DR. B. C.
ROY ENGINEERING COLLEGE, DURGAPUR
DEPARTMENT OF MECHANICAL ENGINEERING
Syllabus: B. Tech. in Mechanical Engineering (ME) for Working Professionals
Name of the Course: Subject Code: Semester of Study:
Machining Principles & Machine Tools PC-ME403 4th
Credit Points: 04 Theory: 3Hrs/Week Tutorial:1Hr /Week
COs Description BL
CO1 Analyze the mechanisms of chip formation, built-up edge formation, and the effects A
of orthogonal and oblique cutting on machining chips
CO2 Determine the cutting forces using analytical methods and Merchant’s circle P
diagram, and describe the concept of cutting zone temperatures, tool failure and tool
life.
CO3 Describe the construction and functions of various machine tools (lathes, shaping, U
planning, drilling, milling) and related automation
CO4 Design the speed layout & gear layout to achieve wide ranges of speeds and P
feeds in centre lathes and determine the machining time.
CO5 Discuss the understanding of NC/CNC machine tools and systems, including their U
components, functions, and automation capabilities.
CO6 Write the part programming for CNC lathe and milling machines P
Module Contact
Syllabus/Lecture Schedule CO
No. Hrs.
1 Introduction: Machining: Basic principle, purpose, definition and CO1
1
requirements
Geometry of cutting tools:
1. Geometry of single point turning (shaping, planning and boring)
tools in ASA, ORS and NRS systems
4
2. Conversion of tool angles from one system to another by
graphical and vector methods
3. Geometry of drills and milling cutters
Mechanism of machining: 3
1. Chip formation mechanism, yielding and brittle fracture, chip
reduction coefficient, cutting ratio, shear angle and cutting strain
2. Built-up edge formation, cause, type and effects, orthogonal
cutting and oblique cutting
3. Machining chips: types and conditions, chip formation in drilling
and milling
Mechanics of machining:
1. Purposes of determination of cutting forces and basic two
approaches, cutting force components in ORS and Merchant’s circle
diagram
3
2. Determination of cutting forces, analytical methods, measurement
3. Dynamometers, construction and working principles of strain
gauge type and piezoelectric crystals type turning drilling, milling
and grinding dynamometers
Cutting temperature:
1. Heat generators and cutting zone temperature, sources, courses
and effects on job and cutting tools, role of variation of the
machining parameters on cutting temperature
2 CO2
2. Determination of cutting temperature by analytical and
experimental methods
3. Control of cutting temperature and application of cutting fluids
(purpose, essential properties, selection and methods of application)
Cutting tools-failure, life and materials:
1. Methods of failure of cutting tools mechanisms, geometry and
assessment of tool wear
2. Tool life, definition, assessment and measurement, Taylor’s tool
3
life equation and it’s use
3. Cutting tool materials, essential properties, characteristics and
applications of HSS, carbide (uncoated/coated), ceramic, diamond
and CBN tools
2 Machine tools – Introduction:
1. Purpose of use, definition and general features of machine tools
2
2. Generatrix and Directrix and tool – work motions in different
operations of conventional machine tools
General constructions function of machine tools:
1. Major components and their functions in lathes; shaping,
planning and slotting machines; drilling machines and melting
3
machines
2. Machining operations and application of the common machine CO3
tools and their way of specification
Broaching and grinding:
1. Modes and mechanisms of chip formation, selection and
2
application
2. Grinding forces, surface roughness and wheel life
Automation and classification:
1. Purposes, degree, type and economy of machine tool automation; 1
broad classification of machine tools
3 Kinematic structure of machine tools : 3 CO4
1. Kinematic structure of centre lathe, shaping, planning and slotting
machine
2. Kinematic structure of drilling (column /radial) and milling
machines, capstan lathe, turret lathes
3. Kinematic structure of single spindle automatic lathe, by
hydraulically driven machine tools, hobbling machine and gear
shaping machine
Control of speed and feed machine tools:
1. Need of wide ranges of speeds and feeds, and machine tool drive
2. Design of speed, gear box, speed layout, gear layout, ray
3
diagrams, gears and spindle
3. Control (selection and change) of feed in centre lathes and by
hydraulically driven machine tools
Machining time:
1. Estimation of time required for various operations like turning, 1
drilling , shaping , milling and gear teeth generation
Machinability and machining economics:
1. Machinability (and grindability), definition, assessment,
1
improvement and evaluation of optimum cutting velocity and tool
life
4 NC/CNC Machine Tools and SystemsTypes of automation: Fixed
(or hard) and programmable (or flexible); need, advantages and
applications of flexible automation over fixed
automation.Components and Their Functions in NC/CNC
MachinesMCU, DPU and CLU, Feed drives using stepper/ servo
motors and recirculating ball screw-nut system, Automatic Tool
Changers- Tool Turret and Tool Magazine, Automatic pallet
Changer.Basic systems of NC and CNC machinesCoordinate
system, Control– open loop and closed loop, Dimensioning–
8 CO5
absolute and incremental, Point–to–point and contour motion,
Linear and circular Interpolation.CNC Machine Tools and
Integrated AutomationStructure and working principle of CNC
lathe, milling machine,
Examples and use of CNC machines, Machining Centre (Vertical
and Horizontal), Integrated Automation systems (DNC- Direct and
Distributed or BTR and Dedicated system, FMS- FFMS, FMC and
FMM)– characteristics and applications.
Part Programming for CNC machines Manual Part Programming
using ISO G and M Codes in CNC lathe and milling machine for
simple jobs, Canned cycle.Computer Aided Part Programming 8 CO6
using MACRO statements in APT for simple jobs in CNC lathe and
milling machine.
TOTAL 48
Books recommended:
1. A.B. Chattopadhyay, Machining and Machine Tools, Wiley India (P) Ltd., New
Delhi.
2. G. Kuppuswamy, Principles of Metal Cutting, University Press, Hyderabad.
3. Stephenson & Agapion, Metal Cutting Theory and Practice, Taylor and Francis, NY.
4. M.C. Shaw, Metal Cutting Principles and Practices, Oxford University Press.
5. G.C. Sen and A. Bhattacharyya, Principles of Machine Tools, New Central Book
Agency (P) Ltd., Kolkata.
6. Acharkan, Machine Tool Design, Vol. I, II, III and IV, Mir Publication, Moscow.
7. P.N. Rao, N.K. Tewari and T.K. Kundra, Computer Aided Manufacturing, McGraw
Hill, 2017.
8. Y. Koren, Computer Control of Manufacturing Systems, McGraw Hill, 1986.
9. M.P. Grover, Fundamentals of Modern Manufacturing, 3rd Edition, Wiley.
10. M.P. Groover, Automation, Production Systems and CIM, Prentice Hall.
11. A. Ghosh & A.K. Mullick, Manufacturing Science, EW Press.
12. S. Kalpakjian and S.R. Schmid, Manufacturing Processes for Engineering Materials,
5th Edition, Pearson India, 2014.
