BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani Pilani Campus

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1 First Semester Instruction Division Course Handout (Part II) Date: 02/08/2017 In addition to Part I (General Handout for all courses appended to the Time Table), this portion gives further specific details regarding the course. Course No. Course Title Instructor In-charge Practical Instructors : ME F313 : Production Techniques-II : TUFAN CHANDRA BERA : Tufan Chandra Bera, Manikandan H, Prateek Kala and Rajesh P. Mishra 1. Course Description Metal cutting theory, basic metal cutting processes, mechanics of various machining processes, analysis, economics and quality control of metal cutting, Laboratory exercises in metal cutting and fabrication project. Introduction to non-traditional machining processes, mechanics and their applications. Introduction to micromanufacturing technologies, Introduction to CNC technology and CAM. 2. Scope and Objectives In-depth comprehension of metal cutting and machining processes which are common and versatile operations in product manufacturing. To nurture fresh talents and transform them to competent manufacturing engineers by studying metal cutting theory, various conventional and non-conventional machining processes in detail. To introduce micromachining and its recent development as a future scope of micromanufacturing along with CNC technology and CAM. Finally, to enrich theoretical, analytical as well as practical knowledge about metal cutting, various conventional and non-conventional machining processes. 3. Prescribed Text Book T1. Amitabha Ghosh and Asok Kumar Mallik, Manufacturing Science, 2 nd Edition, ISBN 13: affiliated East-West Press, New Delhi, Reference Books R1. Serope Kalpakjian and Steven R. Schemed, Manufacturing Engineering and Technology, Pearson Education, New Delhi, Fourth Edition, 2001.

2 R2. Milton C. Shaw, "Metal Cutting Principles", Oxford University Press, Second Edition, R3. A. Bhattacharyya, Metal Cutting Theory and Practice", New Central Book Agency, R4. P. C. Pandey and H. S. Shan, "Modern Machining Processes", Tata McGraw-Hill, New Delhi, First Edition Course Plan Module Number Lecture session/tutorial Session. Reference Learning Outcome 1. Introduction to metal cutting and machining L1.1.Introduction of machining and its importance in part and product manufacturing. L1.2 Introduction of conventional machining process, its advantages & disadvantages, machining terminology & its identification. L 1.3.Various conventional machining processes. Identification of directrix & generatrix to generate machined surface. 4.1, (R2) Ch-1 (R3) Ch-1 (R1) Ch-23 (R3) Ch-11 (R1) Ch-23 (R3) Ch-11 Realization of metal cutting and machining in part and product manufacturing. Identification of various motions in various machining processes and machined surface generation. 2. Geometry of cutting tools and tool nomenclature. L2.1 Cutting tool material and its desired properties, cutting tool geometry and tool nomenclature. L2.2 Cutting insert nomenclature and importance of geometrical parameters in metal cutting. 4.2, (R1) Ch-21 (R3) Ch-3 4.2, (R1) Ch-21 (R3) Ch-3 Understanding of cutting tool geometry and tool & insert nomenclature. 3. Theory of metal cutting L3.1 Chip formation mechanism and various types of chips L3.2 Mechanics of metal cutting Comprehension about interaction between tool and workpiece. Mechanism of chip formation in metal cutting. 4. Determination of cutting L4.1 Determination of cutting forces Understanding

3 forces and Merchant s circle diagram 5. Mechanics of various machining processes such as turning, shaping, milling and drilling 6. Thermal aspects of machining, tool life and machinability L4.2. Merchant s model and modified Merchant s theory. L4.3 Estimation of cutting forces by energy consideration and effect of cutting parameters on chip formation L5.1 Mechanics of turning L5.2.Mechanics of shaping L 5.3 Mechanics of end milling L 5.3 Mechanics of face milling L 5.3 Mechanics of drilling L6.1. Thermal aspects of machining and estimation of temperature in cutting zone. L6.2. Tool wear mechanism L 6.3 Tool life and its assessment L 6.3 Machinability study Ch-12 (R3) Ch-8 Ch-11 (R3) Ch-9 Ch-11 (R3) Ch-9 Ch-11 about various components of cutting forces and its importance in metal cutting. Determination and estimation of cutting forces. Comprehension about mechanics of common machining operations such as turning, shaping, milling and drilling. Understanding about heat generation and analysis in machining and role of cutting fluids in machining. Familiarization about tool wear, tool life and machinability of workpiece.

