishing and Magnetic abrasive finishing.
Part 2: Discusses thermal machining processes like Electric discharge machining, Laser beam machining, and Electron beam machining.
Part 3: Elaborates on chemical and electrochemical machining processes, covering hybrid processes such as Electrochemical grinding and Electric discharge grinding.

Course details include:

Introduction: Importance and overview of advanced machining processes.
Mechanical Advanced Machining Processes:

Abrasive Jet Machining (AJM)
Ultrasonic Machining (USM)
Abrasive Flow Finishing
Magnetic Abrasive Finishing (MAF)
Water Jet Cutting (WJC)
Abrasive Water Jet Machining (AWJM)

Thermal Advanced Machining Processes:

Electric Discharge Machining (EDM)
Electric Discharge Grinding (EDG)
Wire Electric Discharge Machining
Laser Beam Machining
Plasma Arc Machining
Electron Beam Machining
Focused Ion Beam Machining

Chemical and Electrochemical Machining:

Electrochemical Machining (ECM)
Electrochemical Grinding
Electrostream Drilling
Chemical Machining (ChM)
Shaped Tube Electrolytic Machining

Additional topics include tool design and process capabilities.

Course Lectures

Mod-01 Lec-01 Advanced Machining Processes
Prof. Vijay K. Jain

Play

This module introduces the concept of Advanced Machining Processes (AMPs), explaining their significance in modern manufacturing. It provides an overview of why AMPs are necessary, highlighting their advantages over conventional machining techniques. The module also includes discussions about the various types of AMPs, their applications, and potential challenges. By understanding the need for these processes, participants will gain insights into the advancements in machining technology and the critical role they play in achieving precision and efficiency.
Mod-01 Lec-02 Advanced Machining Processes
Prof. Vijay K. Jain

Play

In this module, the focus is on the mechanical aspects of Advanced Machining Processes. It covers Abrasive Jet Machining (AJM), including its setup, components, and parametric analysis. The module explains the significance of various parameters such as Stand-off-Distance, Abrasive Flow Rate, and Nozzle Pressure. Participants will learn about the process capabilities, applications, and challenges associated with AJM. Additionally, the module provides insights into problem-solving techniques related to mechanical machining processes.
Mod-01 Lec-03 Advanced Machining Processes
Prof. Vijay K. Jain

Play

This module delves into Ultrasonic Machining, a critical mechanical advanced machining process. The module begins with an introduction to the ultrasonic machining system and the mechanics of cutting involved. It further explores parametric analysis and the process capabilities, providing a comprehensive understanding of its applications. Participants will engage with problem-solving exercises to reinforce their understanding of the ultrasonic machining process and its practical applications in various industries.
Mod-01 Lec-04 Advanced Machining Processes
Prof. Vijay K. Jain

Play

This module introduces Abrasive Flow Finishing, detailing its working principle and system components. Participants will learn about the abrasive flow machining system, including the machine, tooling, and media used. The module covers process variables, performance analysis, and the modeling of abrasive flow machined surfaces. Applications in the aerospace industry and for dies and molds are highlighted. Review questions are included to reinforce the learning and ensure a clear understanding of abrasive flow finishing techniques.
Mod-01 Lec-05 Advanced Machining Processes
Prof. Vijay K. Jain

Play

This module provides an in-depth look at Magnetic Abrasive Finishing (MAF), explaining its working principle and material removal techniques. It covers the use of bonded and unbonded magnetic abrasives, the role of machining fluid, and the influence of magnetic flux density. The module also includes an analysis of the process to enhance understanding. Review questions are provided to consolidate knowledge and facilitate further exploration of magnetic abrasive finishing.
Mod-01 Lec-06 Advanced Machining Processes
Prof. Vijay K. Jain

