Unit 1

Theory of metal cutting: Types of metal cutting processes, Mechanism of chip formation – Forces and temperature in metal cutting, Tool wear, Tool life – Machinability and surface finish, Cutting tool materials and cutting fluids.

Cylindrical Surface Machining: Basics of turning process, lathe and its accessories, operations, process parameters. Machining time calculations. Drilling Machines: Types, operations, process parameters. Design considerations for drilling operations. Machining time calculations.

Unit 2

Flat and Profile Machining: Milling operations – Milling machines: types, operations, process parameters.

Unit 3

Finishing Processes: Theory of grinding process – Fundamentals of abrasives – Grinding wheels- Grinding operations and machines. Super finishing processes.

Lab Session

Process Planning: Selection of tooling and optimum process parameters and preparation of process plan for machining a given component.

Machining practice: Study and practice various metal cutting operations in lathe, milling, drilling and grinding machines.

Cutting force measurement: Measurement of cutting forces in turning, milling and drilling processes using tool dynamometers.

Group Project: Process planning, Tool life studies, selection of optimum machining conditions for MRR and Surface finish criterions in lathe, drilling, grinding and milling operations and perform machining operation as per the given drawing using the machines available in the workshop.

Course Objectives

This course is expected to enable the students to

• To impart knowledge on theory of metal cutting, its mechanics, and the influence of its parameters on machining processes.
• Understand the working principles of lathe, milling and grinding and independently operate these machines by selecting optimum machining parameters.
• Measure cutting forces in turning, milling and drilling processes using cutting tool dynamometers.

Course Outcomes

• CO1: Interpret the machining characteristics using theory of metal cutting
• CO2: Understand the construction and mechanisms of machine tools
• CO3: Select and perform machining operations with optimum machining parameters, cutting tools and accessories for a machining process.
• CO4: Measure cutting forces using tool dynamometers
• CO5: Follow safety rules and good practices in machining operations.

CO – PO Mapping

Textbook(s)

• SeropeKalpakjian and Steven R. Schmid – ‘’Manufacturing Engineering and Technology’ – Prentice Hall – 2013 – 7th Edition

Reference(s)

• Hajra Choudhury S. K., Hajra Choudhury A. K., Roy N. – ‘Elements of Workshop Technology’ Media Promotors & Publishers Pvt. Ltd. – 2010 – Vol.II: Machine Tools, 13e
• Jain R. K. and Gupta S. C. – ‘Production Technology’ – Khanna Publishers – 2008
• Ghosh A. and Mallik A. S. – ‘Manufacturing Science’ – Affiliated East West Press Private Limited – 2010
• ‘H.M.T. Production Technology: Hand book` – Tata McGraw-Hill Publishing Company Limited – 1990

Evaluation Pattern