18AU45 Manufacturing Process -II syllabus for AU

Theory Of Metal Cutting & Cutting Tool Materials:

Single point cutting tool nomenclature, geometry, Mechanics of Chip Formation, Types of Chips. Merchants circle diagram and analysis, Ernst Merchant’s solution, shear angle relationship, problems on Merchant’s circle diagram analysis. Tool Wear and Tool failure, tool life. Effects of cutting parameters on tool life. Tool Failure Criteria, Taylor’s Tool Life equation, Problems on tool life evaluation. Desired properties and types of cutting tool materials – HSS, carbides coated carbides, ceramics. Cutting fluids - Desired properties, types and selection. Heat generation in metal cutting, factors affecting heat generation. Heat distribution in tool and work piece and chip. Measurement of tool tip temperature.

Turing, Shaping and Planning:

Classification of Lathe, constructional features of Turret and Capstan Lathe. Tool Layout, Different operations on lathe, machining. Classification of Shaping Machine, Planning Machine, shaping and planning machines, construction and working principle of planning and shaping machine. Machining time calculation on above machining

Milling & Grinding Machines:

Classification, constructional features, milling cutters nomenclature, milling operations, up milling and down milling concepts. Various milling operations. Indexing: Simple, compound, differential and angular indexing calculations. Simple problems on simple compound indexing.

Grinding Machines:

Types of abrasives, Grain size, bonding process, grade and structure of grinding wheels, grinding wheel types. Classification, constructional features of grinding machines (Centre-less, cylindrical and surface grinding). Selection of grinding wheel. Grinding process parameters. Dressing and truing of grinding wheels.

Drilling, Broaching Process and Finishing Operations:

Drilling Machine:

Classification, constructional features, drilling & related operations. Types of drill & drill bit nomenclature, materials.

Broaching Machine:

Principle of broaching. Details of a broach. Types of broaching machines-constructional details. Applications. Advantages and Limitations.

Finishing and other Processes:

Lapping and Honing operations – Principles, arrangement of set up and application. Super finishing process, polishing, buffing operation and application.

Non-Traditional Machining Processes:

Need for non-traditional machining, Principle, equipment & operation of Laser Beam, Plasma Arc Machining, Electro Chemical Machining, Ultrasonic Machining, Abrasive Jet Machining, Water Jet Machining, Electron Beam Machining, Electron Discharge Machining and Plasma Arc Machining.

Course Outcomes:

At the end of the course the student will be able to:

• Explain the nomenclature of single point cutting tool, mechanics of chip formation, tool failure criteria and to solve problems on evaluation of tool life. construction and working of various systems in a Lathe, Shaper, Planeing and Drilling machine.
• Classify grinding and milling machines and explain their construction.
• Explain the principles of broaching.
• Select non-traditional machining process for given application.

Question paper pattern:

• The question paper will have ten full questions carrying equal marks.
• Each full question will be for 20 marks.
• There will be two full questions (with a maximum of four sub- questions) from each module.

Textbook/s

1 Workshop Technology Hazara Choudhry Media Promoters & Publishers Pvt. Ltd. Vol-II, 2004

2 Production Technology R. K. Jain Khanna Publications 2003.

Reference Books

3 Manufacturing Science Amitabh Ghosh and Mallik affiliated East West Press 2003

4 Fundamentals of Metal Machining and Machine Tools G. Boothroyd McGraw Hill 2000

5 Production Technology HMT Tata MacGraw Hill 2001