Play

This module examines Water Jet Cutting (WJC), detailing its machine setup, process characteristics, and performance. Participants will learn about the advantages of using water jets for cutting and the specific applications where WJC is beneficial. The module includes a bibliography for further reading and self-test questions to assess understanding. Review questions are available to solidify the knowledge gained about water jet cutting processes.
Mod-01 Lec-07 Advanced Machining Processes
Prof. Vijay K. Jain

Play

This module focuses on Abrasive Water Jet Machining (AWJM), covering its working principle and system components like the pumping system, abrasive feed, and jet nozzle. It explores the process characteristics with an emphasis on water and abrasive parameters such as pressure, flow rate, and particle size. Participants will learn about cutting parameters, process capabilities, and applications of AWJM. The module concludes with review questions to ensure comprehension and retention of the material.
Mod-01 Lec-08 Advanced Machining Processes
Prof. Vijay K. Jain

Play

This module introduces Electric Discharge Machining (EDM), explaining its working principle and components such as the R-C pulse generator and dielectric system. It examines the EDM machine, including the power supply, electrodes, and servo system. Participants will analyze R-C circuits, current, and material removal processes. The module also covers process variables and characteristics, including gap cleaning, and highlights various applications. Review questions are included to enhance understanding of EDM processes.
Mod-01 Lec-09 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module introduces advanced machining processes (AMPs) and their significance in modern manufacturing. Students will explore:

The need for advanced machining processes in various industries.

An overview of the types of advanced machining processes.

Key remarks on the evolution and technological advancements in machining.

Overall, this module sets the foundation for understanding the complexities and applications of AMPs.
Mod-01 Lec-10 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module focuses on the mechanical type advanced machining processes, which includes:

Abrasive Jet Machining (AJM) - setup, mechanics, and applications.

Ultrasonic Machining (USM) - principles, systems, and performance.

Abrasive Flow Finishing - working principles and process variables.

Magnetic Abrasive Finishing - operational principles and outcomes.

Water Jet Cutting - characteristics and performance metrics.

Abrasive Water Jet Machining - working principles and cutting parameters.

Students will gain insights into the operational mechanics, applications, and parametric analysis of these processes.
Mod-01 Lec-11 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module covers thermal machining processes, focusing on cutting-edge technologies such as:

Electric Discharge Machining (EDM) - principles, components, and applications.

Laser Beam Machining - types of lasers and their uses.

Electron Beam Machining - working principles and system components.

Plasma Arc Machining - operational principles and performance metrics.

Students will explore the mechanics behind these processes and their practical applications in various industries.
Mod-01 Lec-12 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module delves into chemical and electrochemical machining processes, highlighting:

Electrochemical Machining (ECM) - systems, advantages, and limitations.

Electrochemical Grinding - operational principles and applications.

Electrostream Drilling and Electrochemical Deburring - processes and significance.

Each section includes discussions on the mechanics, performance, and applications of these advanced machining techniques.
Mod-01 Lec-13 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module discusses the principles and applications of Focused Ion Beam (FIB) machining. Key topics include:

The working principle of FIB machining.

System components used in FIB technology.

Parametric analysis relevant to machining performance.

Applications in microfabrication and materials science.

Students will understand the significance of FIB in precision manufacturing and its role in advancing technology.
Mod-01 Lec-14 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module focuses on the intricacies of tool design for electrochemical machining (ECM). It covers:

The importance of anode shape prediction and methodologies used.

Tool (cathode) design considerations and techniques.

Various approaches to optimize ECM processes.

Students will learn about the theoretical foundations and practical aspects of tool design in ECM, enhancing their engineering skills.
Mod-01 Lec-15 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module discusses the various applications of advanced machining processes in industries such as:

Aerospace - precision components and materials.

Automotive - efficiency in manufacturing processes.

Biomedical - fabrication of medical devices and implants.

Electronics - microfabrication for circuit boards.

Students will understand how AMPs contribute to innovation and advancements in these sectors through practical examples and case studies.
Mod-01 Lec-16 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module summarizes the entire course, highlighting key points from each section. It includes:

A review of mechanical, thermal, and chemical machining processes.

