DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

COURSE PLAN
Name of the Faculty Mr. KALAIYARASAN.R
Designation/Department Assistant Professor / Mechanical Engineering
Course Code/Name ME8451 / MANUFACTURING TECHNOLOGY – II
Year/Section/Department II / A/ Mechanical Engineering
Credits Details L: 3 T: 0 P: 0 C: 3
Total Contact Hours Required 45

Syllabus:

UNIT I THEORY OF METAL CUTTING No. of Periods : 9

Mechanics of chip formation, single point cutting tool, forces in machining, Types of chip, cutting tools –
nomenclature, orthogonal metal cutting, thermal aspects, cutting tool materials, tool wear, tool life, surface
finish, cutting fluids and Machinability.

UNIT II TURNING MACHINES No. of Periods : 9

Centre lathe, constructional features, specification, operations – taper turning methods, thread cutting
methods, special attachments, machining time and power estimation. Capstan and turret lathes- tool layout –
automatic lathes: semi automatic – single spindle : Swiss type, automatic screw type – multi spindle:

UNIT III SHAPER, MILLING AND GEAR CUTTING MACHINES No. of Periods : 9
Shaper - Types of operations. Drilling, reaming, boring, Tapping. Milling operations-types of milling
cutter. Gear cutting – forming and generation principle and construction of gear milling ,hobbing and gear
shaping processes –finishing of gears.

UNIT IV ABRASIVE PROCESS AND BROACHING No. of Periods : 9

Abrasive processes: grinding wheel – specifications and selection, types of grinding process– cylindrical
grinding, surface grinding, centreless grinding and internal grinding- Typical applications – concepts of surface
integrity, broaching machines: broach construction – push, pull, surface and continuous broaching machines.

UNIT V CNC MACHINING No. of Periods : 9

Numerical Control (NC) machine tools – CNC types, constructional details, special features, machining
centre, part programming fundamentals CNC – manual part programming – micromachining – wafer
machining.

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Objective:

 To understand the concept and basic mechanics of metal cutting, working of standard machine
tools such as lathe, shaping and allied machines, milling, drilling and allied machines, grinding
and allied machines and broaching.
 To understand the basic concepts of Computer Numerical Control (CNC) of machine tools and
CNC Programming

Text Book
T1. Hajra Choudhury, "Elements of Workshop Technology", Vol.II., Media Promoters 2014
T 2. Rao. P.N “Manufacturing Technology - Metal Cutting and Machine Tools", 3 rd Edition, Tata
McGraw-Hill, New Delhi, 2013.

Reference Book
R1. Richerd R Kibbe, John E. Neely, Roland O. Merges and Warren J.White “Machine Tool
Practices”, Prentice Hall of India, 1998
R2. Geofrey Boothroyd, "Fundamentals of Metal Machining and Machine Tools", Mc Graw Hill,
1984
R 3. HMT, "Production Technology", Tata McGraw Hill, 1998.
R 4. Roy. A.Lindberg, “Process and Materials of Manufacture,” Fourth Edition, PHI/Pearson
Education 2006.

Website
W1: https://www.sanfoundry.com/1000-finite-element-method-questions-answers/
W2: https://easyengineering.net/me6302-manufacturing-technology-i/
W3: https://nptel.ac.in/courses/112/104/112104195/

Online Mode of Study (if Any):

 https://nptel.ac.in/courses/112/104/112104204/
 https://nptel.ac.in/courses/112/104/112104195/
 https://nptel.ac.in/courses/112/104/112104189/
 https://nptel.ac.in/courses/112/104/112104188/

Course Plan:

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 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

S.No

Topic Name

Books to be referred

Page No

Teaching Aids

No of periods required

Cumulative periods

UNIT 1 THEORY OF METAL CUTTING

9

Mechanics of chip formation

T1

38-40

online

01

single point cutting tool

T1

35-36

online

01

forces in machining

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 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

