ME3190 Machining & Metrology

Machining: Dr. Sushanta Kumar Panigrahi

Metrology: Dr. G.L. Samuel
Machining: Dr. Sushanta Kumar Panigrahi
Metrology: Dr. G.L. Samuel
Machining: Dr. L. Vijayaraghavan
Metrology: Dr. N. Arunachalam
Principles of Metal cutting orthogonal and oblique cutting; Shaping, turning, drilling,
milling Machine Tools and their working Process variables; Cutting tools
Nomenclature, Tool life;
Abrasive machining processes grinding, honing, lapping, burnishing and super
finishing Equipment, process variables and surface features; Surface integrity
concepts.
Introduction to NC and CNC Concepts and programming Constructional features of
various machine tools: Introduction to CIM.
Fundamentals of Measurement, Errors, Length Standards, Gauging, Comparators, Fits
and Tolerances; Role of metrology in quality assurance; Linear and angular
measurements; Optical metrology and laser interferometry; Slip gauges; Form
measurements Flatness, Straightness, Form errors; Surface finish
measurements; Coordinate measuring machines; Vision applications in
Metrology; Nano measurements.
Course Outline
ME3190 Machining & Metrology
Principles of Metal cutting orthogonal and oblique cutting; Shaping, turning, drilling,
milling Machine Tools and their working Process variables; Cutting tools
Nomenclature, Tool life;
Abrasive machining processes grinding, honing, lapping, burnishing and super
finishing Equipment, process variables and surface features; Surface integrity
concepts.
Introduction to NC and CNC Concepts and programming Constructional features of
various machine tools: Introduction to CIM.
Fundamentals of Measurement, Errors, Length Standards, Gauging, Comparators, Fits
and Tolerances; Role of metrology in quality assurance; Linear and angular
measurements; Optical metrology and laser interferometry; Slip gauges; Form
measurements Flatness, Straightness, Form errors; Surface finish
measurements; Coordinate measuring machines; Vision applications in
Metrology; Nano measurements.
Machining
Introduction (1 classes)
Principle of metal cutting (5 classes approx.)
- Mechanism of machining
- Mechanics of machining
Machine tool drives (5 classes aprox.)
Conventional machine tools (20 classes)
References:
1. Production Technology, HMT, Tata McGraw Hill.
2. S.K. Hajra Choudhury, A.K. Hajra Choudhury and N. Roy, Elements of Workshop
Technology (Machine Tools), Volume-II, Media Promoters and Publishers Pvt. Ltd.
3. J.T. Black, R.A. Kohser, Degarmos Materials and Processes in Manufacturing, John Wiley
& Sons, 2011.
4. A.B. Chattopadhyay, Machining and Machine Tools, John Wiley & Sons.
5. G.C. Sen and A. Bhattacharya, Principles of Machine Tools, New central Book Agency
Pvt. Ltd.
6. S. Kalpakjian and S.R. Schmid, Manufacturing Processes for Engineering Materials,
Pearson.
SYLABUS
Sl. No. Title
1 Introduction to Machining (1 Class)
2 Mechanisms of Machining (3 Classes)
3 Mechanics of Machining (2 Classes)
4 Machine Tool Drives (4 Classes)
5 Lathe (5 Classes) 5 Lathe (5 Classes)
6 Milling (6 Classes)
7 Grinding (6 Classes)
8 Shaping & Planning (2 Class)
9 Drilling (2 Class)
INTRODUCTION
Lecture No. 1
Outline
Classification of Basic Manufacturing processes
Brief overview of primary manufacturing processes
Introduction to machining/material removal processes
Influence of input parameters on machining
Basic Machining processes used in chip formation
Basic differences between traditional/conventional
and non-traditional metal removal processes
Classification of Basic Manufacturing processes
Brief overview of primary manufacturing processes
Introduction to machining/material removal processes
Influence of input parameters on machining
Basic Machining processes used in chip formation
Basic differences between traditional/conventional
and non-traditional metal removal processes
What is manufacturing ?
Technologically, manufacturing is the application of
mechanical, chemical, electrochemical and thermal
processes to alter the geometry, property and/or
appearance of a given starting material to make parts
and products.
Economically, manufacturing is the transformation of
materials into items of greater value by means of one
or more processing and/or assembly operation
Technologically, manufacturing is the application of
mechanical, chemical, electrochemical and thermal
processes to alter the geometry, property and/or
appearance of a given starting material to make parts
and products.
