Manufacturing Processes – II (ME-317)

Course Teachers: Miss Ifrah Asif

Mr. Kashif Azher
CREDIT HOURS
Theory = 3, Practical = 1

COURSE LEARNING OUTCOMES (CLOs)

S. No. CLOs Taxonomy
1 Describe machining process and technical detail and Coginitive
discuss their applications according to particular Level 2*
manufacturing requirements.
2 Analyze manufacturing tasks, identify relevant machining Coginitive
processes and perform pertinent calculations Level 4*
3 Classify and characterize various measurement and Coginitive
tolerance technique Level 3*
4 Observe performance of various machining operations Psychomotor
and perceive the importance of sustainable use of Level 1,3,4*
resources and their environmental impact
5 Contribute in Lab work at individual and group level Affective
Level 2*

COURSE CONTENT
1. Machine Tools
• Machine tools using single point tools, description, functions, operations
performed on lathe, shaper, planer, and boring machines.
• Machine tools using multiple cutting edge tools, description, functions, and
operations performed on drilling, milling, gear cutting, broaching machines,
and thread manufacturing.
• Machine tools using abrasive wheels, description and functions of various
types of grinding machines, wheel dressing and wheel balancing, honing,
lapping, and super finishing operations.
2. Work Holding Devices: Basic concept and design of different work holding
devices like chuck, vices, jigs and fixtures for lathe, milling, drilling etc.
3. Machining Parameters: Determination of machining time and material removal
rate for various machining operations, cutting tools for manufacturing, cutting
tool material characteristics, cutting tool materials, tool steels, HSS, sintered
carbides, ceramics, tin-coated HSS, diamonds and cubic boron nitrides, tool
geometry, tool life, tool wear and machinability, Taylor’s tool life model,
sharpening and reconditioning of cutting tools, Basic concept and design of jigs
and fixtures.
4. Non-Traditional Machining Processes: EDM, ECM, and ultrasonic machining.
5. Metrology:
• Light waves as standard of length, design and operation of linear measuring
instruments, slip and block gauges, length bars, limit gauges, sine bar,
reference temperature, limits and fits, hole-basis, shaft basis comparators,
mechanical, electrical, pneumatic and optical.
• Errors in measurement, sensitivity, accuracy and variation, economics of
measurement, measurement of squareness, flatness, straightness,
roundness, gear and screw threads, advanced measuring and inspection
non-contact measurement, machine tool metrology, alignment tests, level
of installation, spindle straightness, flatness and squareness.
6. Surface Texture and Measurement: Roughness and measurement of roughness
lay, waviness and flaws, CLA and RMS values, predication and average values of
roughness for various manufacturing processes like turning, drilling, milling and
grinding.
7. Standardization: Introduction, Interchangeability, assembly, principles,
preparation of standards, application of standards in design and manufacturing.
Standards organizations.

RECOMMENDED BOOKS
(01) DeGarmo's Materials and Processes in Manufacturing by J. T. Black
(02) Fundamentals of Modern Manufacturing: Materials, Processes, and Systems
by Mikell P. Groover
(03) Manufacturing Engineering and Technology by Serope Kalpakjian & Stephen R.
Schmid
• Production Engineering:
It is a combination of manufacturing technology, engineering sciences
with management science. A production engineer typically has a wide
knowledge of engineering practices and is aware of the management
challenges related to production.

• Purpose:
Production engineers will have design duties related to materials,
processes and work flows. They perform these duties using drafting
tools and design software such as CAD. Production engineers
must develop efficient design and manufacturing methods to find the
right balance between cost, safety and quality.

• Factors:
The factors of production are:
• Land
• Labor
• Capital
• Entrepreneurship
• Manufacturing Processes:
A manufacturing process converts unfinished materials to finished products, often using
machines or machine tools. For example, injection molding, die casting, progressive
stamping, milling, arc welding, painting and assembling are commonly called processes or
manufacturing processes.

