SANJIVANI K.B.

P POLYTECHNIC
KOPARGAON

SANJIVANI RURAL EDUCATION OF SOCIETY

S.K.B.P.POLYTECHNIC, KOPARGAON
DIST.AHMEDNAGAR-423601
(2023-2024)

AMP (22563)
ADVANCE MANUFACTURING PROCESSES
A PROJECT REPORT ON
NON CONVECTIONAL MACHINING PROCESS

SUMITTED TO THE MSBTE, MUMBAI IN PARTIALFULFILLMENT OF THE

REQUIREMENT FOR THE AWARDDIPLOMA IN MECHANICAL ENGINEERING
BY

1. (105) jadhav ravindra 2. (106) jadhav vivek

3. (107) jawale yash 4. (108) jaypatre sagar
 SANJIVANI K.B.P POLYTECHNIC
KOPARGAON

CERTIFICATE

THIS IS TO CERTIFY THAT PROJECT

SUBMITTED BY

1. (105) jadhav ravindra 2. (106) jadhav vivek

3. (107) jawale yash 4. (108) jaypatre sagar

Are a bonafide work carried out by above student under the supervision Of
Mr.A.M.PATIL .and it is submitted towards the fulfilment of the requirement of
MSBTE, Mumbai for the award of Diploma in Mechanical Technology

(Project Coordinator)
Mr A.M.PATIL
 Electric Discharge Machining (EDM):

Definition: EDM is a non-traditional machining process that uses electrical discharges to remove
material from a workpiece.

Principle: EDM works on the principle of thermoelectric erosion, where an electrical discharge
creates a high-temperature plasma arc that melts and vaporizes the workpiece material.

 Types of EDM:

1. Die-Sinking EDM (Sinker EDM): Uses a pre-shaped electrode to create a cavity in the workpiece.

2. Wire EDM (WEDM): Uses a thin wire electrode to cut complex shapes in the workpiece.

3. Hole Drilling EDM (H EDM): Uses a rotating electrode to drill holes in the workpiece.

4. Micro EDM: Uses a small electrode to machine micro-features in the workpiece.

 Advantages:

1. High accuracy: EDM can achieve high accuracy and precision.

2. Complex geometries: EDM can machine complex shapes and geometries.

3. Hard materials: EDM can machine hard and brittle materials.

4. Low tool wear: EDM electrodes can last for a long time.

5. No mechanical stress: EDM does not induce mechanical stress in the workpiece.
 Disadvantages:

1. Slow process: EDM is a relatively slow process.

2. High equipment cost: EDM machines are expensive.

3. Limited material removal: EDM is limited to removing small amounts of material.

4. Risk of overcutting: EDM can cause overcutting if not controlled properly.

 Applications:

1. Aerospace: EDM is used to machine complex shapes in aircraft and spacecraft components.

2. Automotive: EDM is used to machine engine components, such as cylinder blocks and gearboxes.

3. Medical: EDM is used to machine medical implants, such as hip and knee replacements.

4. Die and mold making: EDM is used to machine complex shapes in dies and molds.

 EDM Machine Components:

1. Power supply: Provides the electrical energy for the EDM process.

2. Electrode: The tool that is used to machine the workpiece.

3. Workpiece: The material that is being machined.

4. Dielectric fluid: The fluid that is used to cool and flush the EDM process.

5. Control system: The system that controls the EDM process, including the power supply, electrode,
and workpiece.

 EDM Process Parameters:

1. Voltage: The electrical potential difference between the electrode and the workpiece.

2. Current: The flow of electrical current between the electrode and the workpiece.

3. Frequency: The number of electrical discharges per second.

4. Pulse duration: The length of time that the electrical discharge is applied.
5. Electrode feed rate: The speed at which the electrode is fed into the workpiece.

 EDM Safety Precautions:

1. Electrical shock: EDM machines can generate high voltages, which can cause electrical shock.

2. Fire hazard: EDM machines can generate sparks, which can ignite flammable materials.

3. Chemical hazards: EDM machines use dielectric fluids, which can be hazardous if not handled
properly.

4. Noise hazard: EDM machines can generate loud noises, which can cause hearing damage.

2 .Electrochemical Machining (ECM):

Definition: ECM is a non-traditional machining process that uses an electrochemical reaction to

remove material from a workpiece.