Economically, manufacturing is the transformation of
materials into items of greater value by means of one
or more processing and/or assembly operation
Casting
Expandable mold
Multiple use mode
Shaping or Forming
Deformation processes
Particulate processing / powder metallurgy
Machining
Conventional machining processes
Non traditional machining processes
Joining and Assembly
Permanent joining processes
Mechanical fastening
Additive Processes
Five basic classification of manufacturing
processes
Primary Manufacturing Processes
(to manufacture the products with
basic shape and size)
Casting
Expandable mold
Multiple use mode
Shaping or Forming
Deformation processes
Particulate processing / powder metallurgy
Machining
Conventional machining processes
Non traditional machining processes
Joining and Assembly
Permanent joining processes
Mechanical fastening
Additive Processes
Casting
Expandable mold
Multiple use mode
Shaping or Forming
Deformation processes
Particulate processing / powder metallurgy
Machining
Conventional machining processes
Non traditional machining processes
Joining and Assembly
Permanent joining processes
Mechanical fastening
Additive Processes
Five basic classification of manufacturing
processes
Primary Manufacturing Processes
(to manufacture the products with
basic shape and size)
Casting
Expandable mold
Multiple use mode
Shaping or Forming
Deformation processes
Particulate processing / powder metallurgy
Machining
Conventional machining processes
Non traditional machining processes
Joining and Assembly
Permanent joining processes
Mechanical fastening
Additive Processes
Secondary Manufacturing Processes
(to manufacture the products with
basic shape and size with tight control
on dimension and shape)
Machining
Machining is a process of removing unwanted materials in
the form of chips.
Purpose of Machining
To meet its functional requirement
To provide improved performance
To improve the service life
To make products with dimensional
accuracy and good surface finish
Machining may act as a system which contains workpiece,
cutting tool and machine.
Machining is a process of removing unwanted materials in
the form of chips.
Purpose of Machining
To meet its functional requirement
To provide improved performance
To improve the service life
To make products with dimensional
accuracy and good surface finish
Machining may act as a system which contains workpiece,
cutting tool and machine.
Conventional Metal
Removal Processes
Material Removal Processes/Machining
Non Traditional Metal
Removal Processes
Turning
Milling
Drilling
Sawing
Shaping
Grinding
Broaching
Mechanical Machining Processes
Chemical Machining Processes
Electrochemical Machining Processes
Thermal Machining Processes
Machining/Metar Removal Processes
Turning
Milling
Drilling
Sawing
Shaping
Grinding
Broaching
Mechanical Machining Processes
Chemical Machining Processes
Electrochemical Machining Processes
Thermal Machining Processes
Machining is a process of removing unwanted materials in the form of chips.
Purpose of Machining
To meet its functional requirement
To provide improved performance
To improve the service life
Conventional Metal Removal Processes
Turning Milling
Drilling
Grinding
Drilling
Non Traditional Metal Removal Processes
Mechanical Process: AWJ
Mechanical Process: UM
Work Piece
Tool
Work Piece
Water jet
Electro Thermal Process: EDM Electro Chemical Process: ECM
Tool
Work Piece
Electrolyte
Work Piece
Tool
Dielectric
Conventional Metal
Removal Processes
Material Removal Processes/Machining
Non Traditional Metal
Removal Processes
Mechanical Machining Processes
Chemical Machining Processes
Electrochemical Machining Processes
Thermal Machining Processes
Machining/Metar Removal Processes
Mechanical Machining Processes
Chemical Machining Processes
Electrochemical Machining Processes
Thermal Machining Processes
Machining is a process of removing unwanted materials in the form of chips.
Purpose of Machining
To meet its functional requirement
To provide improved performance
To improve the service life
Turning
Drilling
Milling
Grinding
Shaping
Planing
Tool-Workpiece Interaction
Basic Machining Processes Used in Chip Formation
Why machining process is difficult to analyze ?
Prior work hardening of material greatly affects the
process
Different materials deforms differently
The process is asymmetrical and unconstrained
High level of strain
High strain rate
The process is sensitive to variation in
tool geometry
tool material
tool wear
temperature
environment
process dynamics
Prior work hardening of material greatly affects the
process
Different materials deforms differently
The process is asymmetrical and unconstrained
High level of strain
High strain rate
The process is sensitive to variation in
tool geometry
tool material
tool wear
temperature
environment
process dynamics