Machining Science

By Prof. Sounak Kumar Choudhury | IIT Kanpur

Learners enrolled: 1149

Introduction : Machining; Plastic Deformation, Tensile Test, Stress and Strain; Mechanism of Plastic Deformation: Slips, defects, plastic deformation on atomic scale.
Machining Process : Types of machining processes; Chip formation; Orthogonal and Oblique Cutting; Types of Chips; Built-up edge formation.
Tool Geometry : Reference planes; Tool specification: American System (ASA), continental or Orthogonal System (ORS), International or Normal Rake system (NRS); Tool angle relationships in ORS, ASA and NRS; Selection of Tool Angles; Multiple-point cutting tools: twist drill, helical milling cutter.
Mechanics of Metal Cutting : Merchant's Circle Diagram; Co-efficient of Friction: Determination of stress, strain and strain rate; Measurement of shear angle; Thin Zone model: Lee and Shaffer's Relationship; Thick Zone model: Okushima and Hitomi Analysis
Friction in Metal Cutting : Nature of sliding friction; Friction in Metal Cutting: Sticking and Sliding Zones, Analysis of Stress Distribution on the tool face: Zorev’s model; Determination of mean angle of friction.
Mechanism of Oblique cutting : Rake angles in oblique cutting: Analytical determination of Normal Rake angle, velocity rake angle and effective rake angle; their relationship; shear angles in oblique cutting; velocity relationship; Force relationships in oblique cutting.
Practical Machining Operations : Turning, shaping and planning, Slab milling, Drilling: Machining Parameters, force magnitudes, power consumption, material removal rate, time per pass.
Measurement of cutting Forces : Basic methods of measurement: Axially Loaded members, Cantilever Beam, Rings and Octagon, dynamometer requirements; machine tool dynamometers.
Tool Material, Tool Wear and Tool Life : Types of tool wear; Mechanisms of wear: Abrasion, Adhesion and Diffusion. Progressive tool wear: flank and crater wear. Tool Life: variables affecting tool life - cutting conditions, tool geometry, Types of tool materials, fabrication of cutting inserts, coatings, work material and cutting fluid; Machinability and their criteria.
Abrasive Machining Processes: Processes and analyses
Economics of Machining: determination of optimal cutting conditions for minimum cost, maximum production rate and maximum profit rate
Thermal Aspects of Machining: analytical determination of temperature in the shear zone and the chip-tool contact area
Surface finish: comparison and analytical determination of surface finish in turning, milling and grinding

INTENDED AUDIENCE : Mechanical Engineering, Metallurgy, Aerospace Engineering, Production Engineering

PREREQUISITES : Basic Manufacturing Engineering Courses

INDUSTRY SUPPORT : All Manufacturing industries, Machine tool manufacturing industries, Automobile Industries and aeronautical industries

Summary

Course Status :	Completed
Course Type :	Elective
Language for course content :	English
Duration :	4 weeks
Category :	Mechanical Engineering Manufacturing Processes and Technology
Credit Points :	1
Level :	Postgraduate
Start Date :	24 Jan 2022
End Date :	18 Mar 2022
Enrollment Ends :	07 Feb 2022
Exam Date :	27 Mar 2022 IST

Note: This exam date is subject to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1 : Machining; Plastic Deformation, Tensile Test, Stress and Strain; Mechanism of Plastic Deformation: Slips, defects, plastic deformation on atomic scale; Types of machining processes; Chip formation; Orthogonal and Oblique Cutting; Types of Chips; Built-up edge formation; Tool specification; Tool angle relationships in ORS and ASA and NRS; Selection of Tool Angles; Multiple-pointcutting tools: twist drill, helical milling cutter.

Week 2 : Merchant's Circle Diagram; Co-efficient of Friction: Determination of stress, strain and strain rate; Measurement of shear angle; Thin Zone model: Lee and Shaffer's Relationship; Thick Zone model: Okushima and Hitomi Analysis; Nature of sliding friction; Friction in Metal Cutting: Sticking and Sliding Zones, Determination of mean angle of friction
Week 3 : Mechanism of Oblique Cutting: Normal Rake angle, velocity rake angle and effective rake angle; shear angles; velocity relationship; Force relationships in oblique cutting; Practical Marching Processes: Turning, shaping and planning, Slab milling, Drilling: Machining Parameters, force magnitudes, power consumption, material removal rate, time per pass.
Week 4 : Measurement of Cutting Forces: Basic methods of measurement: Axially Loaded members, Cantilever Beam, Rings and Octagon, dynamometer requirements; machine tool dynamometers; Types of tool wear; Mechanisms of wear: Abrasion, Adhesion and Diffusion. Progressive tool wear: flank and crater wear. Tool Life: variables affecting tool life - cutting conditions, tool geometry, Types of tool materials, fabrication of cutting inserts, coatings, work material and cutting fluid; Machinability and their criteria. Abrasive Machining Processes; Oblique Cutting; Economics of Machining; Thermal Aspects of Machining; Surface Finish.

Books and references

1. E.J.A. Armarego and R.H.Brown-The Machining of Metals

2. G Boothroyd-Fundamentals of Metal Machining and Machine tools

3. A.Ghosh and Asok Mallik- Machining Science

4. G.K.Lal and S.K.Choudhury-Fundamental of Manufacturing Processes

5. M.C.Shaw-Metal Cuttting Principles

Instructor bio

Prof. Sounak Kumar Choudhury

IIT Kanpur

I have completed my Ph.D. in Mechanical Engineering from Moscow, Russia in 1985 followed by post-doctoral at the same university till 1986. From 1986 I am involved in teaching and research in the Mechanical Engineering Department of Indian Institute of Technology Kanpur. My areas of specialization are conventional and non-conventional machining, automatic control, hydraulic control, machine tools and manufacturing automation.

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
Date and Time of Exams: 27 March 2022 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 3 assignments out of the total 4 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Kanpur .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team

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