BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani

Pilani Campus
AUGS/ AGSR Division

First Semester 2019-2020

Course Handout (Part II)

Date: 02.07.2019

In addition to Part I (General Handout for all courses appended to the Time Table), this portion
gives further specific details regarding the course.

Course No. : ME F313

Course Title : Production Techniques-II
Instructor In-charge : TUFAN CHANDRA BERA
Practical Instructors : Nitish Gokhale, Santosh Saraswat, Tufan Chandra Bera
1. Course Description
Metal cutting theory, basic metal cutting processes, mechanics of various machining processes, analysis,
economics and quality control of metal cutting, Laboratory exercises in metal cutting and fabrication
project. Introduction to non-traditional machining processes, mechanics and their applications.
Introduction to micromanufacturing technologies, Introduction to CNC technology and CAM.

2. Scope and Objectives

 In-depth comprehension of metal cutting and machining processes which are common
and versatile operations in product manufacturing.
 To nurture fresh talents and transform them to competent manufacturing engineers by
studying metal cutting theory, various conventional and non-conventional machining
processes in detail.
 To introduce micromachining and its recent development as a future scope of micromanufacturing
along with CNC technology and CAM.
 Finally, to enrich theoretical, analytical as well as practical knowledge about metal cutting,
various conventional and non-conventional machining processes.

3. Prescribed Text Book

T1. Amitabha Ghosh and Asok Kumar Mallik, “Manufacturing Science”, 2nd Edition, ISBN
13: 9788176710633 affiliated East-West Press, New Delhi, 2010.

4. Reference Books
R1. Serope Kalpakjian and Steven R. Schemed, “Manufacturing Engineering and
Technology,” Pearson Education, New Delhi, Fourth Edition, 2001.

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AUGS/ AGSR Division

R2. Milton C. Shaw, "Metal Cutting Principles", Oxford University Press, Second Edition,
2005.

R3. A. Bhattacharyya, “Metal Cutting Theory and Practice", New Central Book Agency,
2000.

R4. P. C. Pandey and H. S. Shan, "Modern Machining Processes", Tata McGraw-Hill, New
Delhi, First Edition 1980.

5. Course Plan
Module Number Lecture session Reference Learning Outcome
1. Introduction to metal L1.1.Introduction of machining and its (T1) Ch- Realization of metal
cutting and machining importance in part and product 4.1, (R2) cutting and machining
manufacturing. Ch-1 in part and product
(R3) Ch-1 manufacturing.
Identification of
L1.2 Introduction of conventional (T1) Ch- various motions in
machining process, its advantages & 4.3, (R1) various machining
disadvantages, machining terminology Ch-23 processes and
(R3) Ch-11 machined surface
& its identification.
generation.
L 1.3.Various conventional machining (T1) Ch-
processes. Identification of directrix & 4.3, (R1)
generatrix to generate machined Ch-23
(R3) Ch-11
surface.

2. Geometry of cutting tools L2.1 Cutting tool material and its (T1) Ch- Understanding of
and tool nomenclature. desired properties, cutting tool 4.2, cutting tool geometry
geometry and tool nomenclature. (R1) Ch-21 and tool & insert
(R3) Ch-3
nomenclature.
L2.2 Cutting insert nomenclature and (T1) Ch-
importance of geometrical parameters 4.2,
in metal cutting. (R1) Ch-21
(R3) Ch-3

3. Theory of metal cutting L3.1 Chip formation mechanism and (T1) Ch- Comprehension about
various types of chips 4.3, interaction between
(R2) Ch-8 tool and workpiece.
(R3) Ch-4

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L3.2 Mechanics of metal cutting (T1) Ch- Mechanism of chip

4.3, formation in metal
(R2) Ch-8 cutting.
(R3) Ch-4

4. Determination of cutting L4.1 Determination of cutting forces (T1) Ch- Understanding

forces and Merchant’s circle diagram 4.3, about various
(R2) Ch-8 components of cutting
(R3) Ch-4
forces and its
L4.2. Merchant’s model and modified (T1) Ch-
importance in metal
4.3,
Merchant’s theory. cutting.
(R2) Ch-8
(R3) Ch-4 Determination and
L4.3 Estimation of cutting forces by (T1) Ch- estimation of cutting
energy consideration and effect of 4.3, forces.
cutting parameters on chip formation (R2) Ch-8
(R3) Ch-4
5. Mechanics of various L5.1 Mechanics of turning (T1) Ch- Comprehension about
machining processes such as 4.3, mechanics of
turning, shaping, milling and (R2) Ch-8 common machining
(R3) Ch-4
drilling operations such as
L5.2.Mechanics of shaping (T1) Ch-
turning, shaping,
4.3,
(R2) Ch-8 milling and drilling.
(R3) Ch-4
L 5.3 Mechanics of end milling (T1) Ch-
4.3,
(R2) Ch-8
(R3) Ch-4
L 5.3 Mechanics of face milling (T1) Ch-
4.3,
(R2) Ch-8
(R3) Ch-4
L 5.3 Mechanics of drilling (T1) Ch-
4.3,
(R2) Ch-8
(R3) Ch-4
6. Thermal aspects of L6.1. Thermal aspects of machining (T1) Ch- Understanding about
machining, tool life and and estimation of temperature in 4.2, (R2) heat generation and
cutting zone. Ch-12 analysis in machining
machinability (R3) Ch-8
and role of cutting
L6.2. Tool wear mechanism (T1) Ch- fluids in machining.
4.2, (R2)
Familiarization about
Ch-11

