Machine Tools and Machining (ME 30604); Spring Semester 2012

Name of the text: Machining and Machine Tool, Prof. A B Chattopadhyay, Willey India, 2011, 1st edition ISBN no: 978-81-265-3098-4 Both the chapter and in many places the article number of interest has been included for the benefit of the students. Articles/ chapter for self study have been separately indicated. It may be noted that while this course include but is not limited to the following. Introduction 1 Chapter 1 of the text (Machining and Machine Tool, Prof. A B Chattopadhyay, Willey India, 2011, 1st edition ISBN no: 978-81-265-3098-4) What is manufacturing? Classification of manufacturing What is machining? Process parameters Material Removal rate (MRR) Constraints in machining.

Introduction 2 Chapter 11 of the text plus Chapter 18+19+20(Self study) and 21.1+21.2+21.3.1 classification of lathe (self study) Primary idea about lathe, milling and shaping external features and kinematic chain of a lathe gear boxes speed gear box and feed gear box Norton Cone and Meander Drive (only characteristics) apron sliding apron and swivelling apron, and apron constant, work holding in lathes machining operations using lathe basics of longitudinal feed, cross feed and thread cutting

Generatrix and Directrix Chapter 12 of text Tracing forming tangent tracing and generation as applied to various machining processes

Tool geometry Articles 2.1 + 2.2+ 2.3 (till page 41) + 2.4(till p.58) + 2.4.1.2 of the text Single point tunring tool All axes tool in hand nomenclature ASA and ORS systems Master line MRS system conversion of angles from one system to other inclination angle of the auxiliary cutting edge basics of vector method basics of normal rake system WRS (Tool in Use) systems Primary idea of straight fluted and helical fluted slab milling cutter and drill geometry.

Chip formation Articles 3.1 + 3.2 + 3.3.1 + 3.3.2 + 3.3.2 + 3.4 + 3.4.1 3.4.6 + 3.4.7.1. + 3.4.7.2 (1st para) + 3.4.7.2 + 3.4.8 + 3.6 of the text Schematic representation of chip formation in ductile materials Depiction of s, t, a1, a2, b1, b2, Vc, Vf 3D depiction &3D pipe turning depiction 2D special case = 90 Definition and schematic for cutting ratio =1/ Piispanen model Why does chip thicken? Relation between , o and Kronenbergs model Velocity triangle Cutting strain Strain rate Effect of Vc and S on BUE; effect of o on Chip deviation , nose radius and restricted cutting effect Orthogonal machining Pure orthogonal machining Derivations of chip deviation concept of effective rake Chip formation in slab milling Contact length- Abuladzes model Chip formation in brittle material Irregular chips Segmented chips in high speed machining, and certain work materials 2

Cutting forces Articles 4.1 + 4.2 + 4.3 + 4.6 + 4.7 + 4.8 + 4.8.1 + {4.8.2 (self study)} of the text Cutting force components power estimation Merchants Circle Diagram Angle relationships Specific cutting energy Significance of cutting force components primary idea of forces in drilling and milling Measurements (self study)

Cutting temperature Articles 5.1 + 5.2 + 5.3 + 5.4.2.2 + 5.4.2.3 + 5.4.3 + 5.4.4 + 5.5 (self study) of the text Heat sources in machining power calculation temperature calculations (mainly shear plane temperature) effect of process parameters on cutting temperature control of temperature temperature measurement

Tool Wear, Tool Life & Tool Materials Articles 6.1 + 6.2 + 6.3 + 6.4 + 6.5 (self study) + for machinability 8.1+8.2+8.2.1+8.2.2 (self study) Tool wear types tool wear mechanism role of parameters tool life test Taylors primary and modified equation tool materials machinability

Machining Time and Machining Economics Articles 7.1+7.2+7.3+7.4+7.4.1+7.4.2+7.4.3+7.4.4 of the text

Machining time tm, and cycle time tc distance travelled tm = feed rate Volume of material removed tm = mrr distance tm = feed rate 3

Calculation for straight turning, Taper turning(CNC and centre Lathe) facing( in CNC and centre Lathe) drilling, side and face milling, face milling, end milling, machining cost per piece calculation

Surface roughness (self study; to be dealt in the lab course) Articles 8.6+8.6.1+8.6.2+8.6.3+8.6.4+8.6.5 of the text Machine Tools Articles15.1 + 15.2 + 15.3 + 21.3.2 (drilling) + 21.3.4 (milling)

Speed change mechanisms Norton and Meander drives thread cutting kinematic schemes of drilling and milling