A1- ASSIGNMENT 1: INDIVIDUAL TASK (25%)

Download a recent journal paper on machining and precision manufacturing. Try to understand the
content of it and mak e a presentation (10 to 15 slides) based on the paper. Ref: Sciencedirect, ASME

A2 ASSIGNMENT/TASK 2: GROUP TASK (45 to 50 %)

Group of 4 students
A2 PART 1: TRY TO ANSWER THIS QUESTION

1. Explain the circuit diagram and working of an ‘Auto Lub rication System’ in a universal milling machine (Ref:
BFW milling machines in our workshop). We have a heavy duty vertical milling machine also in our
workshop. Identify the methodology of cutting fluid application in this machine tool. If you are asked to
select a cutting fluid for the end milling of cast iron in this machine using HSS end milling cutters, which
fluid you will select?
2. What do you mean b y Turn-Mill Centre? How it is different from a Turning centre and a Milling Centre.
Suppose you are asked to cut a spiral groove on the face of a disc, can you do it in Turn -Mill Centre?
3. Let us assume that your task is to drill eight holes equally spaced in a bolt hole circle. The positions of the
hole are at 12, 3, 6, 9’O clock and four additional holes equally spaced between them. The diameter of the
bolt hole circle is 6 inch. The designer says that the holes must be at 45 ° from each other around the
circle. Can you propose a tool holding or work clamping setup which can reduce the machining time and
machining cost (especially set up cost)
4. What are the difficulties involved in drilling a hole with an aspect ratio 300: 1. Ho w can you overcome these
difficulties? Does the force or torque in drilling change as the hole depth increases? Explain.
5. Find the arrangement for cutting a screw thread of 26 TPI in a lathe with a lead screw having 4 TPI,
change gear wheels availab le are from 20 to 120 teeth with a progression of 5. (20, 25, 30 to 120).
6. Calculate all machining particulars for cutting a spur gear of 3 module and 54 teeth with proper index plate
hole circle and sector in a universal milling machine.
7. Working mechanism of a universal dividing head to cut a spur gear in a universal milling machine. How can
you cut a helical gear in this machine? What are the changes required in the settings? Can you cut a bevel
gear in this machine?
8. What do you mean b y chatter in metal cutting operation? What are the effects of chatter in machine tool
performance? Explain it with a spring-mass analogy. Can you propose a simple experiment to assess
chatter during machining?
9. What do you mean b y stick -slip effect and how can you avoid it in machine tools? Explain it with a spring-
mass analogy. Can you propose a simple experiment to assess stick -slip effect?
10. What do you mean b y laser assisted machining and what are the advantages? If you would like to perform
it in the lathe available in our lab , what are the modifications required in the machine tool? Design it for the
machine available in lab (don’t make it a general vague design)
11. What do you mean b y vibration assisted machining and what are the advantages? If you would like to
perform it in the lathe available in our lab , what are the modifications/additional setups required in the
machine tool? Design it for the machine available in lab (don’t make it a general vague design)
12. Describe your thought on whether chips produced during machining can be used to make useful products.
Give some examples of possible products
 13. Discuss the relative advantages and limitations of minimum quantity lubrication in metal cutting. Consider
the relevant technical and economic aspects. If you would like to perform it in the lathe available in our lab ,
what are the modifications/additional setups required in the machine tool? Design it for the machine
availab le in lab (don’t make it a general vague design)
14. Discuss the relative advantages and limitations of using liquid nitrog en in cutting zone. Consider the
relevant technical and economic aspects. If you would like to perform it in a machine tool available in our
lab , what are the modifications/additional setups required? Design it for the machine available in lab (don’t
make it a general vague design)
15. What do you mean by Dry-EDM? Can you suggest some methods b y which we can perform EDM
operation on ceramic/non-conducting composite materials?

A2 PART 2: Design / Modelling and Simulation TASK

1. Modelling and Simulation of important mechanisms in machine tools using CATIA / AD AMS.
(Example: Thread cutting mechanism in a lathe, including the working of half nut, Apron Mechanism of a
lathe, Turret Indexing Mechanism in Capstan and Turret lathe, Bar feeding mechanism in Capstan and
Turret lathe, Quick return mechanism in a shaper, including tool head mechanism, Hydraulic Shaper
Mechanism, Full Mechanism of working of a drilling machine, Working Mechanism of a power hack saw and
band saw, Working Mechanism of a copying lathe, Working Mechanisms of a slotting machine, Automatic
Feed mechanism of a shaper, Quick return mechanism of a planer by open and cross belt, Feed disc and
automatic feed mechanism of a planer, Working of Three Jaw Self Centering, Four Jaw Independent and Air
operated chucks in lathe, Working Mechanism of a universal dividing head, Working of automatic tool
changer (ATC) in CNC Milling machine, etc. or Similar)

OR
2. Design/modelling of a 3D additive fabrication system and its related components (a desktop type/prototype
level system). It should be a system that can make metal components. Raw material can be in the form of
wires (filaments), powders/granules. Don’t simply copy the existing system s. The design should be complete
with all sub-components, approximate cost analysis etc.

OR
3. Modelling and Simulation of metal cutting (turning, milling, drilling or grinding operation)-chip formation,
cutting forces or cutting temperature (ABAQUS or ANSYS or an appropriate software). You may refer
software tutorials/e-resources for the same.

The choice i s yours. But avoid duplications.

Consider it as an open tri al. However the attempts should be sincere and systematic.

A3 ASSIGNMENT/TASK 3: OPEN BOOK TASK (25 to 30%)

TOTAL 20 MARKS