machine tools & machining me 210_1
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Machine Tools and Machining
ME 210 (3-0-0-3)
Vikrant Sharma
Assistant Professor
Mechanical Engineering DepartmentFET, MITS
9887342424
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Course Objective
Understanding the basic parameters in the metal cutting operation.
Different types of chips formed in metal cutting.
Select cutting tool material for metal cutting.
Understand tool wear and tool life.
Determine cutting forces.
Understand classification of various machine tools.
Understand different components of the machine tools and theirfunctions.
Identify various methods used to generate different types of surfaces.
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Books
Rao P N, “Manufacturing Technology”
Lindberg Roy, “Processes and materials of manufacturing”
Ostwald Phillip, “ Manufacturing Processes and Systems”
Chapman, “Workshop Technology”
DeGarmo, “Materials and Processes in Manufacturing”
Kalpakjian, “Manufacturing Engineering & Technology”
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Manufacturing:
Manufacturing is an industrial activity that changes
the form of raw materials to create product.
Manufacture is derived from the Latin, manu factus,means “made by hand”.
Manufacturing is value addition processes. It isprocess of conversion of low utility and low value into aproduct of high utility and more value of required shape,
size and dimension.
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Lump of
iron /steel(Raw Material)
Product
Processes
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Manufacturing is science & technology for producing objects
Effectively
Efficiently
Economically
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This can be achieved through
Proper selection & application of existing processes &systems.
Proper selection & use of materials, tools, machine,environment etc.
Improvement of existing material & processes
Development of new material, processes, machine,technology etc.
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raw finished
material product
Conversion Process
Selection of optimum process is based on some objective
manufacturing time
production rate
manufacturing cost
profit
profit rate
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Classification of manufacturing processes
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Machining :
Machining is an essential process of finishing by which jobs of
desired dimensions and surface finish are produce bygradually removing the excess material from the preformedblank in the form of chips with the help of cutting toolsmove past the work surface.
Machine Tool :
A machine tool is a non portable power operating device orsystem of devices in which energy is expanded to produce
job of desired size by gradually removing the excess material
from the preformed blank in the form of chips with the helpof cutting tools move past the work surface.
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Major functional component of machine tools:
Device for holding job and tools Drive(s) for providing power and motions
Kinematics system(s) to transmit motion
Automation and control system
Structure/body
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Machining is a process of gradual removal of excess material
from the preformed blanks in the form of chips.
The form of the chips is an important index of machiningbecause it directly or indirectly indicates :
Nature and behavior of the work material under machining
condition Specific energy requirement (amount of energy required to
remove unit volume of work material) in machining work.
Nature and degree of interaction at the chip-tool interfaces.
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Mechanism of chip formation
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Chip formation
There are three types of chips that are commonly
produced in cutting,
Œdiscontinuous chips
•continuous chips
Žcontinuous chips with built up edge
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Discontinuous chips :
When relatively brittle materials (e.g., cast irons) aremachined at low cutting speeds, the chips often form into
separate segments.
This tends to impart an irregular texture to the machinedsurface. High tool – chip friction and large feed and depth ofcut promote the formation of this chip type.
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Continuous chips :
When ductile work materials are cut at high speeds and
relatively small feeds and depths, long continuous chips areformed.
A good surface finish typically results when this chip type isformed. A sharp cutting edge on the tool and low tool – chip
friction encourage the formation of continuous chips. Long, continuous chips (as in turning) can cause problems
with regard to chip disposal and/or tangling about the tool.To solve these problems, turning tools are often equippedwith chip breakers
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Continuous chips with built up edge (BUE) :
When machining ductile materials at low-to medium cutting
speeds, friction between tool and chip tends to causeportions of the work material to adhere to the rake face ofthe tool near the cutting edge. This formation is called abuilt-up edge (BUE)
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