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(R3) Ch-9 tool wear, tool life

L 6.3 Tool life and its assessment (T1) Ch- and machinability of
4.2, (R2) workpiece.
Ch-11
(R3) Ch-9

L 6.3 Machinability study (T1) Ch-

4.2, (R2)
Ch-11
(R3) Ch-9
7. Abrasive cutting processes L7.1. Construction of grinding wheel (T1) Ch- Comprehension about
4.4, (R1) abrasive machining
Ch-25 process and other
(R3) Ch-15
finishing processes
L7.2. Mechanics of grinding (T1) Ch-
such as lapping and
4.4, (R1)
Ch-25 honing etc.
(R3) Ch-15
L 7.3 Honing, Lapping, Buffing and (T1) Ch-
4.4, (R1)
polishing operations
Ch-25
(R3) Ch-15
8. Surface integrity and L8.1 Surface integrity and surface (T1) Ch- Understanding about
economics of machining. 4.5, (R2) surface integrity in
topography
Ch-17 machining process
(R3) Ch-14
and economics of
L8.2. Economics of machining. (T1) Ch-
machining in terms of
4.6, (R2)
Ch-1 production cost and
(R3) Ch-10 production rate.

9. Non-conventional L9.1 Preface with non-traditional (T1) Ch-6, Understanding about

machining processes (R1) Ch-26 need of non-
machining.
(R4) Ch-1 traditional machining
in part and product
manufacturing

10. Various NTM processes L10.1 Study of AJM mechanics, (T1) Ch-6, Comprehension about
such as AJM, USM, ECM, applications and influence of various (R1) Ch-26 various non-
EDM, EBM, LBM, PAM (R4) Ch-1 traditional processes.
process variables.

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L10.2 Study of USM mechanics, (T1) Ch-6,

(R1) Ch-26
applications and influence of various
(R4) Ch-1
process variables.

L10.3 Study of ECM mechanics, (T1) Ch-6,

(R1) Ch-26
applications and influence of various
(R4) Ch-1
process variables.

L10.4 Study of EDM mechanics, (T1) Ch-6,

(R1) Ch-26
applications and influence of various
(R4) Ch-1
process variables.

L10.5 Study of EBM mechanics, (T1) Ch-6,

(R1) Ch-26
applications and influence of various
(R4) Ch-1
process variables.

L10.6 Study of LBM mechanics, (T1) Ch-6,

(R1) Ch-26
applications and influence of various
(R4) Ch-1
process variables.

L10.7. L10.1 Study of PAM (T1) Ch-6,

(R1) Ch-26
mechanics, applications and influence
(R4) Ch-1
of various process variables.

11. Introduction to micro- L11.1.Preface with micro (T1) Ch-

manufacturing manufacturing and micro technology. 7.2, (R1)
Ch-26

Lab experiments and open ended product manufacturing.

1) Mechanics of metal cutting & chip formation.

2) Cutting force measurement in conventional lathe.
3) Geometrical accuracy measurement of a part produced in CNC lathe.
4) Practice of Form Milling by Producing A Spur Gear on conventional milling.
5) Taper turning in CNC lathe and taper angle measurement.

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6) Practice of peripheral and face milling operation in VMC and surface roughness
measurement

After completing this course the students will be able to

1) Select suitable conventional machining process for common part manufacturing.

2) Control machining conditions to obtain desired surface quality of a part.
3) Improve part quality by analyzing mechanics of the process using same machine tool.
4) Analyze machining cost and economics of machining in part manufacturing.
5) Select either conventional or non-conventional machining process depending upon
workpiece material, quality and cost of the part.

Closed Book Test: No reference material of any kind will be permitted inside the exam hall.

Open Book Exam: Use of any printed / written reference material (books and notebooks) will
be permitted inside the exam hall. Loose sheets of paper will not be permitted. Computers of any
kind will not be allowed inside the exam hall. Use of calculators will be allowed in all exams. No
exchange of any material will be allowed.

6. Evaluation Scheme:
Component Duration Weightage Date & Time Nature of
(%) component
(Close Book/ Open
Book)
Mid-Semester Test 90 Min. 30% <TEST_1> Open Book
Comprehensive 3h 35% <TEST_C>
Closed Book
Examination
Class Assignments 10% Homework & Closed
& Surprise Quiz. book
Lab Practical 25% Experimentations,
Fabrications

7. Chamber Consultation Hour:

To be announced in the class.

8. Notices:
All notices related to the course will be displayed on Notice Board of Mechanical
Engineering Department only.

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9. Make-up Policy:
Make-up will be granted ONLY in genuine cases with prior permission. The request
application for make-up test MUST be reached to the Instructor-in-Charge before
commencement of the scheduled test along with DOCUMENTARY PROOF. No make-up
will be allowed for the Surprise Quiz Tests.
10. Note:
It shall be the responsibility of the individual student to be regular in maintaining the self
study schedule as given in the course handout, attend lectures and the lab demonstration as
per the schedule announced in Nalanda. Mid Semester Test and Comprehensive Examination
are according to the Evaluation Scheme given in the respective Course Handout. If the
student is unable to appear for the Regular Test/Examination due to genuine exigencies, the
student must refer to the procedure for applying for Make-up Test/Examination. There is no
make up for any surprise quiz or tutorial.

Instructor-in-Charge
ME F313.

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