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    ME30604 Nontraditional Manufacturing Processes

    Uploaded by

    shubham jaiswal
    The document is an examination for a course on nontraditional manufacturing processes. It contains 8 questions assessing students' knowledge of various topics: 1) thermal machining processes and laser cutting, 2) abrasive jet machining calculations, 3) fiber laser cutting, 4) electrochemical machining principles, 5) hybrid manufacturing processes, 6) electrochemical honing and grinding processes, 7) micro-lithography and scaling, and 8) micro-EDM fundamentals and wire electrodischarge grinding. Students are asked to define processes, derive equations, explain principles and applications, compare methods, and diagram sequences and tool fabrication techniques involving various nontraditional manufacturing technologies.

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    ME30604 Nontraditional Manufacturing Processes

    Uploaded by

    shubham jaiswal
    34 views3 pages
    The document is an examination for a course on nontraditional manufacturing processes. It contains 8 questions assessing students' knowledge of various topics: 1) thermal machining processes and laser cutting, 2) abrasive jet machining calculations, 3) fiber laser cutting, 4) electrochemical machining principles, 5) hybrid manufacturing processes, 6) electrochemical honing and grinding processes, 7) micro-lithography and scaling, and 8) micro-EDM fundamentals and wire electrodischarge grinding. Students are asked to define processes, derive equations, explain principles and applications, compare methods, and diagram sequences and tool fabrication techniques involving various nontraditional manufacturing technologies.

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    ME30604-Nontraditional-Manufacturing-Processes

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    The document is an examination for a course on nontraditional manufacturing processes. It contains 8 questions assessing students' knowledge of various topics: 1) thermal machining processes and laser cutting, 2) abrasive jet machining calculations, 3) fiber laser cutting, 4) electrochemical machining principles, 5) hybrid manufacturing processes, 6) electrochemical honing and grinding processes, 7) micro-lithography and scaling, and 8) micro-EDM fundamentals and wire electrodischarge grinding. Students are asked to define processes, derive equations, explain principles and applications, compare methods, and diagram sequences and tool fabrication techniques involving various nontraditional manufacturing technologies.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    34 views3 pages

    ME30604 Nontraditional Manufacturing Processes

    Uploaded by

    shubham jaiswal
    The document is an examination for a course on nontraditional manufacturing processes. It contains 8 questions assessing students' knowledge of various topics: 1) thermal machining processes and laser cutting, 2) abrasive jet machining calculations, 3) fiber laser cutting, 4) electrochemical machining principles, 5) hybrid manufacturing processes, 6) electrochemical honing and grinding processes, 7) micro-lithography and scaling, and 8) micro-EDM fundamentals and wire electrodischarge grinding. Students are asked to define processes, derive equations, explain principles and applications, compare methods, and diagram sequences and tool fabrication techniques involving various nontraditional manufacturing technologies.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 3

    Department of Mechanical Engineering

    lIT Kharagpur
    Nontraditional Manufacturing Processes: Mf30604
    End Sem. Examination: Spring 2017-18 Time: 3 hours FilII marks: 100

    Attempt All Questions of Part-A and Part-B

    Part - A (50 marks)

    1. Answer the following in brief (5x5=25)

    1. Name different nontraditional machining processes in which material removal


    mechanism is thermal. Describe briefly with a schematic diagram the
    construction and operating principle of a machine which utilizes photons for
    machining. How is material removed while cutting metal sheets by this
    machine?
    11. Among different nontraditional machines which one will you prefer to make a
    square groove in a glass plate? Describe briefly the construction of the
    machine with a schematic diagram. What are process parameters that
    determine the material removal rate?
    III. Name the nontraditional machining process which can produce the minimum
    feature size with highest resolution and also image it? What is the basic
    mechanism of material removal in this process and on what factors machining
    rate depends?
    IV. What is the main difference between the conventional forming and high
    energy rate forming? Name the different methods of HERF? Explain the basic
    principle of electromagnetic forming of a stainless steel sheet having low
    electrical conductivity?
    v. What is the role of magnetic field in magnetron sputtering process? Why is
    the step coverage better in magnetron sputtering process of coating than that
    in thermal evaporation process? What are the factors that influence the quality
    of film deposited?

