9/1/2011

AnalysisofPreviousIESPapers
Production Materials 28 19 16 15 15 13 12 17
Noofquestionsasked

Total Question 59 52 54 40 49 36 40 47

By

IES-2011 IES-2010 IES 2009 IES-2009 IES-2008 IES-2007 IES-2006 IES-2005 Average

31 33 38 25 34 23 28 30

Swapan KumarMondal
IESOfficer(Railway) NTPCLtd(5Years) TeachingExperience(12Years) GATEpercentile99.96

AnalysisofPreviousGATEPapers
Production GATE-2011 GATE-2010 GATE GATE-2009 2009 GATE-2008 GATE-2007 GATE-2006 GATE-2005 Average 13 13 16 26 25 25 19 15.22 % Materials 1 1 2 0 2 1 1 0.9 % Total Marks 14 out of 100 14 out of 100 18 out of 100 26 out of 150 27 out of 150 26 out of 150 26 out of 150 16.57 %

WhyPPTandVideoneeded?

NoofMarksasked

DiscussedQuestionsareavailableat
www.scribd.com Email:bestmadeeasy@gmail.com Password:reliancejain Thenopen"MyDocumentanddownload desiredfile.

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ClassificationofManufacturingProcess

TheoryofMetalCutting

Shapingorforming Joiningprocess Removalprocess Regenerativemanufacturing

BySKMondal

RegenerativeManufacturing
Production of solid products in layer by layer from

BasicPrincipleofRegenerative Manufacturing

raw materials in different forms.

Very rapid, accurate used for Rapid prototyping

and tooling.

Advantages: ProcessisIndependentofPartFeature NoBlanksareRequires Toolless process EasilyAutomationPossible

Machining
Machining is an essential process of finishing by

Machiningaimto
Fulfillitsfunctionalrequirements Improveitsperformance Prolongitsservice.

which jobs are produced to the desired dimensions y g gradually y removing g the and surface finish by excess material from the preformed blank in the form of chips with the help of cutting tools moved past the work surface. Machining is a removal process.

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DrawbackinMachining
Loss of material in the form of chips.

Machinetool
A machine tool is a nonportable power operated

and reasonably valued device or system of device in which energy is expended to produce jobs of desired size, shape and surface finish by removing excess material from the preformed blanks in the form of chips with the help of cutting tools moved past the work surface.

Why even a battery operated pencil sharpener cannot be accepted as a machine tool?
Ans. A In I spite i of f having h i all ll other h major j features f of f

IAS2009main
Name four independent variables and three

dependent variables in metal cutting. [5marks] IndependentVariables Startingmaterials (tool/work) Toolgeometry CuttingVelocity Lubrication DependentVariables Forceorpowerrequirements Maximumtemperaturein cutting Surfacefinish

machine tools, the sharpener is of low value.

RackangleandClearanceangle

RackSurfaceandFlank
The surface along which the chip moves upward is

called Rack surface of tool.

The other surface which is relieved to avoid

rubbing with the machined surface, is called Flank.

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RakeangleandClearanceAngle
Rake angle () Angle of inclination of rake surface from reference plane i.e. normal to horizontal machined surface. Clearance angle ( ) :Angle of inclination of clearance or flank surface from the finished surface.

The nomenclature of different angle and surface in turning

DiscussiononRackangle

Positiverake
Reducecuttingforce Reducecuttingpower

Positiverakeanglesisrecommended
Machininglowstrengthmaterial Lowpowermachine Longshaftof smalldiameter Set uplacksstrengthandrigidity Lowcuttingspeed

Negativerake
Increase edge strength Increases life of the tool Increases the cutting force High cutting speeds Requires ample power

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Negativerakeanglesisrecommended
Machininghighstrengthalloy Heavyimpactloads High Hi hspeed dcutting i Withrigidset up

Zerorake
To simplify design and manufacturing of the form

tools.
Increases tool strength Avoids digging of the tool into the workpiece Brass is turned with zero rake angle

Clearanceangle
Provided to avoid rubbing of the tool (flank) with

TypesofMachining

the machined surface.

Reduce tool wear Increase tool life. Must be positive (30 150)

OrthogonalCutting
1. Cutting edge of the tool is perpendicular to the

direction of cutting velocity.