T1

46-47

online

01

Types of chip

T1

50-51

online

01

cutting tools– nomenclature,

T1

52-53

online

01

orthogonal metal cutting

T1

37

online

4
 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

01

thermal aspects, cutting tool materials

T1

55-59

online

01

tool wear, tool life, surface finish

T1

59-62

online

01

cutting fluids and Machinability

T1

68-74

online

01

Learning outcomes:

At the End of the unit

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 Students able to know the objective of the metal cutting mechanism and methods
 Students able to develop machining operations.
UNIT 2 TURNING MACHINES
9

10

Centre lathe, constructional features, specification, operations

T1

83-104

online

01

10

11

taper turning methods, thread cutting methods

T1

124-139

online

01

11

12

special attachments, machining time and power estimation

T1

178-180

online

01

12

13

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Capstan and turret lathes

T1

180-185

online

01

13

14

tool layout – automatic lathes

T1

210-214

online

01

14

15

semi automatic – single spindle

T1

186-190

online

01

15

16

Swiss type

T1

191-199

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 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

01

16

online

17

automatic screw type

T1

205-210

online

01

17

18

multi spindle

T1

215-217

online

01

18

Learning outcomes:

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At the End of the unit

 Students able to know about the working of conventional lathe machines.

 Students able to develop and implement of machining operations and accuracy.
 Students were able to extending the original product information to next one.
UNIT 3 SHAPER, MILLING AND GEAR CUTTING MACHINES
9

19

Shaper - Types of operations

T1

297-298

online

01

19

20

Shaper - Types of operations

T1

299-300

online

01

20

21

Drilling ,reaming, boring

T1

227-278

online

01

21

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 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

22

Tapping. Milling operations

T1

397-450

online

01

22

23

types of milling cutter

T1

420-426

online

01

23

24

Gear cutting – forming and generation

T1

451-473

online

01

24

25

principle and construction of gear milling, hobbing

T1

474-486

online

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 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

01

25

26

gear shaping processes

T1

482-484

online

01

26

27

finishing of gears

T1

545-550

online

01

27

Learning outcomes:

At the End of the unit

 Students able to make the gear generation methods

 Students able to know the shaping and milling methods.
 Students able to know the drilling and boring process.
UNIT 4 ABRASIVE PROCESS AND BROACHING
9

28

Abrasive processes

T1

379-381

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 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

online

01

28

29

Grinding wheel – specifications and selection

T1

375-379

online

01

29

30

Types of grinding process- cylindrical grinding

T1

360-361

online

01

30

31

Surface grinding, centreless grinding

T1

367-369

online

01

31

32

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Internal grinding- Typical applications

T1

366-370

online

01

32

33

Concepts of surface integrity

T1

371-377

online

01

33

34

Broaching machines

T1

533-541

online

01

34

35

Broach construction – push, pull, surface

T1

536-540

online

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 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

01

35

36

Continuous broaching machines

T1

537-538

online

01

36

Learning outcomes:

At the End of the unit

 Students able to abrasive process

 Students able to make a accuracy of broaching process.
 Students are able to know the grinding operations and development of finishing methods.
UNIT 5 CNC MACHINING
9

37

Numerical Control (NC) machine tools

T1

571-575

online

01

37

38

CNC types

T1

590-595

14
 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

online

01

38

39

CNC types

T1

596-599

online

01

39

40

constructional details, special features, machining centre

T1

578-580

online

01

40

41

part programming fundamentals CNC

T1

581-583

online

01

41

42

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 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

manual part programming

T1

581-585

online

01

42

43

micromachining

T1

713-718

online

01

43

44

micromachining

T1

719-721

online

01

44

45

wafer machining

T1

722-724

online

16
 DSEC/MECHANICAL ENGINEERING/ME8451/II/IV

01

45

Learning outcomes:

At the End of the unit

 Students able to know the programmable machining process.

