ADVANCED MANUFACTURING PROCESSES

Unit I : Non-Conventional Machining Processes                                     

1.1    Fundamentals of Non-conventional Methods: Needs and Types of Non-conventional methods. Importance of methods.

1.2    Working Principle, Set-up of: EDM, WEDM, ECM, PAM, AJM, USM, EBM and LBM.

1.3    Advantages, Limitations and Applications of: EDM, WEDM ECM, PAM, AJM, USM, EBM & LBM.

Unit II : Milling Machines and Milling Processes                                      

2.1    Milling: Working Principle of Milling Machine, Types of Milling Machines.

2.2    Milling Cutters: Different types of Cutters used in Milling, Face Milling Cutter, End Milling Cutter, Staggered tooth Milling Cutter, Side & Face Milling Cutter, Form Milling Cutters, Metal Slitting Saw etc.

2.3    Milling Processes: Plain Milling, Face Milling, Side Milling, End Milling, Straddle Milling, Gang Milling, Slotting, Slitting, Up milling and Down Milling.

2.4    Cutting Parameters: Cutting Speed, Feed.

2.5    Dividing Head: Types, Function of Dividing Head, Method of Indexing, Index Plates.

Unit III : Gear Manufacturing                                                                     

3.1    Gear Manufacturing Methods – Function and Types of Gears, Gear Manufacturing Methods

3.2    Gear Hobbing – Working Principle, Types of Gear Hobbing, Advantages, limItations and Applications of Gear Hobbing

3.3    Gear Shaping – Gear Shaping by Pinion Cutter, Gear Shaping by Rack Cutter, Advantages, Limitations and Applications of both the Methods and Comparison of Gear Hobbing and Gear Shaping

3.4    Gear Finishing Methods – Need of Gear Finishing, Gear Finishing Methods:

(a)  Gear Shaving

(b)  Gear Grinding

(c)  Gear Burnishing

(d)  Gear Lapping

(e)  Gear Honing

Unit IV : Fundamentals of Computer Aided Manufacturing (CAM)      

4.1    CAM Concept, NC (Numerical Control), CNC (Computerized Numerical Control)  and DNC (Direct Numerical Control) – Concept, Features and Differences.

4.2.    CNC Machines: Types, Classification, Working and Constructional Features Advantages, Limitations and selection Criteria.

4.3    Elements of CNC machines – Types, Sketch, Working and Importance of: Slide Ways; Re-circulating Ball Screw; Feedback Devices (transducers, encoders); Automatic Tool Changer (ATC); Automatic  Pallet Changer (APC);

4.4    CNC Tooling: Tool Presetting – Concept and Importance; Qualified Tools – Definition Need and Advantages; Tool holders – Types and Applications.

4.5    CNC Turning Centres: Types; Features; Axes Nomenclature; Specification; Work Holding Devices -Types, Working and Applications.

4.6    CNC Machining Centres: Types; Features; Axes Nomenclature; Specification; Work Holding Devices – Types, Working and  Applications.

Unit V : CNC Part Programming                                                              

5.1    Definition and Importance of various Positions like Machine Zero, Home Position, Work Piece Zero and Programme Zero.

5.2    CNC Part Programming: Programming Format and Structure of Part Programme.

5.3    ISO G and M Codes for Turning and Milling-Meaning and Application Important Codes.

5.4    Simple Part Programming for Turning using ISO Format having Straight Turning, Taper Turning (Linear Interpolation) and Convex/Concave Turning (circular interpolation).

5.5    Simple part Programming for Milling using ISO format.

5.6    Importance, Types, Applications and Format for: Canned Cycles; Macro; Do Loops; Subroutine.

5.7    CNC Turning and Milling Part Programming using Canned Cycles, Do loops and Subroutine.

5.8    Need and Importance of various Compensations: Tool Length Compensation; Pitch Error Compensation; Tool Radius Compensation; Tool Offset.

5.9    Simple Part Programming using various compensations.

5.10  Virtual CNC Machine Simulators. Generation of Generating Shop Documentation using a CAM Software, Cycle Time Sheets, Tools List with Tool Layout, Spindle Utilization Graphs, Program for different Control Systems and different Configuration of Machines.

Unit VI : Automation and Robotics                                                           

6.1    Automation – Define, Need of Automation, High And Low Cost Automation, Examples of Automations.

6.2    Types of Automation – Fixed (Hard) Automation, Programmable Automations and Flexible Automations (Soft).Comparison of types of Automations.

6.3    Group Technology – Concept, Basis for Developing Part Families, Part Classification and Coding with Example, Concept of Cellular Manufacturing. Advantages and Limitations.

6.4    Flexible Machining System – Introduction, Concept, Definition and Need, Sub-systems of FMS, comparing with other Manufacturing Approaches.

6.5    Introduction to Robotics – Definition of Robot and Robotics, Advantages Disadvantages and Applications.

6.6    Components of Robotics Manipulators, End Effectors, Actuators, Sensors, Controller, Processor and Software.