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The Development of a New Course in Nontraditional Machining

Explore how a new course on nontraditional machining bridges theory and practice, offering students a knowledge-oriented approach. The course includes lectures, workshop experiments, and focuses on EDM, ECM, USM, AJM, and LBM processes.

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The Development of a New Course in Nontraditional Machining

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  1. The Development of a New Course in Nontraditional Machining Kuen-Ming Shu* and Shan-ying Pan** *National Formosa University, Huwei, Yunlin, Taiwan, R.O.C **National Tsing Hua University, Hsinchu, Taiwan, R.O.C

  2. Introduction • Nontraditional machining course was initiated in the MMED at NFU in Taiwan in 1998. • 2 credits with a 2hrs lecture per week. • It is developed to offer students with a knowledge-oriented nontraditional machining technology.

  3. To increase the student’s learning experience, it is necessary that learning process should involve more than the usual learning by doing approach. • In order to bridge the gap between theory and practice, we establish this new course called “Nontraditional machining technology and practice”.

  4. Nontraditional machining • Nontraditional machining is a group of processes involving mechanical, thermal, electrical or chemical energy (or combinations of these energies). • They do not use a sharp cutting tool in the conventional sense.

  5. LECTURE COURSE • There are literally dozens of nontraditional machining processes, most of which are unique in their range of applications. • The nontraditional processes are often classified according to principal form of energy used to effect material removal.

  6. Four types of nontraditional machining

  7. Problems with traditional instruction • Students didn't learn skills • Students are not given the opportunity to pursue new knowledge in the service of achieving intrinsically motivating goals. • The knowledge or skills is divorced from real life

  8. New course description • We developed a practice-based course for teaching and learning. • It has 1 hr lecture and two hrs of workshop experiments per week for 18 weeks.

  9. The chose practice courses

  10. EDM processes • Electrode fabrication • Set EDM parameters • EDM • Surface polishing

  11. Guide rod and Engraving cutting tool grinding

  12. 3D engraving

  13. The products of 3D engraving

  14. Electrical discharge machining（EDM） • Remove metal by a series of discrete electrical discharges (sparks) that cause localized temperatures high enough to melt or vaporize the metal in the immediate vicinity of the discharge.

  15. The products of EDM

  16. Electrochemical machining（ECM） • Remove or plate metal from an electrically conductive workpiece by anodic dissolution or cathode reduction, in which the shape of the workpiece is obtained.

  17. The products of ECM

  18. Ultrasonic machining • A tool vibrating at low amplitude and high frequency to weld material, or abrasives contained in a slurry are driven by tool at high velocity against the work.

  19. The products of USM

  20. Abrasive jet machining • A material removal process that results from the action of a high-velocity stream of gas containing small abrasive particles.

  21. The products of AJM

  22. Laser beam machining • The source of energy is a laser, which focuses optical energy on the surface of the workpiece. The highly focused, high-density energy melts and evaporates portions of the workpiece in a controlled manner.

  23. The products of LBM

  24. Work sheet

  25. Worksheet (Cont.)

  26. Instruction methods • For the first week, all the equipments to perform the experiments were introduced. • The following weeks, the students were asked to prepare materials, design projects, implement projects, and evaluate and demonstrate their products in teams.

  27. Evaluate and demonstrate products in teams

  28. Evaluation sheet

  29. Evaluate results • 84 students (i.e. 70%) were very satisfied after took this course, while 34students (i.e. 28%) were satisfying. • Only 1 student choice the “Average” or “unsatisfying” item respectively. • It seems that almost all students enjoy this new developed course.

  30. The intention of students to take similar course • It is shown that 111 students (i.e. 93%) are very interested in this new developed course and claimed that they would take the similar course if they were provided

  31. Conclusions • In order to promote traditional instructing methods, we have developed of a new course on nontraditional machining. • Both contents of lecture and practice are demonstrated in this new course. • The worksheet for practice experiments and evaluate questionnaire sheet were also developed. • The new course was developed successfully.

  32. END Thanks for your attention

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