Key takeaways from each module and their significance.

Future trends in advanced machining technologies.

Students will be encouraged to reflect on their learning journey and how they can apply their knowledge in real-world settings.
Mod-01 Lec-17 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module provides an overview of advanced machining processes, focusing on their significance and applications in modern manufacturing. Students will learn about the necessity of these processes, including various mechanical, thermal, chemical, and hybrid techniques.

Key concepts covered in this module include:

Definition and classification of advanced machining processes

Reasons for the adoption of unconventional machining methods

Insights into the latest technologies in machining
Mod-01 Lec-18 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module delves into mechanical advanced machining processes, where students will explore techniques such as Abrasive Jet Machining (AJM) and Ultrasonic Machining (USM). The focus will be on understanding the working principles, setup, and applications of these processes.

Topics include:

Abrasive Jet Machining setup and parameters

Ultrasonic Machining systems and mechanics

Applications in various industries
Mod-01 Lec-19 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module focuses on thermal advanced machining processes, including Electric Discharge Machining (EDM), Laser Beam Machining, and Electron Beam Machining. Students will gain insights into the working principles, types of machines, and the parameters affecting these processes.

Key components covered include:

Understanding the working of EDM and its applications

Exploring Laser Beam Machining and its various types

Studying Electron Beam Machining systems
Mod-01 Lec-20 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module examines chemical and electrochemical machining processes, providing students with a comprehensive understanding of Electrochemical Machining (ECM) and its various applications. The module also covers hybrid processes such as Electrochemical Grinding.

Topics include:

Fundamentals of Electrochemical Machining

Advantages and limitations of ECM

Applications in modern manufacturing
Mod-01 Lec-21 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module covers the Abrasive Flow Finishing process, which is critical for achieving high-quality surface finishes in various components. Students will learn about its working principles, performance variables, and applications across different sectors.

Key points include:

Understanding the mechanism of Abrasive Flow Finishing

Analyzing process performance and variables

Applications in aerospace and mold making
Mod-01 Lec-22 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module focuses on the principles and applications of Water Jet Machining and Abrasive Water Jet Machining. Students will explore the setups, process characteristics, and performance metrics essential for utilizing these techniques effectively.

Topics include:

Working principle of Water Jet Machining

Characteristics of Abrasive Water Jet Machining

Applications across various industries
Mod-01 Lec-23 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module explores the advancements in Laser Beam Machining, including types of lasers and their specific applications. Students will learn about the production of lasers, working principles, and the various applications of laser technology in manufacturing.

Topics covered include:

Types of lasers used in machining

Working principles of Laser Beam Machining

Applications in drilling, cutting, and marking
Mod-01 Lec-24 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module focuses on the fundamentals of Electrical Discharge Machining (EDM) and its variants, including Wire EDM and Electrical Discharge Grinding. Students will gain insights into the principles, machine setup, and applications of these advanced machining techniques.

Key concepts include:

Working principles of various EDM processes

Machine components and their functions

Applications in precision machining
Mod-01 Lec-25 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module provides an overview of advanced machining processes, focusing on the significance and applications of unconventional machining techniques. The necessity for these processes arises from the limitations of traditional machining methods in creating intricate and precise components. The module covers:

Definition and importance of Advanced Machining Processes (AMPs)

Classification of AMPs into mechanical, thermal, and chemical processes

Remarks on the evolution and future trends in machining technology

Understanding these topics is critical for students and professionals aiming to innovate in manufacturing and engineering fields.
Mod-01 Lec-26 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module delves into mechanical advanced machining processes, specifically Abrasive Jet Machining (AJM), Ultrasonic Machining (USM), and Abrasive Flow Finishing. Key aspects include:

Abrasive Jet Machining Setup and components

Mechanics and operational parameters of Ultrasonic Machining

Process characteristics and applications of Abrasive Flow Finishing

Students will gain insights into the advantages and limitations of these processes, along with practical applications in industries such as aerospace and manufacturing.
Mod-01 Lec-27 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module covers thermal machining processes, including Electric Discharge Machining (EDM), Laser Beam Machining, and Electron Beam Machining. The curriculum focuses on:

Working principles and setups of thermal machining techniques

Process characteristics and performance metrics

Applications in various industries, including precision machining and component fabrication

Students will explore how thermal processes can enhance machining efficiency and accuracy, addressing challenges faced in traditional methods.
Mod-01 Lec-28 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module introduces chemical and electrochemical machining processes, highlighting Electrochemical Machining (ECM), Electrochemical Grinding, and Chemical Machining. Key topics include:

Fundamental principles of electrochemical removal and its advantages

Process setups and system components for effective machining

Applications across various sectors, including complex geometries and delicate materials

By the end of this module, students will understand how these processes can provide solutions where traditional methods fall short.
Mod-01 Lec-29 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module focuses on the nuances of Electric Discharge Machining (EDM) and its variants, including Electric Discharge Grinding (EDG) and Electric Discharge Diamond Grinding (EDDG). The curriculum includes:

Working principles and machinery setup for EDM processes

Analysis of R-C pulse generators and their effects on machining

Applications and capabilities of EDM in producing intricate designs

Students will learn how EDM can be effectively utilized for hard-to-machine materials and precision components.
Mod-01 Lec-30 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module examines advanced laser machining processes, focusing on the production of lasers and their applications in various contexts. Key topics include:

Types of lasers and their distinct characteristics

Working principles of laser beam machining

Applications in drilling, cutting, marking, and other industrial uses

Students will gain insights into how laser technology revolutionizes machining with precision and efficiency.
Mod-01 Lec-31 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module provides an in-depth look at the principles and applications of Electron Beam Machining (EBM) and Focused Ion Beam (FIB) machining. The content includes:

Working principles and system setups for EBM

Parameters that influence the machining process

Applications in high-precision environments and micro-machining

Students will learn how these advanced techniques can achieve intricate designs and modifications in various materials.
Mod-01 Lec-32 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module covers hybrid machining processes, emphasizing the integration of conventional and advanced techniques to improve manufacturing efficiency. Key focus areas include:

Overview of hybrid processes such as Electrochemical Grinding and others

Advantages of combining techniques for enhanced performance

Real-world applications and case studies demonstrating effectiveness

Students will understand how hybrid approaches can solve complex machining challenges in modern manufacturing environments.
Mod-01 Lec-33 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module delves into the intricacies of advanced machining processes, focusing on the mechanical types that are pivotal in modern manufacturing. Key topics include:

Abrasive Jet Machining (AJM): Understanding its setup and operational principles.

Ultrasonic Machining (USM): Exploring the system mechanics and parametric analysis.

Abrasive Flow Finishing: Analyzing the performance and applications in industries like aerospace.

Magnetic Abrasive Finishing (MAF): Investigating stock removal and surface finish characteristics.

Water Jet Cutting (WJC) and Abrasive Water Jet Machining (AWJM): Understanding their working principles and applications.

Overall, this module provides a comprehensive overview of the mechanical advanced machining processes essential for precision engineering.
Mod-01 Lec-34 Advanced Machining Processes
Prof. Vijay K. Jain

Play
This module is dedicated to the exploration of thermal machining processes, a crucial segment of advanced machining techniques. It covers:

Electric Discharge Machining (EDM): Understanding its working principles and machine setup.

Electric Discharge Grinding (EDG) and Electric Discharge Diamond Grinding (EDDG): Examining their unique capabilities and applications.

Wire Electric Discharge Machining: Insights into its operational principles and system components.

Laser Beam Machining: An overview of laser types and their applications in various industries.

Plasma Arc and Electron Beam Machining: Exploring their working principles and process characteristics.

This module aims to provide a thorough understanding of thermal machining processes, highlighting their significance in achieving precision in manufacturing.