Principle: ECM works on the principle of electrochemical dissolution, where an electric current is
passed between an electrode (tool) and the workpiece, causing the workpiece material to dissolve
into the electrolyte solution.

 Types of ECM:

1. Electrochemical Grinding (ECG): A combination of ECM and grinding.

2. Electrochemical Honing (ECH): A combination of ECM and honing.

3. Electrochemical Deburring (ECD): A process used to remove burrs and sharp edges.
 Advantages:

1. High accuracy: ECM can achieve high accuracy and precision.

2. Complex geometries: ECM can machine complex shapes and geometries.

3. Hard materials: ECM can machine hard and brittle materials.

4. Low tool wear: ECM electrodes can last for a long time.

5. No mechanical stress: ECM does not induce mechanical stress in the workpiece.

 Disadvantages:

1. Slow process: ECM is a relatively slow process.

2. High equipment cost: ECM machines are expensive.

3. Limited material removal: ECM is limited to removing small amounts of material.

4. Risk of over-machining: ECM can cause over-machining if not controlled properly.

 Applications:

1. Aerospace: ECM is used to machine complex shapes in aircraft and spacecraft components.

2. Automotive: ECM is used to machine engine components, such as cylinder blocks and gearboxes.

3. Medical: ECM is used to machine medical implants, such as hip and knee replacements.

4. Die and mold making: ECM is used to machine complex shapes in dies and molds.

 ECM Machine Components:

1. Power supply: Provides the electrical energy for the ECM process.

2. Electrode: The tool that is used to machine the workpiece.

3. Workpiece: The material that is being machined.

4. Electrolyte solution: The solution that facilitates the electrochemical reaction.

5. Control system: The system that controls the ECM process, including the power supply, electrode,
and workpiece.
 ECM Process Parameters:

1. Voltage: The electrical potential difference between the electrode and the workpiece.

2. Current: The flow of electrical current between the electrode and the workpiece.

3. Electrolyte concentration: The concentration of the electrolyte solution.

4. Temperature: The temperature of the electrolyte solution.

5. Electrode feed rate: The speed at which the electrode is fed into the workpiece.

 ECM Safety Precautions:

1. Electrical shock: ECM machines can generate high voltages, which can cause electrical shock.

2. Chemical hazards: ECM machines use electrolyte solutions, which can be hazardous if not handled
properly.

3. Fire hazard: ECM machines can generate sparks, which can ignite flammable materials.

4. Noise hazard: ECM machines can generate loud noises, which can cause hearing damage.

3. Wire Electric Discharge Machining (WEDM):

Definition: WEDM is a non-traditional machining process that uses a thin wire electrode to cut
complex shapes in a workpiece.

Principle: WEDM works on the principle of electrothermal erosion, where an electrical discharge is
generated between the wire electrode and the workpiece, causing the workpiece material to melt
and vaporize.
 Process:

1. The wire electrode is fed into the workpiece at a controlled rate.

2. An electrical discharge is generated between the wire electrode and the workpiece.

3. The electrical discharge causes the workpiece material to melt and vaporize.

4. The melted material is flushed away by a dielectric fluid.

5. The wire electrode is continuously fed into the workpiece to maintain a consistent cutting rate.

 Advantages:

1. High accuracy: WEDM can achieve high accuracy and precision.

2. Complex geometries: WEDM can cut complex shapes and geometries.

3. Hard materials: WEDM can cut hard and brittle materials.

4. Low tool wear: WEDM wire electrodes can last for a long time.

5. No mechanical stress: WEDM does not induce mechanical stress in the workpiece.

 Disadvantages:

1. Slow process: WEDM is a relatively slow process.

2. High equipment cost: WEDM machines are expensive.

3. Limited material thickness: WEDM is limited to cutting materials up to a certain thickness.

4. Risk of wire breakage: WEDM wire electrodes can break if not properly maintained.

 Applications:

