MCMT Course File Doc 30th Juky2016 Unit 1 2 and 3,4

COURSE FILE
Metal Cutting and Machine Tools
R13
III B. Tech – I SEMESTER
MECHANICAL ENGINEERING
VIGNAN’S INSTITUTE OF INFORMATION TECHNOLOGY
www.vignaniit.com (Approved by AICTE & Affiliated to JNTUK) Estd. – 2002
NAAC, NBA Accredited & ISO 9001:2008, ISO14001:2004, OHSAS 18001:2007 Certified Institution
Beside VSEZ, Duvvada, Visakhapatnam-530049. A.P.
Phone : 0891- 2755222 / 333 / 444 :: Fax : 0891 - 2752333 :: E-Mail : vignaniit@yahoo.com
TABLE OF CONTENT
S.NO. Content Page No.
1 Course Objectives & Outcomes
2 Syllabus
3 Lecture Plan
4 Unit wise course Material (As per given format)
Unit-I: Fundamentals of Machining
Unit-II: Lathe Machines
Unit-III: Shaping, Slotting and Planning Machines
Unit-IV: Milling Machines
Unit-V: Finishing processes
Unit-VI: Jigs and Fixtures
5 Reference text books/web material etc.,
6 Mid Question Paper + Schemes of Evaluation.
7 Fast track material for Back-Log students.
8 Sample Question Papers with solutions
9 Virtual Labs if required

Mapping of Assignments / Question Papers with course objective
10
learning outcomes.
11 Bloom’s Taxonomy checklist
1. Course Objectives & Outcomes
1.1. Course Objectives
The objectives of the course are:
1. The course provides students with fundamental knowledge and principles in

material removal processes.
2. In this course, the students apply the fundamentals and principles of metal
cutting to practical applications through multiple labs using lathes, milling
machines, grinding machines, and drill presses, Computer Numerical Control
etc.
3. To demonstrate the fundamentals of machining processes and machine tools.
4. To develop knowledge and importance of metal cutting parameters.
5. To develop fundamental knowledge on tool materials, cutting fluids and tool

wear mechanisms.
6. To apply knowledge of basic mathematics to calculate the machining

parameters for different machining processes.
1.2. Course Outcomes
After completing this Course, the student should be able to:
1) Apply cutting mechanics to metal machining based on cutting force and power consumption.
2) Operate lathe, milling machines, drill press, grinding machines, etc.
3) Select cutting tool materials and tool geometries for different metals.
4) Select appropriate machining processes and conditions for different metals.
5) Learn machine tool structures and machining economics.
6) Write simple CNC programs and conduct CNC machining.

2. Syllabus
UNIT – I
FUNDAMENTALS OF MACHINING: Elementary treatment of metal cutting theory –
element of cutting process – geometry of single point tool angles, chip formation and types of
chips – built up edge and its effects chip breakers, mechanics of orthogonal cutting – Merchant’s
force diagram, cutting forces, cutting speeds, feed, depth of cut, tool life, coolants, tool materials.
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
SHAPING, SLOTTING AND PLANNING MACHINES: Principles of working –
principal parts – specifications, operations performed, machining time calculations.
DRILLING & BORING MACHINES: Principles of working, specifications, types,
operations performed – tool holding devices – twist drill – Boring Machines – fine Boring
Machines – jig boring machine, deep hole Drilling Machine.
UNIT – IV
MILLING MACHINES: Principles of working – specifications – classification of Milling
Machines – Principle features of horizontal, vertical and universal Milling Machine, machining
operations, types of cutters, geometry of milling cutters – methods of indexing, accessories to
milling machines.
UNIT –V
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 & Broaching
operations, comparison to grinding.
UNIT - VI
JIGS & FIXTURES: Principles of design of jigs and fixtures and uses, classification of jigs
& fixtures, principles of location and clamping, types of clamping & work holding devices,
typical examples of jigs and fixtures.
CNC MACHINE TOOLS: CNC Machines, working principle, classification,

constructional features of CNC machines, CNC controller, types of motion controls in CNC
machines, applications of CNC machines.
3. Lecture Plan
Lecture no. Unit Number Topic
1 Introduction-Metal cutting theory, Element of cutting
2 process of single point cutting tool
Geometry
3 Tool significance-Tool designation
4 Chip formation mechanism, Types of chips-
Built up edge-Chip breaker-Mechanics of orthogonal
5 FUNDAMEN cutting-Chip velocity ratio-thick ratio
TALS
6 Mechanics of force diagram
OF
MACHINING Turning-stress-strain-work done-Force relationships and
7 cutting forces
8 Feed, speed, depth of cut, cutting speeds.
9 Tool material, Coolants and Tool life.
10 Problems
11 Revision of UNIT -I
12 Lathe introduction-Engine lathe

