Term 2011-2012

COURSE CODE M E C 4 0 5 COURSE TITLE Theory of Metal Cutting

L 3

T 0

P 0

CREDITS (or Max. Marks) 3

Attendance 5

WEIGHTAGES MTE CA P Th 20 25

ETE Th 50

COURSE OBJECTIVES: To impart knowledge and enhancing the students to enquire the principle of Metal Cutting and optimization. PRE-REQUISITES: NIL COURSE CONTENTS: S No. 1 2 Description Introduction: Importance of material removal, Classification of metal removal operation, Overview of cutting processes and types of chips, Chip formation analysis. Cutting operations: Principle cutting operations, other cutting operations, orthogonal cutting. Mechanics of orthogonal steady state cutting: Card Model, forces, stresses, shear angle, shear strain, velocity relation, rate of strain, energy consideration, flow lines in a chip, other chip types, estimation of cutting forces Plastic Behavior: Theoretical shear strength, dislocation theory, Metal Whiskeras, constancy of volume and Possions ratio, von mises flow criterion, Tresca flow criterion, uniaxial compression test, slip line field theory, upper bound approach, Elastic theory, torsion Fracture: Griffith theory, fracture mechanics, crack initiation in compression, theory assuming spherical voids, Weibull statistics, disc test, fracture of cemented tungsten carbide Dynamometry: Dynamometer requirement force measurement, electric transducer, bonded strain gages, whetstone bridge, design consideration, strain gage lathe dynamometer, strain rings. Shear strain in steady state cutting: dimensional analysis, early complete solution, slip line field solution, Shear stress in cutting: strain rate and temperature. Plastic behavior at large strain, new mechanism of large strain plastic flow in homogeneous strain. MTE Wear and tool life: Types of cutting tool wear, Wear-Land wear, crater wear, tool life testing, groove formation, gross tool fracture, simplified Griffith theory for circular voids, stress intensification for a spherical void, tool fracture at entrance and exit, thermal contraction Cutting Temperature: thermal energy in cutting, experimental techniques Cutting Fluids: low speed cutting fluid action, carbon tetrachloride, practical consideration Tool material: machining system, tool material requirement, major tool material types, Physical vapor deposition, design and performance, Work material consideration: fracture during chip formation, hot hardness of work piece, machining high strength materials Chip control: chip flow direction and chip types, chip barker performance, rational approach control, chip breaking grooves, chip curling/breaking analysis Optimization: levels of optimization, machining economics, optimum productive rate, adaptive control

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7 8 9 10 11

TEXT BOOKS: 1. Principles of Metal Cutting, Shaw,M.C., Oxford & IBH OTHER READINGS: 1. Principles of Machine Tools, Sen & Bhattacharya, New Central Book Agency 2. Metal Cutting Theory and Cutting Tool Design, Arshinov & Acherken, MTR Publishers 3. Machine Tool Design, Acherken, MIR Publishers 4. Fundamentals of Tool Engineering Design, Basu, Mukhopadhyay & Mishra, Oxford & IBH . SALIENT PEDAGOGICAL FEATURES: 1. More focus should be on different manufacturing processes and methods of manufacturing a product in Industry .