1. Aerospace: WEDM is used to cut complex shapes in aircraft and spacecraft components.

2. Automotive: WEDM is used to cut complex shapes in engine components, such as cylinder blocks
and gearboxes.

3. Medical: WEDM is used to cut complex shapes in medical implants, such as hip and knee
replacements.

4. Die and mold making: WEDM is used to cut complex shapes in dies and molds.
 WEDM Machine Components:

1. Power supply: Provides the electrical energy for the WEDM process.

2. Wire electrode: The thin wire that is used to cut the workpiece.

3. Workpiece: The material that is being cut.

4. Dielectric fluid: The fluid that is used to flush away the melted material.

5. Control system: The system that controls the WEDM process, including the power supply, wire
electrode, and workpiece.

 WEDM Process Parameters:

1. Voltage: The electrical potential difference between the wire electrode and the workpiece.

2. Current: The flow of electrical current between the wire electrode and the workpiece.

3. Wire feed rate: The speed at which the wire electrode is fed into the workpiece.

4. Dielectric fluid flow rate: The rate at which the dielectric fluid is pumped through the WEDM
machine.

5. Workpiece thickness: The thickness of the material being cut.

 WEDM Safety Precautions:

1. Electrical shock: WEDM machines can generate high voltages, which can cause electrical shock.

2. Chemical hazards: WEDM machines use dielectric fluids, which can be hazardous if not handled
properly.

3. Fire hazard: WEDM machines can generate sparks, which can ignite flammable materials.

4. Noise hazard: WEDM machines can generate loud noises, which can cause hearing damage.

4. Laser beam machining

Definition: LBM is a non-traditional machining process that uses a high-powered laser beam to
remove material from a workpiece.

Principle: LBM works on the principle of thermal ablation, where the laser beam heats the workpiece
material to the point of vaporization, creating a high-pressure plasma that removes the material.

 Types of LBM:

1. Pulsed Laser Beam Machining (PLBM): Uses high-energy pulses to remove material.

2. Continuous Wave Laser Beam Machining (CWLB): Uses a continuous laser beam to remove
material.

3. Q-Switched Laser Beam Machining (QSLBM): Uses high-energy pulses with a short duration to
remove material.

 Advantages:

1. High accuracy: LBM can achieve high accuracy and precision.

2. Complex geometries: LBM can machine complex shapes and geometries.

3. Hard materials: LBM can machine hard and brittle materials.

4. Low thermal distortion: LBM causes minimal thermal distortion in the workpiece.

5. No mechanical stress: LBM does not induce mechanical stress in the workpiece.

 Disadvantages:

1. High equipment cost: LBM machines are expensive.

2. Limited material thickness: LBM is limited to machining materials up to a certain thickness.

3. Risk of thermal damage: LBM can cause thermal damage to the workpiece if not controlled
properly.

4. Limited machining speed: LBM is a relatively slow process.

 Applications:

1. Aerospace: LBM is used to machine complex shapes in aircraft and spacecraft components.

2. Automotive: LBM is used to machine engine components, such as cylinder blocks and gearboxes.
3. Medical: LBM is used to machine medical implants, such as hip and knee replacements.

4. Electronics: LBM is used to machine complex shapes in electronic components, such as printed
circuit boards.

 LBM Machine Components:

1. Laser source: Provides the high-powered laser beam.

2. Beam delivery system: Transfers the laser beam to the workpiece.

3. Workpiece: The material that is being machined.

4. Control system: The system that controls the LBM process, including the laser source, beam
delivery system, and workpiece.

 LBM Process Parameters:

1. Laser power: The energy density of the laser beam.

2. Laser pulse duration: The length of time that the laser beam is applied.

3. Laser frequency: The number of laser pulses per second.

4. Beam spot size: The diameter of the laser beam at the workpiece surface.

5. Workpiece feed rate: The speed at which the workpiece is moved relative to the laser beam.

 LBM Safety Precautions:

1. Eye protection: Laser beams can cause eye damage.

2. Skin protection: Laser beams can cause skin damage.

3. Fire hazard: Laser beams can ignite flammable materials.

4. Noise hazard: Laser machines can generate loud noises.