13 Principle of working-Types of lathes-specification of lathes
14 Work holders-Tool holders, box tools
15 II taper turning, thread turning, attachments
16 LATHE Constructional features of Speed Gear Box and Feed Gear
17 MACHINES Box and capstan lathes, Collect chucks and Other work
Turret
18 holders
Tool Holding devices, Box and Tool Layout.
19 Automatic lathes, Classification, Single spindle - Multi
20 spindle
Tool lay out and Cam Design for Automats.
21 Principles of working- Principle parts- Specification

22 Operations performed
23 Machining Time calculations, Problems.
III Drilling and Boring Machines- Introduction
24
Shaping,
25 Principles of Working of Drilling and Boring.
Slotting and
26 Types and Operations Performed.
Planning
27 Tool handling devices
Machines
28 Twist drills, Boring Machines, Fine Boring
29 Jig boring machine, Deep hole drilling machine
30 Revision
31 Principles of working – Specifications – Classifications.

Principle features of Horizontal, Vertical and Universal
32
Milling Machine.
33 IV Machining Operations
34 MILLING Types of Cutters
35 MACHINES Geometry of Milling Cutters
36 Methods of Indexing
37 Accessories to milling machines
38 Revision
39 Introduction – Theory of Grinding- Classification of
40 Grinding Machines
Cylindrical and Surface Grinding Machines
41 V Tool and Cutter grinding machines
42 FINISHING Different types of abrasives, Bonds
43 PROCESSES Specification and selection of grinding wheel
44 Lapping, Honing and broaching operations – Comparison
45 to grinding
Revision
46 Introduction- Principles of Design of Jigs and Fixtures-

47 Uses
Classification of Jigs and Fixtures.
48 Principles of Location and clamping
49 Types of clamping and work holding devices
50 VI Typical examples of jigs and fixtures
51 JIGS AND CNC Machines – Introduction
52 FIXTURES Working principle – classification
53 Constructional features of CNC machines – CNC
54 controller
Types of motion control in CNC machines
55 Applications of CNC machines
56 Revision
4. Unit-wise course material
4.1. Unit – I - Fundamentals of Machining
Elementary treatment of metal cutting theory – element of cutting process –geometry of single
point tool angles, chip formation and types of chips – built up edge and its effects chip breakers,
mechanics of orthogonal cutting –Merchant’s force diagram, cutting forces, cutting speeds,
feed, depth of cut, tool life, coolants, tool materials.
4.1.1. Unit Objectives:

After reading this Unit, you should be able to understand:
- Metal Cutting and Theory of Machining
- Types of machining process
- How to calculate machining forces
- Relation between cutting forces
- Types of coolants
- How to calculate tool life
4.1.2. Unit Outcomes:

- Apply cutting mechanics to metal machining based on cutting force and power
consumption.
- Apply tool life relation equation based on mechanics of metal cutting.
- Nomenclature of single point cutting tool

4.1.3. Unit Lecture Plan
Lecture
Topic Methodology Quick reference
no.
CH-4,pg.no.105
Introduction-Metal cutting theory,
1 Chalk and Board B.S Raghuwanshi text
Element of cutting process
book
Chalk and
2 Geometry of single point cutting tool Concern material
Board ,OHP sheets
CH-4,pg.no.110-
3 Tool significance-Tool designation Chalk and Board B.S Raghuwanshi txt.
book
CH-4,pg.no.116
Chip formation mechanism, Types of
4 Chalk and Board B.S Raghuwanshi txt.
chips-
book
Built up edge-Chip breaker- CH-4,pg.no.118-
Chalk and
5 Mechanics of orthogonal cutting-Chip B.S Raghuwanshi txt.
Board,PPT
velocity ratio-thick ratio book
6 Mechanics of force diagram Chalk and Board Concern material
CH-4,pg.no.126-
Turning-stress-strain-work done-
Force relationships and cutting forces
book
CH-4,pg.no.145-
Feed, speed, depth of cut, cutting
speeds.
book
CH-4,pg.no.148-
Chalk and
9 Tool material, Coolants and Tool life. B.S Raghuwanshi txt.
Board,PPT
book
10 Problems Chalk and Board Concern material
11 Revision of UNIT -I Chalk and Board Concern material
4.1.4. Teaching Material / Teaching Aids as per above lecture plan.
4.1.4.1. Lecture-1
 Include / Attach PPT / Handout (typed)

