PRODUCTION TECHNOLOGY-I

UNIT-I Metal cutting & tool life : Basic tool geometry, Single point tool nomenclature, Chips-various types and their characteristics, Mechanism of chip formation, Theoretical and experimental determination of shear angle, orthogonal and oblique metal cutting, Metal cutting theories ,relationship of velocities, Force and power consumption. Each of operating parameters, Tool life, Tool geometry, Cutting speed, feed, depth of cut, coolant, materials etc., Effect of cutting forces on tool life, surface finish etc. ,Tool life relationship, Taylor equation of tool life, Tool material and mechanism. UNIT-II Economics of metal machining & Multi edged tools: Element of machining cost, Tooling economics, Machine economics and optimization, Broach tools-Types, Materials and applications, geometry of twist drills, thrust torque and power calculation in drills, Form tools-application UNIT-III Metal Forming & Jigs and Fixtures: Metal blow down condition and theories of plasticity conditions of plane strains, Friction condition in metal working, Wire drawing-extension of rods, Theory of forging, Rolling of metals and elementary rolling theory, no slip angle and forward slip, Tool engineering ,Types of Tools, Usefulness, Principle of location, Locating and clamping devices, jigs, jigs bushes ,Drilling jigs, Milling fixtures, Turning fixtures, Boring and Broaching fixtures, Different materials for Jigs and fixtures, Economics of jigs and Fixtures. UNIT-IV Metrology Measurements, linear and angular simple measuring instruments, Various clampers, Screw Gauge, Sine bar, Autocollimator, Comparator Mechanical, Electrical, Optical, Surface finish and its measurement, micro and macro deviation factors influencing surface finish and evaluation of surface finish

Suggested reading: 1. Manufacturing science: Ghosh and Malik, E.W. Press 2. Principles of metal cutting: Sen and Bhattacharya, New Central Book. 3. Metal cutting principles: Shaw, MIT Press Cambridge 4. Manufacturing analysis: Cook, Adisson-Wesley 5. Modern machining processes: Pandey and Shan, Tata McGraw Hill Publications

Lecture Plan Lecture L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22 L23 L24 L25 Contents Basic tool geometry, Single point tool nomenclature, Chips-various types and their characteristics, Mechanism of chip formation, Theoretical and experimental determination of shear angle Orthogonal and oblique metal cutting, Metal cutting theories Relationship of velocities, Force and power consumption. Each of operating parameters, Tool life, Tool geometry, Cutting speed, feed, depth of cut Effect of cutting forces on tool life, surface finish etc. ,Tool life relationship Taylor equation of tool life, Tool material and mechanism Element of machining cost, Tooling economics Machine economics and optimization, Broach tools-Types Materials and applications, geometry of twist drills Thrust torque and power calculation in drills Form tools-application Metal blow down condition and theories of plasticity conditions of plane strains Friction condition in metal working Wire drawing-extension of rods, Theory of forging Rolling of metals and elementary rolling theory, no slip angle and forward slip Tool engineering ,Types of Tools Usefulness, Principle of location, Locating and clamping devices Jigs, jigs bushes , drilling jigs Milling fixtures, Turning fixtures Boring and Broaching fixtures Different materials for Jigs and fixtures Economics of jigs and Fixtures Measurements, linear and angular simple measuring instruments Various Clampers

L26 L27 L28 L29 L30

Screw Gauge, Sine bar, Autocollimator Comparator Mechanical, Electrical, Optical Surface finish and its measurement Micro and macro deviation factors influencing surface finish evaluation of surface finish

Tutorial Sheet-I 1. Briefly explain the nomenclature of Single Point cutting tool with a neat sketch. Also give the tool signature in ASA System? 2. Describe the mechanism of Chip formation? Name and different types of Chips? Why does a blue chip produce a poor surface finish? Explain function of Chip Breaker? 3. What do you understand by chip cutting ratio? How chip reduction coefficient affect it? 4. What is Merchants Circle diagram? Explain various types of forces acting on tool & work piece, with a neat sketch? 5. What is Tool life? What are the factors which affect the tool life? Also give Taylors equation for the Tool life? 6. What is Tool failure? What are causes for crater & flank wear? 7. What is the purpose of Cutting Fluid? Explain the different types of cutting fluid and their characteristics? 8. Explain the different tool Materials? Also Give their properties. 9. Explain metal blow condition? Theories of plasticity condition of plane strains? 10. Explain metal cutting theories.