2. The cutting edge is wider than the workpiece

width and extends beyond the workpiece on p either side. Also the width of the workpiece is much greater than the depth of cut. 3. The chip generated flows on the rake face of the tool with chip velocity perpendicular to the cutting edge. 4. The cutting forces act along two directions only.

Geometryofsinglepointturningtool

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Classification: (According to the number of major cutting edges (points) involved.)

Single point: turning, turning shaping, shaping planning, planning slotting

SystemofDescriptionofToolGeometry
(I) Machinereferencesystem:ASAorANSI (II) Toolreferencesystem:ORSandNRS (III)Workreferencesystem: WRS

tools etc.
Double point: drilling tools Multipoint: Milling, broaching, hobbing tools etc.

ASinglepointcuttingtool

ASAorANSIsystem

Endcuttingedgeangle,ECEA

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BackRakeangle
It is the angle between the face of the tool and the

Siderakeangle(axialrake)
It is the angle between the face of the tool and the base

base of the shank or holder, and is usually measured in a plane through the sidecutting edge, and at right angles to the base
It affects the ability of the tool to shear the work

of the shank or holder, and is usually measured in a plane perpendicular to the base, to the sidecutting edge Increase in the I i the th side id rake k angle l reduces d th chip hi thickness in turning.

material and form the chip.

Sidereliefangle
It is the angle between the portion of the side flank

Endreliefangle
It is the angle between the portion of the end flank

immediately below the sidecutting edge, and a line drawn through this cutting edge

immediately below the end cutting edge, and a line drawn through this cutting edge perpendicular to the base. It is usually measured in a plane perpendicular to the end flank.
The End Relief Angle prevents friction on the flank

perpendicular to the base.

It is measured in a plane perpendicular to the side

flank.

of the tool.

Sidecuttingedgeangle,SCEA(CS)
Itistheanglewhichpreventsinterferenceasthetoolenters

SCEAandLeadAngle

theworkmaterials.(Normally15 30o ) Largerthisangle,thegreaterthecomponentofforcetending toseparatetheworkandthetool.(MayinduceChatter) Atitsincreasedvalueitwillhavemoreofitslengthinaction foragivendepthofcut. Atitsincreasedvalueitproducethinnerandwiderchipthat willdistributethecuttingheat.(increasetoollife) ZeroSCEAisdesirablewhenmachiningcastingandforging withhardandscalyskins,becauseoftheleastamountoftool edgeshouldbeexposedtothedestructiveactionoftheskin.

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Lipangle
Lip angle or cutting angle depends on the on the

Noseradius
It is curvature of the tool tip. It provides strengthening of the tool nose and better

rake and clearance angle provided on the tool and determine the strength of the cutting edge. A larger lip of l l angle l permits machining h f harder h d metals, allow heavier depth of cut, increase tool life, better heat dissipation. Larger lip angle reduce cutting speed (Disadvantage)

surface finish.
But too large a nose radius will induce chatter. If nose radius increased cutting force and cutting power

increased.

Tooldesignation(ANSI)orASA
Toremembereasilyfollowtherule
rake,relief,cuttingedge Sidewillcomelast finishwithnoseradius(inch)

OrthogonalRakeSystem(ORS)
Inclination angle (i) side rake ( ) side relief ()

i 1 Ce R

b s e s Ce Cs R

1 end relief ( ) End cutting edge (Ce) Approach ( ) nose radius (mm) Approach angle () = 90 - CS [Sometimes is called principal cutting edge angle (Orthogonal cutting)] For Pure orthogonal cutting, i = 0 For Oblique cutting, i 0

InterconversionbetweenASA&ORS

Criticalcorrelations
When = 90 When i = 0 When i = 0 and = 90 (P orthogonal (Pure h l cutting) i )
is principal cutting edge angle
i is inclination angle

s = n = s = n =

s is side rake angle ( ASA) is orthogonal rake angle (ORS ) n is normal rake angle (NRS)

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Causeofchipformation
Yieldinginductilematerial Brittlefracture inbrittlematerial

Mechanismofchipformationin ductilematerial

Mechanismofchipformationin brittlematerial

Typesofchip
Continuouschip Discontinuouschip Co Continuous t uouschip c pwith t BUE U Serratedchip

Fig.Developmentandpropagationofcrack causingchipseparation.

