Mechanics Of Metal Cutting:
Mechanism of chip formation, Orthogonal & Oblique cutting, types of chips, built-up edge, Determination of shear plane angle, forces on the chips, forces in orthogonal cutting, Merchant circle diagram and analysis, Theory of Lee & Shaffer, coefficient of friction, power & energy relationship, velocity relationship, shear-strain, factors affecting forces and power, problems
Geometry Of Cutting Tools:
Single point and multi point cutting tools, tools nomenclature, tool point reference systems, tool signature, Recommended tool angles, Effect of cutting parameters on tool geometry
Tool Materials And Their Properties:
Characteristics of tool materials, types of tool materials – carbon tool steels, high speed steels, cast alloys, cemented carbides, ceramics, diamonds, SIALON, CBN, UCON, recommended cutting speeds for the above tools, discussion on die steels, air, water, oil hardening of tools and their applications
Tool Wear, Tool Life:
Mechanisms of tool wear, Sudden & gradual wear, crater wear, flank wear, tool failure criteria, tool life equations, effect of process parameters on tool life, tool life tests, conventional & accelerated tool wear measurement, machinability index
Measurement Of Cutting Forces:
Reasons for measuring cutting forces, Classification of cutting force dynamometers – mechanical, hydraulic, pneumatic, optical, inductance, piezoelectric, and strain gage type dynamometers,
Dynamometers For Machine Tools:
Dynamometers for lathe, drilling, grinding and milling, Calibration of dynamometers
Thermal Aspects In Metal Cutting:
Heat sources in metal cutting, temperature in chip formation, temperature distribution, and experimental determination of tool temperatures.
Cutting Fluids:
Basic actions of cutting fluids, properties of cutting fluids, selection of cutting fluids, application of cutting fluids, filtration of fluids, recommended cutting fluids.
Economics Of Machining:
Introduction, elements of total production cost, optimum cutting speed and tool life for minimum cost, optimum cutting speed and tool life for maximum production, problems.
Advanced Machining Techniques:
Cryo machining & high speed machining. Causes of vibration and chatter in machining, and their remedy