Tutorial Sheet-II 1. Derive an expression for optimum cutting speed? 2. In Orthogonal cutting the feed is .127mm and depth of cut normal to the plane of the paper is 2.54mm.Cutting speed is 4m/s.The cutting force is found to be 1800N and the feed thruest force is 900N.Take rake angle is 8degree Find power, material removal rate.

3. The following data is observed: Uncut chip thickness t1=.127mm Width of cut b=6.35mm Cutting speed V=2m/s Rake angle =10 degree Cutting Force=567N Thrust Force=227N Chip Thickness t2=.228mm Find: Shear angle, friction angle, shear stress, power required, chip velocity. 4. In Single point cutting tool used for turning, the geometry as per ASA Rake =8 Side Rake s=4 N=240 R.P.M F=.25mm/rev Point Angle 2=118 Helix=30 Rakeangle=18 5. Discuss in detail elements of machine cost. 6. With neat sketch explain different types of broach. 7. Explain geometry of drill with neat sketch. 8. Derive an expression for thrust torque and power consumption in twist drill. 9. Explain form tool and their application with diagram. 10. Write note on machine economics and optimization.

Tutorial Sheet-III

1. Explain difference between a jig & fixture. Briefly describe basic principles of jig and fixture design with neat sketches? 2. What is six point location principle? What type of locator would you prefer for locating a component radially? 3. What are essential requirements of clamps and clamping devices? 4. What are drilling jig bushes and drilling jigs? 5. Explain function of a milling fixture with neat sketch? Why Clamps on milling fixture be extremely rigid? 6. How are broaching fixture classified? What precautions should be taken while designing the fixture for internal broaching ? 7. Give short note on different materials for jigs and fixtures? 8. Explain theories of plasticity conditions of plane strains. 9. Explain milling fixtures with neat sketch. 10. Write economics of jigs and fixtures.

Tutorial Sheet-IV 1. Explain plastic deformation yield criteria for forming process? 2. What do you understand by limiting draw Ratio (LDR)? 3. In Rolling process,25mm thick plate is rolled to 20mm in a four high mill. Determine the coefficient of friction if this is the maximum reduction possible. Roll diameter is 400mm. Find the Neutral section, Backward & Forward slip & Maximum pressure o=200N/mm2 for Hot rolls of mild steel at about 1000C? 4. Calculate the drawing load required to obtain 30% in area on a 12mm diameter copper wire. The following data is given: =240N/mm2,2=12,=.10.Calculate the power of electric motor if the drawing speed is 2.3m/s. Take efficiency of motor as 89%? 5. What do you mean by sensitivity of a measuring instrument? Differentiate between absolute and comparative measuring instruments? 6. Explain the working of auto-collimator with neat & clean sketch?

7. What is comparator? Give its different types? Briefly explain the working of electrical & Optical comparator? Give its different types? Briefly explain the working of electrical and optical comparator. 8. How will you define surface finish? Explain the factors affecting the surface finish & its evaluation? 9. Write short note on 1) Angular measurement 2) Micro and Macro deviation in surface finish 3) Pneumatic comparator 4) Measurement of external dovetail 10. What is autocollimator? Explain different types of autocollimator with diagram.

BT-3/DX PRODUCTION TECHNOLOGY Paper-ME-209E

2(a).Define the term tool life? Explain the effect of operating parameters on Tool life?

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(b)What is merchants circle diagram? Explain various types of forces acting on tool and work piece, with a neat sketch? (10) 3(a)What are the various ways of specifying the drill Sizes? Sketch a Twist drill along with its main geometry elements? (10) (b)Briefly explain Broaching operation, its types and job applications? (10)

4(a) Find the drilling power for 50mm diameter drill having a feed of .50mm/rev. The cutting speed is .75m/sec. The material factor for brass is .55(10) (b)What are form Tools? Also discuss their material and shape applications? 5(a)Explain the functioning of a Milling Fixture with neat sketch? (10) (10)

(b)How, Broaching fixtures are classified? What precautions should be taken while designing the fixture for internal broaching? (10) 6 Discuss briefly the flaw conditions in metal forming? Also explain the various theories of plasticity conditions of plane strain? (10) 7(a)Explain the use of a sinebar for measuring the angle of taper plug gauge with the help of neat sketch? (10) (b)Describe the working principle and construction of optical comparator along with its advantages? (10) 8 Write short notes on any four of the following: a) b) c) d) e) Basic Tool Geometry Auto collimator Economics of jigs and Fixtures Six point location principle Surface finish and its evaluation

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