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Indian Institute of Technology Kanpur

Machining Science

Indian Institute of Technology Kanpur and NPTEL via Swayam

Overview

1. Introduction : Machining; Plastic Deformation, Tensile Test, Stress and Strain; Mechanism of Plastic Deformation: Slips, defects, plastic deformation onatomic scale.2. Machining Process : Types of machining processes; Chip formation; Orthogonal and Oblique Cutting; Types of Chips; Built-up edge formation.3. Tool Geometry : Reference planes; Tool specification: American System (ASA), continental or Orthogonal System (ORS), International or Normal Rake system (NRS); Tool angle relationships in ORS, ASA and NRS; Selection of Tool Angles; Multiple-point cutting tools: twist drill, helical milling cutter.4 . Mechanics of Metal Cutting : Merchant's Circle Diagram; Co-efficient of Friction: Determination of stress, strain and strain rate; Measurement of shear angle; Thin Zone model: Lee and Shaffer's Relationship; Thick Zone model: Okushima and Hitomi Analysis5. Friction in Metal Cutting : Nature of sliding friction; Friction in Metal Cutting: Sticking and Sliding Zones, Analysis of Stress Distribution on the tool face: Zorev’s model; Determination of mean angle of friction.6. Mechanism of Oblique cutting : Rake angles in oblique cutting: Analytical determination of Normal Rake angle, velocity rake angle and effective rake angle; their relationship; shear angles in oblique cutting; velocity relationship; Force relationships in oblique cutting.7. Practical Machining Operations : Turning, shaping and planning, Slab milling, Drilling: Machining Parameters, force magnitudes, power consumption, material removal rate, time per pass.8. Measurement of cutting Forces : Basic methods of measurement: Axially Loaded members, Cantilever Beam, Rings and Octagon, dynamometer requirements; machine tooldynamometers.9. Tool Material, Tool Wear and Tool Life : Types of tool wear; Mechanisms of wear: Abrasion, Adhesion and Diffusion. Progressive tool wear: flank and crater wear. Tool Life: variables affecting tool life - cutting conditions, tool geometry, Types of tool materials, fabrication of cutting inserts, coatings, work material and cutting fluid; Machinability and their criteria.10. Abrasive Machining Processes: Processes and analyses11. Economics of Machining: determination of optimal cutting conditions forminimum cost, maximum production rate and maximum profit rate12. Thermal Aspects of Machining: analytical determination of temperaturein the shear zone and the chip-tool contact area13. Surface finish: comparison and analytical determination of surfacefinish in turning, milling and grinding
INTENDED AUDIENCE : Mechanical Engineering, Metallurgy, Aerospace Engineering, Production EngineeringPREREQUISITES : Basic Manufacturing Engineering CoursesINDUSTRY SUPPORT : All Manufacturing industries, Machine tool manufacturing industries, Automobile Industries and aeronautical industries

Syllabus

COURSE LAYOUT

Week 1 : Machining; Plastic Deformation, Tensile Test, Stress and Strain; Mechanism of Plastic Deformation: Slips, defects,
plastic deformation on atomic scale; Types of machining processes; Chip formation; Orthogonal and Oblique Cutting;
Types of Chips; Built-up edge formation; Tool specification; Tool angle relationships in ORS and ASA and NRS;
Selection of Tool Angles; Multiple-pointcutting tools: twist drill, helical milling cutter.Week 2 : Merchant's Circle Diagram; Co-efficient of Friction: Determination of stress, strain and strain rate; Measurement of
shear angle; Thin Zone model: Lee and Shaffer's Relationship; Thick Zone model: Okushima and Hitomi
Analysis; Nature of sliding friction; Friction in Metal Cutting: Sticking and Sliding Zones, Determination of mean angle of frictionWeek 3 : Mechanism of Oblique Cutting: Normal Rake angle, velocity rake angle and effective rake angle;
shear angles; velocity relationship; Force relationships in oblique cutting; Practical Marching Processes:
Turning, shaping and planning, Slab milling, Drilling: Machining Parameters, force magnitudes, power consumption,
material removal rate, time per pass.Week 4 : Measurement of Cutting Forces: Basic methods of measurement: Axially Loaded members, Cantilever Beam,
Rings and Octagon, dynamometer requirements; machine tool dynamometers; Types of tool wear;
Mechanisms of wear: Abrasion, Adhesion and Diffusion.Progressive tool wear: flank and crater wear. Tool Life:
variables affecting tool life - cutting conditions, tool geometry, Types of tool materials, fabrication of cutting
inserts, coatings, work material and cutting fluid; Machinability and their criteria.Abrasive Machining Processes;
Oblique Cutting; Economics of Machining;Thermal Aspects of Machining; Surface Finish.

Taught by

Prof. Sounak Kumar Choudhury

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