Theory of Metal Cutting

Lovely Professional University, Punjab Course Code

Course Title

Course Planner

Lectures

MEC405

THEORY OF METAL CUTTING

15750::Manoj Kumar R

Course Category

Courses with numerical and conceptual focus

3.0

Tutorials Practicals Credits 0.0

0.0

TextBooks Sr No

Title

Author

Edition

T-1

Principles of Metal Cutting

Shaw,M.C

3rd

Year

Publisher Name Oxford and IBH Publishing Co. Pvt. Ltd New Delhi

Reference Books Sr No

Title

Author

Edition

Year

Publisher Name

R-1

Principles of Machine Tools

Sen & Bhattacharya

2nd

New Central Book Agency (P) Ltd, India.

R-2

Fundamentals of Tool Engineering Design

Basu, Mukhopadhyay & Mishra

2nd

Oxford and IBH Publishing Co. Pvt. Ltd New Delhi

R-3

Metal cutting principle

Dr.B.J.Ranganath

1st

Vikas Publication

Other Reading Sr No

Journals articles as Compulsary reading (specific articles, complete reference)

OR-1

METAL CUTTING THEORY - MISSED CHANCES OR ASCIENCE WITHOUT HISTORY: Part 2 by Viktor P. Astakhov ,

OR-2

Tribology of Metal Cutting by Viktor P. Astakhov ,

OR-3

Metal Cutting Theory and Cutting Tool Design, Arshinov & Acherken, MTR Publishers ,

Relevant Websites Sr No

(Web address) (only if relevant to the course)

Salient Features

RW-1

www.iscar.com

cutting tool manufacturer site

RW-2

www.ehow.com/metal-cutting-tools

metal cutting tools

RW-3

http://www.americanmachinist.com

Metal cutting related site

LTP week distribution: (LTP Weeks)

Detailed Plan For Lectures

Weeks before MTE

7

Weeks After MTE

6

Spill Over

2

3.0

Week Number

Lecture Number

Broad Topic(Sub Topic)

Week 1

Lecture 1

Introduction(Importance of Material Removal)

T-1:Reference 1Chapter 1 R-3:reference 1 chapter 1.1

OR-3

it covers the importance of material removal

understand the concept Slide Show of process

Introduction(Classification of Metal Removal Operation)

T-1:Reference 1Chapter 1 R-3:reference1 chapter 1.3

OR-1

covers the classification

understand the classification

Introduction(Overview of Cutting Processes and Types of Chips)

T-1:Reference 1Chapter 1 R-3:reference 1.3

RW-1

it covers the overview of understand the cutting cutting process process

Slide Show

Introduction(Chip formation Analysis.)

T-1:Reference 1Chapter 1 R-3:reference 1.5

OR-2

it covers the chip analysis

clearly understanding the concept behind the topic

Slide Show

Cutting 0perations(Principle Cutting Operations.)

T-1:Reference 1Chapter 2 R-3:reference 2.2

RW-1

clearly it covers cutting operation

clearly understanding the concept behind the topic

Slide Show

Cutting 0perations(Other Cutting Operations)

T-1:Reference 1Chapter 2 R-3:reference 2.4

RW-1

clearly it covers cutting operation

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Card Model)

T-1:Reference 1Chapter 3 R-3:Reference 2.6

OR-3 RW-2

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Forces)

T-1:Reference 1Chapter 3 R-3:Reference 2.7

RW-1

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Stresses)

T-1:Reference 1Chapter 3 R-3:Reference 2.7

RW-1

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Shear Angle)

T-1:Reference 1Chapter 3 R-3:Reference 2.8

RW-2

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Lecture 2

Lecture 3

Week 2

Lecture 4

Chapters/Sections of Text/reference books

Other Readings, Lecture Description Relevant Websites, Audio Visual Aids, software and Virtual Labs

Learning Outcomes

Pedagogical Tool Demonstration/ Case Study / Images / animation / ppt etc. Planned