    2. a. Derive an expression for the material removal rate of a brittle material in abrasive
    jet machining. (5)
    b. A workpiece has a 10 urn thick ceramic coating on its surface. The strength of
    coating is 4 Gpa. This coating is to be removed by abrasive jet having average grit
    diameter of 50 urn and grit density of 4000 kg/rrr'. IftheIO urn thick coating is to
    be removed in a single impact of grit what should be its velocity? Estimate the
    AJ mass flow rate to remove ceramic coating over a 10 em xl 0 em area in one
    minute machining time. (3+4=7)

    3. I. A fiber laser beam has the following characteristics:


    Wavelength = 1.06/!m, M2 =30, Beam diameter = 16 mm, Laser power = 2 kW.
    The laser beam is to be focused to a spot of diameter '- 500 urn with the help of a
    convex lens on a steel plate for cutting. What should be the focal length or
    lens?

    The sheet thickness is 5 rnrn and the severance energy for O2 assisted laser cutting
    of steel is 8 J/mm2. What will be the maximum cutting speed'!
    What is the role of O2 in this cutting process? (3+2+1=6)

    II. Full penetration butt welding of two 6 mrn thick titanium plates is to be done at 3
    mlmin speed with an electron beam focused to 600 urn diameter spot at the plate
    surface. What will be the e-beam power required to perform the welding and what
    will be the actual weld-bead width? During the welding process ~5% material is
    evaporated and the e- beam power coupling efficiency including conduction loss
    is 0.1.
    The thermo-physical properties of aluminum are given as the following:
    Density = 4510 kg m', Latent heat of fusion=
    437 kJ kg-I, Latent heat of
    vaporization =9000 kJ kg", Specific heat = 520 J kg' K-I, Melting temperature
    =1670°C, Boiling temperature = 3260°C, Thermal conductivity =19 W m-IK-I
    You may assume constant properties over the whole temperature range. PI

    Part - B (50 marks)

    4(a) Explain the functions of servo reference voltage and servo sensitivity in relation to
    maintaining the inter-electrode gap in EDM.

    4(b) Explain with simple diagram how the effect of variation of electrolyte temperature
    {between exit and entry side) in the inter-electrode gap is taken care of during designing for
    tool in ECM.

    4(c) The composition (% by weight) of Nimonic 75 alloy is given in the table below:

    Element Ni Cr Fe Ti Si Mn Cu
    % presence by 72 20 5 0.5 I 1 0.5
    weight
    Atomic weight 58.7 52 56 48 28 54 63
    Valency 2, 3 2,3,4 2, 3 3,4 4 2,4,6,7 1,2
    Density (g/crrr') 8.9 7.2 7.9 4.5 2.3 7.4 9

    Calculate the time required to electrochemically machine a square block (area = 20 mm


    x 20 nun) of this alloy to a depth of 5 mm when a current of 2000 A is used. Use the
    lowest valency of dissolution for each element. Faraday's constant= 96500 coulombs.
    (3+3+4 = 10 Marks)

    5.(a) What are the reasons for developing a hybrid manufacturing process?

    5.(b) How are the hybrid processes classified?


    "

    S.(c) Write short notes on the following two hybrid processes highlighting process mechanism
    with schematic diagrams and their advantages in terms of process capabi lities ..
    I. Abrasive electro-discharge grinding (AEDG)
    II. Lase,' assisted chemical etching
    (I+l+2x4 = 10 Marks)

    6(a) Highlight two application areas where electrochemical honing process may be useful.

    6(a) With a neat diagram explain the different interaction phases of the rotating grinding
    wheel with moving job and corresponding material removal mechanisms during electro-
    chemical grinding (ECG) process.

    6(c) In a photochemical blanking operation a rectangular slit 300 micron width was attempted
    to be made on a copper-beryllium sheet of 200 micron thickness by selectively exposing
    only the top surface with a mask. It resulted in a tapered slit for which the dimension at
    the top was more than the dimension at the bottom.
    Suggest some change in the approach while continuing with the same process so that a
    near-vertical slit could be obtained. (Use suitable diagram for explanation)
    (2+6+2 = 10 Marks)

    7(a) Prove that buckling strength to weight ratio of an Euler column increases if its linear
    dimensions are scaled down.

    7(b) With the help of diagram explain the process sequences for a optical lithography process
    on a silicon wafer.

    7(c) Why is an X-ray source more suitable for high resolution lithography?
    (3+6+1 = 10 Marks)

    8(a) What .·~e of power supply one should use for electro-chemical-discharge
    machining \.ECDM) and why?

    8(b) Why is the manufacture of the micro-electrode tools essentially carried out in situ in a
    micro-EDM set up itself?

    8(c) Explain with a schematic diagram the way a micro-tool (for subsequent use micro-
    EDMing operation) can be fabricated in-situ in a micro-EDM set up by wire
    electrodischarge grinding (WEDG) process?

    8(d) What are the possible sources of stray capacitance in a micro-EDM set up?
    (3+2+4+1 = 10 Marks)

    **** End of question paper *****

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