THENI KAMMAVAR SANGAM COLLEGE OF TECHNOLOGY

KODUVILARPATTI, THENI – 625 534

DEPARTMENT OF MECHANICAL ENGINEERING
SCHEME OF EVALUATION-INTERNAL ASSESSMENT I
Branch/Year/Sem/Sec : MECH /IV/VII/A Exam. Date : 09.09.20
Subject Code/Name : ME8073/Unconventional Machining Process
Exam Time : 1.30 Hrs Max. Marks : 50
Answer All Questions
BT
PART – A (10×2=20) M CO
Level
1. Define UCMP?
An unconventional machining process (or non-traditional machining process) is a
special type of machining process in which there is no direct contact between the tool 2 1 1
and the work piece. In unconventional machining, a form of energy is used to remove
unwanted material from a given work piece.
2. Write the difference between conventional and unconventional machining process?

2 3 1

3. What are all the need for UCMP?

1.Machine all type of engineering materials.
2.Produce high quality finished product
2 1 1
3.Get Higher Productivity
4.Machine complex shape jobs.
5.Avoid physical contact between tool and workpiece.
4. Write the limitations of unconventional machining process?
1.Initial setup cost.
2 1 1
2.Some of the process are highly expensive
3.Commercially not available
5. Write the classifications of UCMP based on energy?
Mechanical: AJM,WJM,AWJM,USM
Electrical: EDM,WCEDM
2 2 1
Chemical: CM
Electro chemical: ECM,ECG,ECH,ECD
Thermal: LBM,PAM,EBM,IBM
6. What types of materials being machined in various UCMP?
Steel: EDM
Super Alloys: AJM,PAM,EDM
2 1 1
Titanium: EDM
Refractory materials: AJM,EBM,EDM
Ceramics: USM,AJM,EBM,LBM
7. Which shapes of Products are suitable for AJM & USM?
AJM: Shallow Pocketing
2 1 1
USM: Shallow holes

8. What Process characteristics are best suitable for AJM,WJM,USM? 2 1 1

AJM: MRR 0.84 mm3/min Accuracy +/- 0.05
WJM: MRR 0.8 mm3/min
 USM: MRR 5 mm3 /min Accuracy +/-0.006mm
9. Define AJM?
Removing unwanted layer of metal from the surface of work piece material by using
2 1 1
High velocity High pressure Abrasive Gas Mixture. Metal is removed with the help of
Abrasive and erosion action of Jet mixture.
10 Define USM & EDM?
. USM: Removing metal by converting ultrasonic wave energy in to mechanical
Vibration and the abrasive action of abrasive particles. 2 1 2
EDM: Removal of metal by creating powerful electric spark in between tool work
piece.
PART – B (2X10= 20)
11 (a) Briefly explain the construction and working principle of AJM with neat sketch?
.

Working
A typical set-up for abrasive jet machining is shown in the figure. The abrasive
particles are held in a suitable holding device, like a tank and fed into the mixing
chamber. A regulator is incorporated in the line to control the flow of abrasive
(10) 2 1
particles compressed air or high-pressure gas is supplied to the mixing chamber
through a pipeline.

This pipeline carries a pressure gauge and a regulator to control the gas flow and
its pressure. The mixing chamber, carrying the abrasive particles is vibrated and
the amplitude of these vibrations controls the flow of abrasive particles. These
particles mix in the gas stream, travel further through a hose and finally pass
through the nozzle at a considerably high speed. This outgoing high-speed
stream of the mixture of gas and abrasive particles is known as abrasive jet.

(OR)

(b) Explain the effects of various parameters of AJM on MRR with graphical (10) 2 1
 representation?

12 (a) Briefly explain the construction and working principle of WJM with neat sketch? (10) 2 1
.

 Water from the reservoir is pumped to the intensifier using a hydraulic

pump.
 The intensifier increases the pressure of the water to the required level.
Usually, the water is pressurized to 200 to 400 MPa.
 Pressurized water is then sent to the accumulator. The accumulator
temporarily stores the pressurized water.
 Pressurized water then enters the nozzle by passing through the control
valve and flow regulator.
 Control valve controls the direction of water and limits the pressure of
water under permissible limits. 5
 Flow regulator regulates and controls the flow rate of water.
 Pressurized water finally enters the nozzle. Here, it expands with a
tremendous increase in its kinetic energy. High velocity water jet is produced
by the nozzle.
 When this water jet strikes the workpiece, stresses are induced. These
stresses are used to remove material from the workpiece.
 The water used in water jet machining may or may not be used with
stabilizers. Stabilizers are substances that improve the quality of water jet by
preventing its fragmentation.

(OR)
(b) Briefly explain the construction and working principle of EDM with neat sketch? (10) 2 2

5
 5

PART – C (1X10= 10)

13 (a) Briefly explain the construction and working principle of USM with neat sketch?
.

(10) 2 1

(OR)
(b) Explain the effects of various parameters of USM on MRR with graphical
representation?

(10) 2 1

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BT Level: 1- Remembering, 2- Understanding, 3- Applying, 4- Analyzing, 5-Evaluating, 6-Creating

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