4 (R3) Ch-9 7. Abrasive cutting processes L7.1. Construction of grinding wheel 4.4, (R1) Ch-25 (R3) Ch-15 L7.2. Mechanics of grinding 4.4, (R1) Ch Surface integrity and economics of machining. L 7.3 Honing, Lapping, Buffing and polishing operations L8.1 Surface integrity and surface topography L8.2. Economics of machining. (R3) Ch , (R1) Ch-25 (R3) Ch , (R2) Ch-17 (R3) Ch , (R2) Ch-1 (R3) Ch-10 Comprehension about abrasive machining process and other finishing processes such as lapping and honing etc. Understanding about surface integrity in machining process and economics of machining in terms of production cost and production rate. 9. Non-conventional machining processes L9.1 Preface with non-traditional machining. 6, Understanding about need of nontraditional machining in part and product manufacturing 10. Various NTM processes such as AJM, USM, ECM, EDM, EBM, LBM, PAM L10.1 Study of AJM mechanics, 6, Comprehension about various nontraditional processes. L10.2 Study of USM mechanics, 6, L10.3 Study of ECM mechanics, 6,

5 L10.4 Study of EDM mechanics, 6, L10.5 Study of EBM mechanics, 6, L10.6 Study of LBM mechanics, 6, 11. Introduction to micromanufacturing L10.7. L10.1 Study of PAM mechanics, applications and influence of various L11.1.Preface with micro manufacturing and micro technology. 6, 7.2, (R1) Ch-26 Lab experiments and open ended product manufacturing. 1) Mechanics of metal cutting & chip formation. 2) Cutting force measurement. 3) Geometrical accuracy measurement on a part. 4) Gear cutting on milling machine. 5) Gear cutting on gear hobbing machine. 6) Surface roughness measurement on a part.

6 6. Evaluation Scheme: Evaluation Weightage Component (Marks) Date & Time Remarks Mid-Sem. 30% (60) 13/10 9:00-10:30 AM Open Book Comprehensive 35% (70) 11/12 FN Closed Book Class Assignments & Homework & Closed 10% (20) Surprise Quiz. book Lab Practical 25% (50) Experimentations, Fabrications After completing this course the students will be able to 1) Select suitable conventional machining process for common part manufacturing. 2) Control machining conditions to obtain desired surface quality of a part. 3) Improve part quality by analyzing mechanics of the process using same machine tool. 4) Analyze machining cost and economics of machining in part manufacturing. 5) Select either conventional or non-conventional machining process depending upon workpiece material, quality and cost of the part. Closed Book Test: No reference material of any kind will be permitted inside the exam hall. Open Book Exam: Use of any printed / written reference material (books and notebooks) will be permitted inside the exam hall. Loose sheets of paper will not be permitted. Computers of any kind will not be allowed inside the exam hall. Use of calculators will be allowed in all exams. No exchange of any material will be allowed. Note: It shall be the responsibility of the individual student to be regular in maintaining the self study schedule as given in the course handout, attend lectures and the lab demonstration as per the schedule announced in Nalanda. Mid Semester Test and Comprehensive Examination are according to the Evaluation Scheme given in the respective Course Handout. If the student is unable to appear for the Regular Test/Examination due to genuine exigencies, the student must refer to the procedure for applying for Make-up Test/Examination. No make up for the tutorials. (T. C. BERA) Instructor-In-Charge ME F313.

To understand the concept of basic engineering mechanism Compulsory : MANUFACTURING TECHNOLOGY II. Office phone

To understand the concept of basic engineering mechanism Compulsory : MANUFACTURING TECHNOLOGY II. Office phone BME505 - MANUFACTURING TECHNOLOGY II Academic Course Description BHARATH UNIVERSITY Faculty of Engineering and Technology Department of Mechanical Engineering BME505 - MANUFACTURING TECHNOLOGY II Fifth