Machine Tools and Machining

ME 210 (3-0-0-3)

Vikrant Sharma Assistant Professor Mechanical Engineering Department FET, MITS vsharma.et@mitsuniversity.ac.in 9887342424

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 their functions. Identify various methods used to generate different types of surfaces.

Vikrant Sharma FET, MITS

ME 210

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

Vikrant Sharma FET, MITS

ME 210

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 is process of conversion of low utility and low value into a product of high utility and more value of required shape, size and dimension.

Vikrant Sharma FET, MITS

ME 210

Lump of

iron /steel
(Raw Material) Product

Processes

Vikrant Sharma FET, MITS

ME 210

Manufacturing is science & technology for producing objects

Effectively Efficiently

Economically

Vikrant Sharma FET, MITS

ME 210

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.

Vikrant Sharma FET, MITS

ME 210

raw material Conversion Process

finished product

Selection of optimum process is based on some objective

manufacturing time

production rate
manufacturing cost

profit
profit rate

Vikrant Sharma FET, MITS

ME 210

Classification of manufacturing processes

Vikrant Sharma FET, MITS

ME 210

Vikrant Sharma FET, MITS

ME 210

Machining :
Machining is an essential process of finishing by which jobs of desired dimensions and surface finish are produce by gradually removing the excess material from the preformed blank in the form of chips with the help of cutting tools move past the work surface.

Machine Tool :
A machine tool is a non portable power operating device or system 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 help of cutting tools move past the work surface.

Vikrant Sharma FET, MITS

ME 210

Machining Requirement

Power Blank Machine Fixture

m/c process

Product

Analysis Tools Environment

Correction

Vikrant Sharma FET, MITS

ME 210

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

Vikrant Sharma FET, MITS

ME 210

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 machining because 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.

Vikrant Sharma FET, MITS

ME 210

Mechanism of chip formation

Vikrant Sharma FET, MITS

ME 210

Vikrant Sharma FET, MITS

ME 210

Vikrant Sharma FET, MITS

ME 210

Vikrant Sharma FET, MITS

ME 210

Chip formation
There are three types of chips that are commonly produced in cutting,

discontinuous chips continuous chips continuous chips with built up edge

Vikrant Sharma FET, MITS

ME 210

Discontinuous chips :

When relatively brittle materials (e.g., cast irons) are machined at low cutting speeds, the chips often form into separate segments. This tends to impart an irregular texture to the machined surface. High toolchip friction and large feed and depth of cut promote the formation of this chip type.

Vikrant Sharma FET, MITS

ME 210

Continuous chips :

When ductile work materials are cut at high speeds and relatively small feeds and depths, long continuous chips are formed. A good surface finish typically results when this chip type is formed. A sharp cutting edge on the tool and low toolchip 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 equipped with chip breakers

Vikrant Sharma FET, MITS

ME 210

Vikrant Sharma FET, MITS

ME 210

Continuous chips with built up edge (BUE) :

When machining ductile materials at low-to medium cutting speeds, friction between tool and chip tends to cause portions of the work material to adhere to the rake face of the tool near the cutting edge. This formation is called a built-up edge (BUE)

Vikrant Sharma FET, MITS

ME 210