Typesofchipdependson
Work material (ductile, brittle) Cutting tool geometry (rake angle, cutting angle

ConditionsforformingDiscontinuouschip
ofirregularsizeandshape workmaterialbrittle(greycastiron) ofregularsizeandshape workmaterial ductilebuthardandworkhardenable feed large toolrake negative cuttingfluid absentorinadequate

etc.)
Cutting velocity and feed rate. Types of cutting fluid and method of application.

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ConditionsforformingContinuous chipwithoutBUE
work material ductile Cutting velocity high Feed low Rake angle positive and high Cutting fluid both cooling and lubricating

ConditionsforformingContinuous chipwithBUE
Workmaterial ductile Cuttingvelocity medium Feed medium Cuttingfluid absentorinadequate.

Built up Edge(BUE)formation
In machining ductile material with long chip tool

Built up Edge(BUE)formation
Withthegrowthof theBUE,theforcealsogradually

contact length, lot of stress and temperature develops in the secondary deformation zone at the chip tool interface. Under such high g stress and temperature p in between two clean surfaces of metals, strong bonding may locally take place due to adhesion similar to welding. Such bonding will be encouraged and accelerated if the chip tool materials have mutual affinity or solubility. The weld material starts forming as an embryo at the most favorable location and thus gradually grows.
Contd.

increasedduetowedgingactionofthetooltipalong withtheBUEformedonit. Whenevertheforceexceedsthebondingforceof the BUE theBUEisbrokenorshearedoffandtakenawayby BUE, theflowingchip.Thenagainstartsformingandgrow. ThisBUEchangesitssizeduringthecuttingoperation. Itfirstincreases,thendecreases,andthenagain increases. Lowcuttingspeedalsocontributestotheformationof BUE.

EffectsofBUEformation
Harmfuleffect Itunfavourably changestherakeangleatthetooltip causingincreaseofcuttingforcei.e.powerconsumption. Inducevibration. Poorsurfacefinish. Goodeffect BUEprotectsthecuttingedgeof thetooli.e.increases toollife.

ReductionorEliminationofBUE
Increase Cuttingspeed Rakeangle Ambientworkpiecetemperature. Reduce Feed Depthofcut Use Cuttingfluid Changecuttingtoolmaterial(ascermets).

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SerratedChips
Serrated chips also called segmented or non

Whenisforcedchipbreakingnecessaryandwhy?
Whenchipscontinuouslyformandcomeoutvery hot,sharpandatquitehighspeed Underthecondition softductileworkmaterial flatrakesurfacewithpositiveornearzerorake For Safetyandconvenienceof theoperator easycollectionanddisposalof chips

homogeneous chips are semicontinuous chips with zones of low and high shear strain.
Metals with

low thermal conductivity and

strength that decreases sharply with temperature, such as titanium exhibit this behaviour, the chips have sawtooth like appearance.

Shearangle( ) V t l sin 1 r= = c = c = = tc l V cos ( )

and

Proof

tan =

r cos 1 r sin

Fororthogonalcutting
1 ==e
2

) Cuttingshearstrain(

= cot + tan ( )
= cos sin cos ( )

Fromthisexpressionwewillget
canbereducedby) (Thevalueof
usingtoolhavinglargepositiverake Reducefrictionbyusinglubricant.

10

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Proof

Velocitiesinmetalcutting
(i) The velocity of the tool relative to the work piece (V) called the cutting speed. (ii) The velocity of the chip relative to the work, work Vs called the shear velocity. (iii) The velocity of the chip up the face of the tool Vc, called chip velocity.

Derivetheexpressionforvelocitiesin metalcutting.ESE2004(Conv.)