Slide Show

Week 2

Week 3

Lecture 4

Mechanics of Orthogonal Steady State Cutting(Shear Strain)

T-1:Reference 1Chapter 3 R-3:Reference 2.9

RW-2

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Velocity Relation)

T-1:Reference 1Chapter 3 R-3:reference 2.5

OR-3

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Lecture 5

Mechanics of Orthogonal Steady State Cutting(Merchant Circle Diagram and Analysis)

T-1:Reference 1Chapter 3 R-3:Reference 2.10

OR-3

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Lecture 6

Mechanics of Orthogonal Steady State Cutting(Power and Energy Relationship)

T-1:Reference 1Chapter 3 R-3:Reference 2.13

OR-1

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Flow Lines in a Chip)

T-1:Reference 1Chapter 3 R-3:Reference 2.14

RW-3

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Rate of Strain)

T-1:Reference 1Chapter 3 R-3:Reference 2.9

OR-3

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Other chip types)

T-1:Reference 1Chapter 3 R-3:Reference 2.14

RW-3

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Estimation of Cutting Force)

T-1:Reference 1Chapter 3 R-3:Reference 2.15

RW-3

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Plastic Behavior(Dislocation Theory)

T-1:Reference 1Chapter 5

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Plastic Behavior(Theoretical Shear Strength)

T-1:Reference 1Chapter 5

OR-3 RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Plastic Behavior(Metal Whisker's)

T-1:Reference 1Chapter 5

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Plastic Behavior(Constancy of Volume and Possion s Ratio)

T-1:Reference 1Chapter 5

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Plastic Behavior(Von Mises Flow Criterion)

T-1:Reference 1Chapter 5

RW-2 RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 7

Lecture 8

Lecture 9

Week 4

Lecture 10

Week 4

Lecture 11

Fracture(Fracture Mechanics)

T-1:Reference 1Chapter 6

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Fracture(Griffith Theory)

T-1:Reference 1Chapter 6

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 12 Week 5

Week 6

Week 7

Lecture 13

Homework,Test 1 Fracture(Crack Initiation in Compression)

T-1:Reference 1Chapter 6

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Fracture(Theory Assuming Spherical Voids)

T-1:Reference 1Chapter 6

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 14

Fracture(Disc Test)

T-1:Reference 1Chapter 6

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 15

Fracture(Fracture of Cemented Tungsten Carbide)

T-1:Reference 1Chapter 6

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 16

Dynamometry(Dynamometer Requirement Force Measurement)

T-1:Reference 1Chapter 7

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 17

Dynamometry(Electric Transducer)

T-1:Reference 1Chapter 7

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 18

Dynamometry(Whetstone Bridge)

T-1:Reference 1Chapter 7

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 19

Dynamometry(Design Consideration)

T-1:Reference 1Chapter 7

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 20

Dynamometry(Strain Gage Lathe Dynamometer)

T-1:Reference 1Chapter 7

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 21

Dynamometry(Strain Rings)

T-1:Reference 1Chapter 7

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Dynamometry(Bonded Strain Gages)

T-1:Reference 1Chapter 7

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

MID-TERM Week 8

Lecture 22

Geometry of Cutting Tools(Single Point and Multi Point Cutting Tools)

R-3:Reference 1Chapter 3

RW-2 RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Geometry of Cutting Tools(Tool Nomenclature)

R-3:Reference 1Chapter 3

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 8

Week 9

Lecture 23

Geometry of Cutting Tools(Effect of Cutting Parameters on Tool Geometry)

R-3:Reference 1Chapter 3

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 24

Wear and Tool Life(Types of Cutting Tool Wear)

T-1:Reference 1Chapter 11

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Wear-Land Wear)

T-1:Reference 1Chapter 11

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Crater Wear)

T-1:Reference 1Chapter 11

OR-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Tool Life Testing)

T-1:Reference 1Chapter 11

OR-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Groove Formation)

T-1:Reference 1Chapter 11

OR-3 RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Gross Tool Fracture)

T-1:Reference 1Chapter 11

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Simplified Griffith Theory for Circular Voids)

T-1:Reference 1Chapter 11

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Stress Intensification for a Spherical Void)

T-1:Reference 1Chapter 11

RW-2 RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Tool Fracture at Entrance and Exit)

T-1:Reference 1Chapter 11

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Thermal Contraction)

T-1:Reference 1Chapter 11

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Cutting Temperature(Experimental Techniques.)