Elementary treatment of metal cutting theory:-
In engineering industry, components are made up of metals in different shapes, sizes and
dimensions. Metals are shaped to the required form by various processes. These processes can be
generally divided into 2 groups
They are,
1) Non-Cutting Shaping Processes
2) Cutting Shaping Process
In non cutting shaping, the metal is shaped under the action of heat, pressure or both. Here there
is no chip formation. This group includes operations like forging, drawing, spinning, rolling,
extruding etc,
In cutting shaping, the required shape of metal is obtained by removing the unwanted material
from the work-piece in the form of chips.
The metal cutting is done by a relative motion between the work-piece and the hard edge of a
cutting tool.
Metal cutting can be done by either by single point cutting tool and multipoint cutting tools.
Basic Elements of Machining:-
The basic elements of all machining operations are,

1) Work-piece
2) Tool
3) Chip
For providing the cutting action, a relative motion between the tool and work-piece is necessary.
This relative motion can be provided by either keeping the work-piece stationary or moving the
tool or vice-versa
The work-piece provides the parental metal from which the unwanted metal is removed by the
cutting action of the tool to obtain the predetermined shape and size of the component
Methods of Metal Cutting:-
The 2 basic methods of metal cutting using a single point cutting tool are,
1) Orthogonal Cutting
2) Oblique Cutting
Orthogonal Cutting: - If the cutting force of the tool is at 900 to the direction of
the tool travel then the cutting action is called as Orthogonal Cutting.
Oblique Cutting: - If the cutting force of the tool is inclined at less than 900 to the
path of the tool, the cutting action is called Oblique Cutting as shown in the
figure.
4.1.4.2. Lecture-2
Geometry of single point cutting tool
Tool Signature: - After tool Nomenclature and geometry
Nomenclature and Geometry of Single Point tools:-
1) Shank: - It forms the main body of a solid tool and it is part of the tool which is
gripped in the tool holder.
2) Face: - It is the top surface of the tool between the shank and the point of the tool.
In the cutting action the chips flow along this surface only.
3) Point:-
4) Flank: - Portion of the tool which faces the work is termed as Flank. It is the surface
adjacent to and below the cutting edge when the tool lies in a horizontal position.
5) Base: - It is actually the bearing surface of the tool on which it is held in a tool
holder or clamped directly in a tool post.
6) Heel: - It is the curved portion at the bottom of the tool where the base and flank of
the tool meet.
7) Nose Radius:- If the cutting tip (Nose) of a single point tool carries a sharp cutting
point the cutting tip is weak, Its values normally varies from 0.4mm to 1.6mm.
Depending upon several factors like depth of cut, amount of feed, type of cutting, type of
tool etc.
Which are shown in the following figures,

Geometry:-
1) Rake Angle: - It the angle formed between the face of the tool and a plane parallel to its
base. If the inclination is towards the shaft, it is known as top/back rake angle. When it is
measured towards the side of the tool, it is called the side rake, these are "Positive Rake Angles".
When no rake is provided on the tool, it is said to have a "Zero Rake". When, the face of the tool
is so ground that it slopes upwards from the point it is said to contain a "Negative Rake"
Negative Rake: - Employed on carbide tipped tools, used for extra hard surfaces, for
intermittent cuts, HSS parts. It will have larger lip angle varies from 50 to 100
2) Lip Angle: - The angle between the face and the flank of the tool is known as a lip angle. It
is also sometimes known as "Angle of Keenness of the Tool".So, lip angle is kept as low as
possible without making the cutting edge. so weak which is not suitable foe metal cutting.
3) Clearance Angle: - It is the angle formed by the front or side surface of the tool which are
adjacent and below the cutting edge, when the tool is held in horizontal position. It is the angle
between one of these surfaces and a plane normal to the base of the total.
4) Relief Angle: - If the angle formed between the flank of the tool and a perpendicular line
drawn from the cutting point to the base of the tool.
5) Cutting Edge Angle: - The angle formed between the tool face and line through the
point, which is a tangent to the machined surface of the work at that point.
6) Nose Angle: - It is the angle between the side cutting edge and end cutting edge.
 Add a snapshot of models used
 Any other
innovative teaching methodologies
OHP Sheets
4.1.4.3. Lecture-3

