Unit-I: Metal Cutting and Machine Tools
Metal Cutting:
1. Mechanics of Metal Cutting:
◦Involves the deformation of material by a cutting tool.
◦Forces include:
▪ Cutting Force (Fc): Main force that removes material.
▪ Thrust Force (Ft): Acts perpendicular to the cutting surface.
▪ Radial Force (Fr): Acts outward from the cutting direction.
◦ Example: Turning a steel rod on a lathe where chips are removed as the cutting tool
moves.
2. Tool Geometry and ASA System:
◦The ASA system de nes angles (rake, clearance, etc.) relative to reference planes:
▪ Rake Angle: Helps chips ow smoothly.
▪ Clearance Angle: Prevents tool rubbing against the workpiece.
◦ Example: A lathe cutting tool with a rake angle of 10° ensures better chip ow in
aluminum machining.
3. Orthogonal vs. Oblique Cutting:
◦Orthogonal Cutting: Chips are formed perpendicular to the cutting edge, producing
a uniform nish.
▪ Example: Planing or shaping a at surface in a workshop.
◦ Oblique Cutting: Cutting edge is inclined, producing helical chips.
▪ Example: Drilling a hole using a twist drill bit.
4. Chip Formation and Types:
◦
Continuous Chips: Found in ductile materials (e.g., copper or mild steel).
◦
Discontinuous Chips: Found in brittle materials (e.g., cast iron).
◦
Built-Up Edge Chips: Occurs due to adhesion of material to the tool edge, reducing
surface quality.
▪ Example: Improper cutting conditions when machining mild steel.
5. Merchant's Force Circle Diagram:
◦Illustrates the relationship between cutting forces, shear forces, and friction forces
during machining.
◦ Example: Used to calculate power requirements for turning operations.
6. Cutting Fluids/Lubricants:
◦ Types of cutting uids:
▪ Water-soluble coolants: For high-speed operations.
▪ Oil-based lubricants: For heavy-duty machining.
◦ Example: Coolants are used in CNC machining to prevent tool overheating.
7. Tool Life and Tool Wear:
◦ Tool wear types:
▪ Crater Wear: Occurs on the rake face.
▪ Flank Wear: Appears on the clearance face.
◦ Example: High-speed steel (HSS) tools wear faster than carbide tools during high-
speed cutting.
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8. Machinability:
◦Machinability is determined by cutting speed, tool wear, and chip formation.
◦Example: Aluminum has better machinability than stainless steel due to lower
cutting forces.
9. Tool Vibration and Surface Finish:
◦
Excessive vibration results in poor surface nish and dimensional inaccuracies.
◦
Example: Damping devices are used in CNC machines to stabilize the tool and
reduce vibration.
10. Economics of Metal Cutting:
◦ Balancing speed, feed, and depth of cut minimizes cost while maintaining
productivity.
◦ Example: High-speed machining increases productivity but requires frequent tool
changes.
Unit-II: Machine Tools
1. Lathe Machine:
◦
Operations:
▪ Turning: Reducing the diameter of a cylindrical workpiece.
▪ Knurling: Producing textured patterns on a surface.
▪ Threading: Creating screw threads on a cylindrical surface.
◦ Example: Creating shafts for automotive applications.
2. Shaper, Slotter, Planer:
◦Shaper: The tool moves in a straight line while the workpiece is stationary.
▪ Example: Machining a at surface on a steel block.
◦ Slotter: Creates slots or grooves in vertical or inclined directions.
▪ Example: Cutting keyways for gears.
◦ Planer: Suitable for large workpieces.
▪ Example: Machining machine beds in heavy industries.
3. Milling Machine:
◦Types of milling cutters:
▪ Face Milling Cutter: For at surfaces.
▪ End Milling Cutter: For grooves and slots.
◦ Example: Milling machine is used for cutting gear teeth in manufacturing.
4. Drilling and Boring:
◦ Drilling: Performed to create new holes.
▪ Example: Drilling holes for rivets in an aircraft wing.
◦ Boring: Enlarges or nishes pre-drilled holes for precision.
▪ Example: Boring engine cylinder holes to exact dimensions.
Unit-III: Grinding and Super Finishing
1. Grinding:
◦ Abrasive machining process used for tight tolerances and ne nishes.
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◦ Types:
▪
Surface Grinding: Produces at surfaces.
▪
Cylindrical Grinding: Machines cylindrical parts.
▪
Centerless Grinding: Machines without clamping the workpiece.
◦ Example: Surface grinding is used to achieve a mirror nish on die components.
2. Super Finishing:
◦ Processes:
▪ Honing: Removes small amounts of material to achieve close tolerances.
▪ Example: Honing engine cylinders for smooth piston operation.
▪ Lapping: Polishes using abrasives for ultra-smooth surfaces.
▪ Example: Polishing optical lenses.
▪ Polishing: Achieves a re ective surface.
▪ Example: Polishing car body panels.
3. Standardization and Interchangeability:
◦ Components meet prede ned tolerances and t perfectly.
◦ Example: Interchangeable bolts and nuts manufactured to IS standards.
◦ Surface Roughness: Measured in microns; lower values indicate smoother surfaces.
Unit-IV: Metal Joining (Welding)
1. Gas Welding:
◦ Uses an oxy-acetylene ame for joining metals.
◦ Example: Joining pipes in plumbing.
2. Arc Welding:
◦ Electric arc generates heat to join metals.
▪ TIG Welding: Produces clean welds for aluminum.
▪ MIG Welding: Suitable for high-speed welding in automotive industries.
3. Resistance Welding:
◦ Spot welding used for sheet metal components like car doors.
4. Other Welding Processes:
◦ Submerged Arc Welding (SAW): Used for welding thick plates in shipbuilding.
◦ Friction Welding: Joins metals using heat from friction.
▪ Example: Joining turbine shafts.
5. Soldering and Brazing:
◦ Soldering: Joins electronic components using low-melting solder.
◦ Brazing: Used for joining dissimilar metals like copper and steel.
6. Weld Defects and Remedies:
◦ Defects include porosity, cracks, and distortion.
◦ Example: Preheating prevents weld cracks in steels.
Unit-V: Unconventional Machining and Welding
1. Unconventional Machining Processes:
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◦ EDM (Electrical Discharge Machining):
Removes material using sparks.
▪ Example: Used for die-making in manufacturing.
◦ ECM (Electrochemical Machining):
Uses electrolytic reactions to machine parts.
▪ Example: Aerospace turbine blades.
◦ LBM (Laser Beam Machining):
High-energy laser cuts materials with precision.
▪ Example: Engraving microchips.
◦ AJM (Abrasive Jet Machining):
High-speed abrasive particles clean and cut surfaces.
▪ Example: Cleaning turbine blades.
2. Non-Conventional Welding Applications:
◦ LBW (Laser Beam Welding): Used in medical device welding.
◦ Explosive Welding: Bonds metals through controlled explosions.
▪ Example: Titanium cladding on steel plates.
