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 of Merchant’s 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.
Classification, constructional features of Turret and Capstan Lathe. Tool Layout, shaping Machine, Planing Machine, Driving mechanisms of lathe, shaping and planing machines, Different operations on lathe, shaping machine and planing machine. Simple problems on machining time calculations
Classification, constructional features, drilling & related operations. Types of drill & drill bit nomenclature, drill materials. Introduction to CNC machines- Principles of operation. Axes of NC machine-Coordinate systems. Basics of Manual part programming methods.
Milling 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 and compound indexing.
Types of abrasives, Grain size, bonding process, grade and structure of grinding wheels, grinding wheel types. Classification, constructional features of grinding machines (Centerless, cylindrical and surface grinding ). Selection of grinding wheel. Grinding process parameters. Dressing and truing of grinding wheels.
Broaching process - 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.
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.