Classification of metal removal process and machines Mechanics of metal cutting: Geometry of
single point cutting tool and tool angles. Tool nomenclature in ASA, ORS, NRS and
interrelationship. Mechanism of chip formation and types of chips, chip breakers. Orthogonal and
oblique cutting, cutting forces and power required, theories of metal cutting. Thermal aspects of
machining and measurement of chip tool interface temperature. Friction in metal cutting.
Units: II
Machinability: Concept and evaluation of machinability, tool life, mechanisms of tool failure,
tool life and cutting parameters, machinability index, factors affecting machinability. Cutting
fluids: Types, properties, selection and application methods
General Purpose Machine Tools: Classification and constructional details of lathe, drilling,
milling, shaping and planning machines. Tooling, attachments and operations performed,
selection of cutting parameters, calculation of forces and time for machining. Broaching
operation.
Units: III
Special Purpose Machine Tools: Automatic lathes, capstan and turret lathe machines. Swiss
automatic, operational planning and turret tool layout, sequence of operations. Tracer attachment
in Machine Tools: mechanical-copying machines; Hydraulic Tracing Devices; Electric Tracing
systems; Automatic tracing.
Abrasive processes: Abrasives; natural and synthetic, manufacturing, nomenclature. Selection of
grinding wheels, wheel mounting and dressing, characteristic terms used in grinding. Machines
for surface and cylindrical grinding, their constructional details and processes. Surface finishing:
Honing, lapping, superfinishing, polishing and buffing processes.
Units: IV
Thread Manufacturing: casting; thread chasing; thread cutting on lathe; thread rolling, die
threading and tapping; thread milling; thread grinding.
Gear Manufacturing Processes: hot rolling; stamping; powder metallurgy; extruding etc. Gear
generating processes: gear hobbling, gear shaping. Gear finishing processes: shaving,
grinding, lapping, shot blasting, phosphate coating, Gear testing.
Units: V
High Velocity Forming Methods: (High-energy rate forming processes) Definition; Hydraulic
forming, Explosive forming, Electro-hydraulic forming, Magnetic pulse forming.
Industrial Safety: Human factor in machine equipment safety; reducing industrial noise;
precautions to be taken by operators for safe working on different machine tools.