T-1:Reference 1Chapter 12

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Cutting Temperature(Thermal Energy in Cutting)

T-1:Reference 1Chapter 12

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Cutting Fluids(Carbon Tetra Chloride)

T-1:Reference 1Chapter 13

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Cutting Fluids(Low Speed Cutting Fluid Action)

T-1:Reference 1Chapter 13

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Tool Material(Tool Material Requirement)

T-1:Reference 1Chapter 14

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 25

Lecture 26

Lecture 27

Week 10

Lecture 28

Lecture 29

Lecture 30

Week 10

Week 11

Lecture 30

Lecture 31

Cutting Fluids(Practical Consideration)

T-1:Reference 1Chapter 13

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Tool Material(Machining System)

T-1:Reference 1Chapter 14

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Tool Material(Major Tool Material Types)

T-1:Reference 1Chapter 14

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Tool Material(Physical Vapor Deposition)

T-1:Reference 1Chapter 14

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Tool Material(Design and Performance)

T-1:Reference 1Chapter 14

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 32 Lecture 33

Week 12

Work Material Consideration (Machining High Strength Materials)

T-1:Reference 1Chapter 15

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Work Material Consideration (Fracture During Chip Formation)

T-1:Reference 1Chapter 15

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 34

Work Material Consideration(hot Hardness of Work Piece)

T-1:Reference 1Chapter 15

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 35

Chip Control(Chip Flow Direction and Chip Types)

T-1:Reference 1Chapter 18

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Chip Control(Chip Barker Performance)

T-1:Reference 1Chapter 18

RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Chip Control(Rational Approach Control)

T-1:Reference 1Chapter 18

RW-1 RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Chip Control(Chip Breaking Grooves)

T-1:Reference 1Chapter 18

RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 37

Chip Control(Chip Curling/Breaking Analysis)

T-1:Reference 1Chapter 18

RW-1 RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 38

Optimization(Machining Economics)

T-1:Reference 1Chapter 19

RW-2 RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Optimization(Levels of Optimization)

T-1:Reference 1Chapter 19

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 36

Week 13

Homework,Test 2

Week 13

Lecture 39

Optimization(Optimum Productive Rate)

T-1:Reference 1Chapter 19

RW-2 RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Optimization(Adaptive Control)

T-1:Reference 1Chapter 19

RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

SPILL OVER Week 37

Lecture 109

T-1:refer full book

OR-3 RW-1 RW-3

Revision

to improve the knowledge of metal cutting principles

Animations

Lecture 110

T-1:refer full book

OR-3 RW-1 RW-3

Revision

to improve the knowledge of metal cutting principles

slide show

Scheme for CA: Component

Frequency

Homework,Test

Out Of 2

Each Marks Total Marks 3

Total :-

10

20

10

20

Details of Academic Task(s) AT No.

Objective

Test 2

To check the basic knowledge of the subject

Homework 1

Test 1

Topic of the Academic Task

Wear and tool life,Cutting Temperature,Cutting Fluids

Nature of Academic Task (group/individuals/field work

Evaluation Mode

Allottment / submission Week

Individual

test

10 / 10

To check the indepth Fracture Mechanics,Dynamometry, plastic behavior. knowledge of the subject

Individual

viva

4/6

To check the basic knowledge of the subject

Individual

test

4/4

Introduction,Typical Cutting Operations,orthogonal cutting,Plastic Behaviour