The signature is a sequence of numbers listing a various angles in degrees and
series of the nose radius.
Ex: 8-14-6-6-6-15-4
1.Bake rake angle(80)
2.Side rake angle(140)
3.End relief angle(60)
4.Side relief angle(60)
5.End cutting edge(60)
6.Side cutting edge angle (150)
7.Nose radius (4 mm)
Tool Nomenclature:-
It consists of two system named as follows
1. ISO system
2. ASA system
ISO system:- ASA system
i. Material of the tool holder i. Back rake angle(αb)
ii. Diameter of the tool holder ii. Side rake angle(αs)
iii. Tool length iii. End relief angle(αer)
iv. Clamping system(top clamp) iv. Side relief angle(αes)
v. Insert shape v. End cutting edge angle(αec)
vi. Approach angle(flank) vi. Side cutting edge angle(αsc)
vii. Insert clearance angle vii. Nose radius(NR)
viii. Hand of tool (R,N,L) Ex: 0-10-6-6-8-90-1
ix. Cutting edge length
x. Shank height
xi. Shank width
xii. Wedge design
4.1.4.4 Lecture-4: Chip formation mechanism, Types of chips

Types of Chips: - The removed layer metal during the cutting operation is known as chips.
The layer undergoes the following operations, elastic deformation,
plastic deformation and the final removal from the parental metal. The
type of chip depends on the material being cut and the cutting
conditions.
 Continuous Chip: - When the cutting tool moves towards the
work-piece there occurs a plastic deformation of the work-piece and the
metal is separated without any discontinuity and it moves like a ribbon.
 Discontinuous Chip: - This can also be called as Segmental Chips.

This mostly occurs while cutting brittle materials
 Continuous (With Built-Up Edge):- When cutting a ductile

material, the compression of the metal is followed by the high heat at
tool face.
Chip Breakers: - During machining, long and continuous chip will affect machining. It will
spoil work, tool and machine. It will be difficult to remove metal and also dangerous to safety.
The chip should be broken into small pieces for easy removal, safety and to prevent damage to
machine and work. This is very important in automatic machines and machines which run at high
speeds. They are used to break the long continuous chips into small pieces. The chip breaker is
provided on the cutting tool. Different type of chip breakers used on a cutting tool.
4.1.4.5 Lecture-5: Mechanics of orthogonal cutting-Chip velocity ratio-thick

ratio

Mechanics of Orthogonal Cutting-Merchant’s Force Diagram-Cutting
Forces: -
The relationships among the forces acting on chip during metal cutting were
established by ‘Merchant’ with the following assumptions.
1. Cutting velocity always remains constant.

2. Cutting edge of the total remains sharp throughout cutting and there is no contact
between the work-piece and tool flank
3. There is no sideways flow of chip
4. Only continuous chip is produced
5. There is no built-up edge, no consideration is made of the uerlia force of the chip
The forces represented are the following
Fs = Metal resistance to shear in chip formation, acting along the shear phase/shear force
Fn = Backing up force exerted by the work-piece on the chip, acting normal to the plane
N = Force excreted by the tool on the chip, acting normal to the total force
F = µn = frictional resistance of the tool against the chip flow
µ= , where µ=coefficient of friction between the tool &chip

The two triangles of forces of the above free body diagram have been combined as shown in the
following figure, called the “Merchant’s Circle Diagram” for cutting force, where,
Fc = Horizontal cutting force
Ft = Vertical/tangential force
From figure, we have
F = AQ+QB [QB=DC]
F = AQ+DC
From ∆le AQP we have,
Sinα =
AQ = FC cosα
∆le PDC, we have,
Cosα =
DC = Ft cosα
N = QD = PQ - PD
From ∆le AQP we have,
Cosα =
PQ = FC cosα
From ∆le PDC we have,
Sinα =
PD = Ft sinα
N = Fc cosα – Ft sinα
Fs = AH – HK
FS = AH - PE
From ∆le AHP, we have,
Cos =
AH = FC COS
We know that, PE = Ft sin
Fs = Fc cosΦ – Ft sinΦ
Then,
Fn = CK = CE+EK
Fn = CE+PH
Fn = Ft cosΦ + Fc sinΦ
Fc =Ac cos(τ -α)
Fc =R cos(τ -α)
Fs=R cos(Φ+τ -α)
Now,
=
Fc = Fs
We know that,
µ= =
= =µ
From ∆le ABC, we have
= tanτ = µ
τ = tan-1(µ) = tan-1
But we have,
= tan PAC
= tan (τ -α)
Chip Thickness Ratio: -