ShearStrainRate
(Note:itisnotshearstrainitisrateof shearstraini.e.flow)

Vs d = dt thickness of shear zone ( ts )

DeterminationofUndeformedchip thicknessinTurning:(VIMP) Forsinglepointcuttingtool t = f sin d b= sin Where

t=Uncutchipthickness f =feed =90 Cs=approachangle Cs=sidecuttingedgeangle

11

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Whenacutismadetheforcesactingonthemetalchipsare:

Force & Power in Metal Cutting

BySKMondal

Fc andFt
The two orthogonal components (horizontal and vertical) Fc and Ft of the resultant force R can be measured by using a dynamometer. The horizontal component is the cutting force (Fc) and the vertical component is the thrust force (Ft)

Theforcerelations

F = Fc sin + Ft cos N = Fc cos Ft sin Fn = Fc sin + Ft cos Fs = Fc cos Ft sin

and = F = tan N

(VIMP)

MerchantforcecircleDiagram(MCD)

MerchantAnalysis Assumption

( )

It is based on single shear plane theory.

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LimitationsofMerchantsTheory
1. Merchant theory is valid only for orthogonal cutting. 2. By the ratio F/N, the Merchant theory gives apparent

FromMerchantForceCircleDiagram

(not actual) coefficient of friction.

ModifiedMerchantTheory
s = so + ks where, s is the normal stress on shear plane. Fn s = As 1 and d then h 2 + - = cot ( k )

TheoryofLeeandShaffer
They applied the theory of plasticity for an ideal-rigid-plastic material. They also assumed that deformation occured on a thin-shear plane. They derive. = + 4

OtherRelations
ByStabler Bydimensionalanalysis

Compareturningwithorthogonalcutting

where, k, a, b, k1, a1 and b1 are empirical constants to be established from the experimental data f is feed and d is depth of cut.

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Fc: primary cutting force acting in the direction of

MetalRemovalRate(MRR)
Metalremovalrate(MRR)=Ac.V =btV Where h Ac =crosssectionareaofuncutchip V=cuttingspeed= DN
60

the cutting velocity, largest force and accounts for 99% of the power required by the process. Ff: feed force acting in the direction of the tool feed. This force is about 50% of Fc, but accounts for only a small percentage of the power required because feed rates are usually small compared to cutting speeds. Fr: radial or thrust force acting perpendicular to the machined surface. This force is about 50% of Ff and contributes very little to power requirements because velocity in the radial direction is negligible.

PowerConsumedDuringCutting

FrictioninMetalCutting

Fc V
Where Fc =cuttingforce V=cuttingspeed=
DN 60

HeatandTemperatureinMetalCutting

Determinationofcuttingtemperature
Analytically using mathematical models (equations) if available or can be developed. This method is simple, quick and inexpensive but less accurate and precise. Experimentally this method is more accurate, precise and reliable.

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ExperimentalMethodsare
Calorimetricmethod Decolourising agent Toolworkthermocouple Movingthermocoupletechnique Embeddedthermocoupletechnique Usingcompoundtool IndirectlyfromHardnessandstructuraltransformation Photocelltechnique Infraraydetectionmethod

Dynamometersformeasuringcuttingforces
Measurement of cutting force(s) is based on three basic principles : (a) measurement of elastic deflection of a body subjected to the cutting force (b) measurement i.e. strain t of f elastic l ti deformation, d f ti i t i induced by the force (c) measurement of pressure developed in a medium by the force.

DesignrequirementsforTool force Dynamometers

Sensitivity The dynamometer should be reasonably sensitive for precision measurement Rigidity The dynamometer need to be quite rigid to withstand the forces without causing much deflection which may affect the machining condition Cross sensitivity The dynamometer should be free from cross sensitivity such that one force (say PZ) does not affect measurement of the other forces (say PX and PY)

TypesofDynamometers
The dynamometers being commonly used nowadays for measuring machining forces desirably accurately and precisely (both static and dynamic characteristics) are Either

Strain gauge type

Or

piezoelectric type
Strain gauge type dynamometers are inexpensive but less accurate and consistent, whereas, the piezoelectric type are highly accurate, reliable and consistent but very expensive for high material cost and stringent construction.

StrainGaugeDynamometers
The strain, induced by the force changes the electrical resistance, R, of the strain gauges which are firmly pasted on the surface of the toolholding beam as

R = G R

where, G = gauge factor (around 2.0 for conductive gauges) The change in resistance of the gauges connected in a wheatstone bridge produces voltage output V, through a strain measuring bridge (SMB)