Introduction
Course Code: 1995403 (Credits: 03)
METAL CUTTING AND MACHINE TOOLS
Course teacher: Dr. K. Chandra Sekhar
Course Objectives
1. To give a clear understanding of the mechanism of machining to the
students
2. To describe the mechanisms of the various metal cutting machines,
types of machines, various operations that can be performed on them,
machining time and force calculations, etc to the students.
3. To expertise in advance numerical control machines to maximise the
work output and efficiency of the numerical machines.
Course Outcomes
The student can be able to know the mechanism of metal cutting and in a position to work
CO1 on the metal cutting machines directly without a little
assistance.
CO2 They can calculate the machining times and forces developed on all metal cutting machines.
CO3 They will know the different cutting machines and their classifications and how to specify the
metal cutting machines and limitations
CO4 They will be in a position to know the different types of finishing operations and cutting
fluids for different metals on all types of machines.
CO5 They know the importance, use, applications, advantages and limitations of various
computer numerical control machines
Unit I
Mechanics of Metal Cutting: Chip formation & Types; Tool geometry and tool signature ASA&ISO
systems; Orthogonal and Oblique Cutting, Merchant Circle analysis, Tool wear and tool life; Cutting
forces and power; Tool materials; Cutting fluid:-simple problems
Unit II
Lathe Machines: Engine lathe – principle of working, specification of lathe – types of lathe – work
holders tool holders – box tools taper turning, thread turning – for lathes and attachments, constructional
features of speed gear box and feed gear box. Turret and capstan lathes – collet chucks – other work
holders – tool holding devices – box and tool layout. Principal features of automatic lathes –
classification – single spindle and multi-spindle automatic lathes – tool layout and cam design for
automats.
Unit III
Drilling & Boring machines: Principles of working, specifications, types, operations performed – tool
holding devices – twist drill – deep hole Drilling Machine.
Boring Machines – fine Boring Machines – jig boring machine & Broaching operations.
Milling Machines: Principles of working – specifications – classification of Milling Machines – Principle
features of horizontal, vertical and universal Milling Machine, machining operations, types of cutters,
Unit IV
Shaping, Slotting and Planing Machines: Principles of working – principal parts – specifications,
operations performed, machining time calculations.
Finishing Processes: Theory of grinding – classification of grinding machines, cylindrical and surface
grinding machines, tool and cutter grinding machines, different types of abrasives, bonds,
specification and selection of a grinding wheel. Lapping, Honing.
Unit V
Computer-Numerical Control Machines: CNC Machines, working principle, classification,
constructional features of CNC machines, CNC controller, types of motion controls in CNC machines,
applications of CNC machines.
Part Programming: Designation of co-ordinate axes for CNC machines, Functions of machine control
units, Tape format, Manual part programming and computer assisted part programming (using APT
language). Exercises involving simple contours and positioning.
Text Books
Text Book
• Process and Materials of Manufacture (4th Edition) by Roy A. Lindberg, Prentice-Hall of India
Private Limited.
• Manufacturing technology II, P.N Rao. TMH Ltd 1998(Revised edition).
• CAD/CAM- Computer Aided Design & Manufacturing, by M.D.Groover & E.W.Zimmer.
Reference Books:
• Metal Cutting Principles by M.C. Shaw, MIT Press, Cambridge.
• Metal Cutting-Theory and Practice by Amitabha Bhattacharya, Central Book Publishers.
• Production Engineering by P.C. Sharma, S. Chand and Company.
• Production Technology by H.M.T. (Hindustan Machine Tools).
• Production Engineering, K.C Jain & A.K Chitaley, PHI Publishers
• Technology of machine tools, S.F.Krar, A.R. Gill, Peter SMID, TMH (I).