• Basic Manufacturing Processes:

It is the manufacturing processes that create or add value to a product. The manufacturing
processes can be classified as:
• Casting, foundry, or molding processes.
• Forming or metalworking processes.
• Machining (material removal) processes.
• Joining and assembly.
• Surface treatments (finishing).
• Rapid prototyping.
• Heat treating.
• Other.
• Classification Of Material Removal Processes:

• Manufacturing Support
System:
To operate its facilities efficiently, a company must organize itself to design the
processes and equipment, plan and control the production orders, and satisfy product
quality requirements. These functions are accomplished by manufacturing support
systems— people and procedures by which a company manages its production
operations. Most of these support systems do not directly contact the product, but they
plan and control its progress through the factory. Manufacturing support functions are
often carried out in the firm by people organized into departments such as the
following:
• Manufacturing engineering. The manufacturing engineering department is
responsible for planning the manufacturing processes—deciding what processes
should be used to make the parts and assemble the products. This department is also
involved in designing and ordering the machine tools and other equipment used by
the operating departments to accomplish processing and assembly.
• Production planning and control. This department is responsible for solving the
logistics problem in manufacturing—ordering materials and purchased parts,
scheduling production, and making sure that the operating departments have the
necessary capacity to meet the production schedules.
• Quality control. Producing high-quality products should be a top priority of any
manufacturing firm in today’s competitive environment. It means designing and
building products that conform to specifications and satisfy or exceed customer
expectations. Much of this effort is the responsibility of the QC department.
 Cutting tools
Introduction to metal cutting
process
By using various types of process, the metals are removed from work piece to
obtain require shape and size. That are classified as below (i) non cutting
process (ii) cutting process. For generally, the metals are shaped in require form
under the action of force and heating. That is no any cutting of metal, chip
formation removal. So, this method of no cutting process. The process such
as forging, drawing, spinning, rolling, extrusion are non cutting process. The
metal of removed and become with required shape and size to be obtained. So
the unwanted metal removing from the work piece is called the form of chip.
The various cutting process obtained such as turning, drilling, boring, shaping,
milling and etc. For generally edge of cutting tools having harder than the work
piece metal. The various metal cutting process done by the relative motion
between work piece and cutting tools.
The relative motion may be occurred during metal cutting process as follows:
• The rotation of work against the cutting tools. Example – turning
• The rotation of tools against the work piece. Ex: milling and drilling
• The linear motion of work against the cutting tool. Ex: planning
• The linear motion of tools obtain against the work. Ex: shaping.

Cutting Tool Technology

Two principal aspects:
• Tool geometry
• Tool material
CLASSIFICATION
According to the number of major cutting edges (points) involved as follows:
• Single point: e.g., turning tools,
shaping, planning and slotting tools
and boring tools
• Double (two) point: e.g., drills

• Multipoint (more than two):

e.g., milling cutters, broaching tools,
hobs, gear shaping cutters etc.
 Types of Tools
Single Point Multipoint
Classification of cutting tools
Single Point Cutting Tool
The single point cutting tool is mainly used to metal remove from work piece
become with require shape and size of product. It remove large amount of metal
in quickly again rotating the work piece. Boring, turning are performed by using
single point cutting tool in lathe machine.
• Parts of Tool:
• Shank: It is main body of tool.

• Flank: surface/ surfaces below & adjacent to cutting edge is flank of tool.

• Face: Surface on which chip slides is called face of tool.

• Nose: It is formed at junction of side & end cutting edges. This junction/ nose has
a curve of small radius, know as nose radius.

• Cutting Edge: It is the edge on the face of the tool which removes the material
from the work piece. The cutting edge consists of the side cutting edge(major
cutting edge) and cutting edge(minor cutting edge) and the nose.
Single point cutting tool

Three ways of holding and presenting the cutting edge for a single-point tool:
(a) solid tool, typical of HSS;
(b) brazed insert, one way of holding a cemented carbide insert; and
(c) mechanically clamped insert, used for cemented carbides, ceramics,
 Common insert shapes:

(a) round, (b) square, (c) rhombus with two 80 point angles, (d) hexagon with three
80 point angles, (e) triangle (equilateral), (f) rhombus with two 55 point angles, (g)
rhombus with two 35 point angles. Also shown are typical features of the geometry.
1.Side Cutting Edge Angle:
The angle between side cutting edge and the side of the tool shank is
called side cutting edge angle.
2.End Cutting Edge Angle:
The angle between the end cutting edge and a line perpendicular to the
shank of the tool shank is called end cutting edge angle.
3. Side Relief Angle:
The angle between the portion of the side flank immediately below the
side cutting edge and a line perpendicular to the base of the tool.
4.End Relief Angle:
The angle between the end flank and the line perpendicular to the base of
the tool is called end relief angle.
5.Back Rake Angle:
The angle between the face of the tool and line perpendicular to the base of the
tool measures on perpendicular plane through the side cutting edge.
6.Side Rake Angle:
The angle between the face of the tool and a line parallel to the base of the tool
measured on plane perpendicular to the base and the side edge.