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Production Engineering: (Fundamental of Metal Cutting)

The document discusses the fundamentals of metal cutting processes used in production engineering. It covers the mechanics of metal cutting, different types of machining operations including turning, drilling and milling, and advantages and disadvantages of machining processes.

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Anmol Malgotra
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97 views12 pages

Production Engineering: (Fundamental of Metal Cutting)

The document discusses the fundamentals of metal cutting processes used in production engineering. It covers the mechanics of metal cutting, different types of machining operations including turning, drilling and milling, and advantages and disadvantages of machining processes.

Uploaded by

Anmol Malgotra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Production Engineering

Course code: MEN-301

Welcome to all of you in the world of


Production Engineering

Lecture 1
(Fundamental of Metal Cutting)
Dr. Sarbjit Singh,
B. Tech (MD&A), M. Tech. (Prod), PhD. (IITR)
Department of Mechanical Engineering
Punjab Engineering College (Deemed to be University)
Chandigarh. 160012
# 9888775760
Syllabus
 MECHANICS OF METAL CUTTING:
Oblique cutting, orthogonal cutting, Types of chips, Tool signature, Tool wear,
Shear angle determination, forces in metal cutting, Merchant diagram.
Economics of metal cutting, Dynamometer and cutting forces measurement.
Introduction to machining parameter optimization.
 SPECIAL MACHINE TOOLS AND TOOL LAYOUT:
Capstan and Turret lathes. methods of holding jobs on the Turret lathe Universal
Chucking equipment, Universal Bar Equipment, CNC Lathe process /Operation
sheet; Time required for operation, Tool layout and Cam layout..
 JIGS & FIXTURE DESIGN:
Principles of jig and fixture design, Principle of Degrees of freedom, Methods of
location and clamping, Various devices for location and clamping, Indexing
devices, Hydraulic and pneumatic actuation of clamping devices, Jig bushes,
Use of standard parts for jig design, types of drilling jigs, Milling fixtures,
Lathe fixtures, Grinding fixtures and their classification.
Syllabus
 DIE DESIGN:
Components of die design, design of die blocks, punches and strippers,
methods of holding, Design procedure for press tool Piercing and Blanking
operation; Forging die design for forged parts.
 METROLOGY& HIGH FINISH GENERATION PROCESSES:
Limits, fits and tolerances, Limit gauges, Gauge Design, Automated
inspection and CMM, Demonstration of various measuring equipment's,
Elements of surface finish, Indian standards on surface finish, Relation of
surface finish to the production methods. Introduction to Advanced and
Nano finishing operations.
 ECONOMICS OF TOOLING:
Break-even Analysis, Cost estimation, Cost optimization, Optimum cutting
speed and feed. Problems on machining time estimation..
Chapter 1
(MECHANICS OF METAL CUTTING)

Machining is a manufacturing
process in which a sharp
cutting tool is used to cut away
material to leave the desired
part shape.
The predominant cutting action in
machining involves shear
deformation of the work material to
form a chip; as the chip is removed,
a new surface is exposed.
Cont’d

A cross-sectional view of the machining process

Tool with negative rake angle; compare with positive


rake angle in above fig
Advantages of Machining processes
 Variety of work materials.
Machining can be applied to a wide variety of work materials. Virtually all
solid metals can be machined. Plastics and plastic composites can also be cut
by machining. Ceramics pose difficulties because of their high hardness and
brittleness; however, most ceramics can successfully cut by the abrasive
machining processes
 Variety of part shapes and geometric features.
Machining can be used to create any regular geometries, such as flat
planes, round holes, and cylinders. By introducing variations in tool shapes
and tool paths, irregular geometries can be created, such as screw threads
and T-slots. By combining several machining operations in sequence, shapes
of almost unlimited complexity and variety can be produced.
Advantages of Machining processes (Cont’d)

Dimensional accuracy.
Machining can produce dimensions to very close tolerances. Some
machining processes can achieve tolerances of 0.025 mm
(0.001 in), much more accurate than most other processes.
Good surface finishes.
Machining is capable of creating very smooth surface finishes.
Roughness values less than 0.4 microns (16 m-in.) can be
achieved in conventional machining operations. Some abrasive
processes can achieve even better finishes.
Disadvantages of Machining processes

 Wasteful of material.
Machining is inherently wasteful of material. The chips generated in a
machining operation are wasted material. Although these chips can
usually be recycled, they represent waste in terms of the unit
operation.
 Time consuming.
A machining operation generally takes more time to shape a given part
than alternative shaping processes such as casting or forging.
Overview of Machining Technology

Machining is not just one process; it is a group of processes. The


common feature is the use of a cutting tool to form a chip that is
removed from the workpart. To perform the operation, relative motion
is required between the tool and work. This relative motion is achieved
in most machining operations by means of a primary motion, called the
cutting speed, and a secondary motion, called the feed. The shape of the
tool and its penetration into the work surface, combined with these
motions, produces the desired geometry of the resulting work surface.
Types of Machining Operations(Turning)

In turning, a cutting tool with a single


cutting edge is used to remove material
from a rotating workpiece to generate a
cylindrical shape, as shown in Figure. The
speed motion in turning is provided by the
rotating workpart, and the feed motion is
achieved by the cutting tool moving
slowly in a direction parallel to the axis of
rotation of the workpiece.
Types of Machining Operations(Drilling)

Drilling is used to create a round hole. It


is accomplished by a rotating tool that
typically has two cutting edges. The tool
is fed in a direction parallel to its axis of
rotation into the workpart to form the
round hole.
Types of Machining Operations(Milling)

In milling, a rotating tool with multiple


cutting edges is fed slowly across the work
material to generate a plane or straight
surface. The direction of the feed motion is
perpendicular to the tool’s axis of rotation.
The speed motion is provided by the
rotating milling cutter. The two basic forms
of milling are peripheral milling and face
milling.

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