Unit - I : Theory of metal cutting Single point cutting tool : Tool geometry, Mechanics of shearing (orthogonal and oblique), Shear plane angle, Shear stress, strain and Shear strain rate. Process parameters and their effect on machining. Merchant’s circle of forces (analytical) Estimation of shear force, Normal shear force, Friction force, Normal friction force, Material Removal Rate (MRR), Cutting power estimation, Calculation of Total power and Specific energy. Introduction to tool dynamometers. Machinability - Factors affecting machinability, Tool life, Tool wear, Types of tool wear and remedial actions, Cutting fluid and their types, Effect of process parameters on tool life, Taylor's tool life equation (Derivation along with numerical). (Chapters 1 and 2) Unit - II : Machine tools and their application Drilling machine : Types of drills and operations. Twist drill geometry, Types of drilling machine, Tool holder. Machining time calculations. Milling machine : Types of milling machines, Cutter-types and geometry and their applications. Universal dividing head, Methods of Indexing: Simple, Compound, Differential. (Numericals based on simple and compound Indexing).Machining time calculations Broaching : Introduction to broaching, Broach tool geometry, Planner and Boring Machines: Introduction. (Chapters 3, 4 and 5) Unit - III : Finishing processes Grinding machines Introduction : Types and Operations of grinding machines. Grinding wheel – Shapes, Designation and selection, Mounting, Balancing and Dressing of grinding wheels, Machining time calculation for cylindrical and plunge grinding. Super-finishing processes – Introduction to Honing, Lapping, Buffing and Burnishing. (Construction, working and controlling parameters) (Chapter 6) Unit - IV : Advanced machining processes Introduction, classification of advanced machining processes. Principles, Working, Process Parameters, Advantages, Limitations and Application for following processes: Electric Discharge Machining (EDM), LASER Beam Machining (LBM), Abrasive Jet Machining (AJM), Ultra Sonic Machining (USM) and Electro Chemical Machining (ECM) Introduction to micro machining. (Chapter 7) Unit - V : CNC technology Introduction, Classification, Construction and working of NC, CNC, DNC and machining center. CNC axes and drives. Automatic Tool Changer (ATC) and Automatic pallet changer (APC) CNC Programming : Word address format (WAF) –ISO Standards, G & M codes, Type of CNC Control systems, Manual part programming (plain milling and Turning), Subroutine, Canned cycles. (Chapter 8) Unit - VI : Jigs and fixtures Concept of degree of freedom, 3-2-1 principle of location, General guidelines to design Jigs and fixtures, advantages of jig and fixtures Jigs: Definition. Elements of jig with the types, Location guidelines, Principles of clamping, Principles of guiding element, Channel jig, Template jig, Plate jig, Angle plate jig, Turn over jig, Box jig, Latch type jig. Fixtures : Definition. Elements of fixtures, Location guidelines, Principles of clamping, Principles of setting element, Turning fixture, Welding fixture, Milling fixture, Introduction to Assembly and Inspection fixtures. Indexing fixtures. Concept, elements and advantages of modular fixture, Pokayoke concept in jigs and fixtures. (Chapter 9)
