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IV SEMESTER
MECHANICAL ENGINEERING
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SESSION 1
SESSION 2
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Objective of MT II
To understand the concept and basic
mechanics of metal cutting
To understand working of standard m/c tools
such as lathe, shaper, milling m/c, drilling m/c,
grinding, and allied machines
To understand the basic concepts of CNC
machine tool and CNC programming
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Introduction
Machine tool types
Theory of metal cutting
Chip formation
Cutting tool
Cutting fluids
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Introduction
MT is study of processes required to make
parts
These parts are then used in mechanism and
machines
Process can be metal cutting or metal forming
Part is obtained by cutting operation metal
cutting
Metal is shaped under pressure and heat
metal forming
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Manufacturing process
Metal working
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Machine tools
General purpose
Single purpose
Limited purpose
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Production
Specialized
Questions
Short answers
1.
2.
3.
4.
5.
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SESSION 2
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Machining
Cutting action involves shear deformation of work
material to form a chip
As chip is removed, new surface is exposed
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Machining Operations
Most important machining operations:
Turning
Drilling
Milling
Other machining operations:
Shaping and planing
Broaching
Sawing
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Turning
Single point cutting tool removes material from a
rotating workpiece to form a cylindrical shape
SESSION 3
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Drilling
Used to create a round hole, usually by means of
a rotating tool (drill bit) with two cutting edges
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Milling
Rotating multiple-cutting-edge tool is moved
across work to cut a plane or straight surface
Two forms: peripheral milling and face milling
Cutting Tools
Figure 21.4 (a) A singlepoint tool showing rake face, flank, and tool
point; and (b) a helical milling cutter, representative of tools with
multiple cutting edges.
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SESSION 4
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Machine Tools
A powerdriven machine that performs a
machining operation, including grinding
Functions in machining:
Holds workpart
Positions tool relative to work
Provides power at speed, feed, and depth
that have been set
The term is also applied to machines that
perform metal forming operations
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Figure 21.7 Shear strain during chip formation: (a) chip formation
depicted as a series of parallel plates sliding relative to each other, (b)
one of the plates isolated to show shear strain, and (c) shear strain
triangle used to derive strain equation.
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Shear Strain
Shear strain in machining can be computed
from the following equation, based on the
preceding parallel plate model:
= tan( - ) + cot
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SESSION 5
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Chip Formation
Discontinuous chip
Continuous chip
Continuous chip with Built-up Edge (BUE)
Serrated chip
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Discontinuous Chip
Brittle work materials
Low cutting speeds
Large feed and depth
of cut
High toolchip friction
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Continuous Chip
Ductile work materials
High cutting speeds
Small feeds and
depths
Sharp cutting edge
Low toolchip friction
Figure 21.9 (b) continuous
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Serrated Chip
Semicontinuous saw-tooth
appearance
Cyclical chip forms
with alternating high
shear strain then low
shear strain
Associated with
difficult-to-machine
metals at high cutting
speeds
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Resultant Forces
Vector addition of F and N = resultant R
Vector addition of Fs and Fn = resultant R'
Forces acting on the chip must be in balance:
R' must be equal in magnitude to R
R must be opposite in direction to R
R must be collinear with R
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Coefficient of Friction
Coefficient of friction between tool and chip:
F
N
Friction angle related to coefficient of friction
as follows:
tan
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Shear Stress
Shear stress acting along the shear plane:
Fs
S
As
where As = area of the shear plane
t ow
As
sin
Shear stress = shear strength of work material
during cutting
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SESSION 6
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45
2 2
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Fcv
HPc
33,000
where HPc = cutting horsepower, hp
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Pc
Pg
E
or
HPc
HPg
E
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Pc
PU =
RMR
or
HPc
HPu =
RMR
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Pc
Fc v
U = Pu =
=
RMR vt ow
Units for specific energy are typically
Nm/mm3 or J/mm3 (inlb/in3)
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SESSION 7
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Cutting Temperature
Approximately 98% of the energy in machining
is converted into heat
This can cause temperatures to be very high at
the toolchip
The remaining energy (about 2%) is retained
as elastic energy in the chip
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Cutting Temperature
Analytical method derived by Nathan Cook
from dimensional analysis using
experimental data for various work materials
0.4U vt o
T
C K
0.333
Cutting Temperature
Experimental methods can be used to measure
temperatures in machining
Most frequently used technique is the
toolchip thermocouple
Using this method, Ken Trigger determined the
speedtemperature relationship to be of the
form:
T = K vm
where T = measured toolchip interface
temperature, and v = cutting speed
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