During the cutting action of a metal it will be observed that the thickness of the
deformed or upward flowing chip is more than the actual depth of cut.
Let: - t1 = Chip thickness before cutting
t2 = Chip thickness after cutting
Then,
Chip thickness ratio = r =
The chip thickness ratio is always less than unity. If the ratio “r” is large the
cutting action is good. The inverse of ”r” is known as “Chip Reduction Coefficient” i.e.
K=
From ∆le OAP, we have
= sin
= sin
OP = —————①
From ∆le OBP, we have
= sin (90- )
= cos ( )
= cos ( )
OP = —————②
Equation ①&②, we have
r=
On expansion, we have
r=
=1
+ rsinα = 1
= 1-rsinα
tan =
We have,
tan =
Where r =
Now in Orthogonal Cutting: -The width of the chip equals the width of the cut.
Considering the specific gravity of the metal as constant, the volume of the chip produced will
be equal to the volume of the metal cut. Then, if L1 and L2 are lengths of the metal cut and chip
then, We have,
t1L1 = t2L2
But,
=r
r= =
k= = =
Velocity Relationships: -
The relationships of different velocities are as shown in figure,
Let,
VC = Velocity of the tool relative to work
Vf = Velocity of chip flow relative to tool
VS = velocity of sheer/velocity of displacement of the chip along the shear plane relative to work
From lame’s theorem, we have,
= =
= =
Of the above three velocities the cutting velocity Vc is always known,
Then we have,
VS = VC
Vf = VC
But we have,
r=
Vf = VC * r
(Or)
We have,
= volume of material flowing up as chip
i.e. VCt1w = Vft2w
Vf = VC
Vf = Vc r
4.1.4.8 Lecture 8: Feed, speed, depth of cut, cutting speeds.

Cutting Speed, Feed, And Depth Of Cut:-
Cutting speed of a cutting tool can be defined as the rate at which its cutting edges passes over
the surface of the work-piece in the unit time. It is normally expressed in terms of the surface
speed in meters per minute. It is very important, since it affects tool life and efficiency.
Feed of the cutting tool can be defined as the distance it travels along or into the work-piece for
each pass of its point through a particular position in unit time. The feed is basically considered
per tooth of the cutter. The cutting speed and feed of a cutting tool are largely influenced by the
following factors:
 Material being machined

 Material of the cutting tool
 Geometry of the cutting tool
 Required degree of surface finish
 Rigidity of the machine tool being used
 Type of the coolant being used.
Depth of the cut:-
It is the penetration of the cutting edge of the tool into the work-piece material which is
measured perpendicular to the machined surface i.e. it determines the thickness of metal layer
removed by the cutting tool in one pass.
Example: - In turning operation, it is given by,
Depth of cut =
Where,
D= Original diameter
D= Diameter after turning.

4.1.4.9 Lecture 9: Tool material, Coolants and Tool life.

Tool Life: - It can be defined as the time interval for which the tool works satisfactorily
between two successive grindings (sharpening). There are 3 common ways of expressing tool
life,
1. As time period in minutes between two successive grindings.

2. In terms of no of components machined between two successive grindings. (when tool oper-
ates continuously)
3. In terms of volume of material removed b/w two successive grindings.(heavy stock removal)
 Volume of metal removal by minute = πDt.f.N mm3/min
Where,
D= diameter of work-piece, t= depth of cut
f= feed rate, N=no of revolutions/min
Let ‘T’ be the time in minutes
T Vd = πDtfNT
We know that, v =
πDn = V.1000
TL = v.1000.t.f.T (mm3)
The life of a cutting tool is affected by the following factors: -
1. Cutting speed
2. Feed & Depth of cut
3. Tool geometry
4. Tool material
5. Work material
6. Nature of cutting
7. Use of cutting fluids
Out of all the above factors, the maximum effect on tool life is cutting speed, the tool life varies
inversely as the cutting speed as shown in the following figure, The relationship between cutting
speed and tool life is given by F.W. Taylor and is expressed as,
VTn = C
Where,
V = cutting speed (n/mm)
T = tool life (min)
n = an exponent, whose value largely depends on tool material (0.1-0.16)
C= A constant, called machine constant
The different variables like V, T, F, t are inter related as given in the following imperial
Formula,
i.e. V =
And also,
V=
Where a, b are deepened on mech. Prop. of the work-piece material.
Coolants: - The cutting fluids/coolants perform the same function in grinding as in other
operations. Mostly used coolants include the water solutions and emulsions. oils are also used.
The use of a suitable coolant is needed in grinding for the following reasons.
a) To reduce the excessive heat generated during the operation and avoid its extreme local-
ization
b) To maintain uniform temperature, inorder to prevent distortion of the job and breakage of
the wheel
c) To prevent the metal chips from clogging into the grain spaces and thus avoid loading the
wheel face.
Important Properties of Fluids: -