 Students able to determine quality and improvement of finishing methods.
 Students able to know the advanced tool holding devices.

Course Outcome:

Upon the completion of this course the students will be able to

CO1. Explain the mechanism of material removal processes.
CO2. Describe the constructional and operational features of centre lathe and other special purpose
lathes.
CO3. Describe the constructional and operational features of shaper, planner, milling, drilling,
sawing and broaching machines.
CO4. Explain the types of grinding and other super finishing processes apart from gear
manufacturing processes.
CO5. Summarize numerical control of machine tools and write a part program.

Course Outcome Vs Program Outcome Mapping:

CO PO1 PO PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO1 PO12
2 1
CO 1 √ √ √ √
CO 2 √ √ √ √
CO 3 √ √ √ √
CO 4 √ √ √ √
CO 5 √ √ √ √

Content Beyond Syllabus:

 the constructional and operational features of centre lathe and other special purpose lathes.
 Explain the types of grinding and other super finishing processes apart from gear
manufacturing processes

Assignment:

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Mode of
Batch Register Total Assignment
Topic
Details Number Number MCQ/Seminar/PP
T
Batch 1 25 MCQ theory of metal cutting
Batch 2 25 Seminar Mechanics of chip formation
Centre lathe, constructional
Batch 3 29 PPT
features, specification, operations
Batch 1 25 Seminar types of milling cutter
special attachments, machining
Batch 2 25 PPT
time and power estimation
shaper, milling and gear cutting
Batch 3 29 MCQ machines
Internal grinding- Typical
Batch 1 25 PPT
applications
thermal aspects, cutting tool
Batch 2 25 MCQ
materials
part programming fundamentals
Batch 3 29 Seminar
CNC

SIM Questions:
1. Describe the different types of chips with neat sketches.
2. Mention the functions of cutting fluids?
3. Explain various cutting tool materials?
4. In an orthogonal cutting operation on a work piece of width 2.5 mm, the uncut chip
thickness was 0.25mm and the tool rake angle was zero degree. It was observed that
the chip thickness was 1.25mm.The cutting force was measured to be 900 N and the
thrust force was found to be 82010 N.
5. (a)Find the shear angle.(b)If the coefficient of friction between the chip and the tool
SIM 1 was 0.5, what is the machining constant Cm.
6. Explain the geometry of a single point cutting tool with suitable sketches?
7. Explain “merchant force circle” along with assumptions
8. Differentiate between orthogonal metal cutting and oblique metal cutting.
9. Explain the various tool parts of a single point cutting tool with a neat sketch.
10. Discuss the various types of chips produced during metal machining.
11. Describe the various types of chips produced during metal machining.

SIM 2 1. Explain the various taper turning methods?

2. Describe the turret indexing mechanism.
3. Describe the constructional features of Swiss type screw machine.
4. Describe the holding devices in a lathe.
5. Discuss the main parts of a turret lathe.
6. What is meant by “Tool layout” of a Turret lathe?
7. Discuss the features of ram type and saddle type Turret.

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8. Explain the Classification and features of multi spindle automatic lathe?

9. Enumerate the various methods of producing taper.
10. Describe the work holding devices in a lathe.

1. Explain various milling cutters with neat sketches?

2. Explain different types of drilling machines with their special features?
3. With a neat sketch explain the column and knee type milling machine and name
its main parts.
4. Write short notes on BTA deep hole drilling.
5. Sketch and briefly explain the following operation performed in milling machine.
SIM 3
6. Write the short notes on gear shaping.
7. List the difference between shaper and planner.
8. Explain the principle of gear hobbing with neat sketch.
9. Discuss various hole making process.
10. Discuss with neat sketch on the various milling operation

Submission Details:

Phase 1(Before AT 1) Phase 2 (Before AT 2) Phase 3 (Before AT 3)

Assignment 1 SIM 1 Assignment 2 SIM 2 Assignment 3 SIM 3

Google Class Code Details:

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