 It should absorb more heat
 It should reduce friction
 It should not be corrosive in nature
 It should have low viscosity
 It should be economical.
Types of Coolants: -
Following are the normally used coolants,
 Carbon tetrachloride
 Acetic acid
 Turpentine
 Kerosene
 Paraffin oil
 Soluble oil
 Water
Cutting Power: -
Cutting power = H.P
Work-done in cutting = (cutting force)(cutting speed)
C.P = H.P
C.P= K.W
4.1.4.10 Lecture 10: Problems
Include / Attach PPT / Handout (typed)

4.1.5. Test Questions
a. Fill in the blanks type of questions <Minimum of ten>
1. In turning mild steel the value of ζ will be ---------------
2. The value of shear angle, βo depends upon ---------------------
3. Shaping grey cast iron block will produce---------------
4. The value of chip reduction coefficient, ζ does not depend upon
5. The master line for the rake surface of the turning tool of geometry: - 10o , 0o , 8o , 6o , 15o ,
30o , 0.1 (inch) is --------------
6. If the approach angle of a turning tool be 30 o , the value of its principal cutting edge angle will be
--------------
7. The angle between orthogonal plane and normal plane of a turning tool is ----------
8. Tool signature consists of_____ elements. (7)
9. Negative rake angle is usually provided on______________tool.
10. ---------------(machine shop) is a floor of assembly of several Machine Tools like, Lathe, Power
Saw, Drilling machines, etc.
b. Multiple choice questions <Minimum of ten>
1. Machining is a (b)
A. Shaping process B. Removal process
C. Regenerative process D. Joining process.
2. An object is machined to (a)
A. Fulfill its functional requirement B. Provide desirably good performance
C. Render longer service life D. All of the above
3. Feed rate is expressed in turning operation by (a)
A. mm/revolution B. mm/stroke
C. mm per min D. None of the above
4. Rapid prototyping is a (c)
A. Joining process B. Removal process
C. Regenerative manufacturing process D. Finishing process.

5. Back rake of a turning tool is measured on its
A. Machine longitudinal plane B. Machine transverse plane
C. Orthogonal plane D. Normal plane
6. Normal rake and orthogonal rake of a turning tool will be same when its
A. φ = 0 B. φ1 = 0
C. λ = 0 D. φ1 = 90o
7. Normal plane of a turning tool is always perpendicular to its
A. πX plane B. πY plane
C. πC plane D. None of them
8. Principal cutting edge angle of any turning tool is measured on its
A. πR B. πY
C. πX D. πo
9. A cutting tool can never have its
A. rake angle – positive B. rake angle – negative
C. clearance angle – positive D. clearance angle – negative
10. Orthogonal clearance and side clearance of a turning tool will be same if its perpendicular
cutting edge angle is
A. φ = 30o B. φ = 45o
C. φ = 60o D. φ = 90o
C. True or False questions <Minimum of ten>
1. Tool signature consists of six elements.(F)
2. In metal cutting, chips are removed due to plastic deformation of metals.(T)
3. Cutting fluid has no effect on the tool life.(F)
4. Continuous chips with built-up edge are formed during machining of mild steel with low
cutting speed, high feed, without using cutting fluid, etc.(T)
5. Machinability increases with the increase of cutting forces.(T)
6. Overloading is possible in individual drive.(T)
7. Tools which are operated or controlled by a motor or any prime mover in performing
different operations known as Hand Tools.(T)
8. There must be two relative motions in any metal cutting.(T)
9. Right hand tool moves from right to the left and end of the Lathe bed.(F)
10. High speed steel tool having 18% Tungsten, 4% Chromium, 1% Vana dium and rest Iron.
(T)
4.1.6. Review Questions

a. Objective type of questions(Very short notes) <Minimum of ten>
1. How tool life defined? Explain the factors effecting tool life?
2. Explain shear zone with respect to machining process.
3. Discuss the methods of chip control.
4. How does the rake angle effect the life of the cutting tool?
5. What are the various types of cutting fluids?
6. Define metal cutting and machine tools.
7. What are the differences between orthogonal and oblique cutting?
8. What is the function of a chip breaker?
9. List out the functions of coolants in machining operation?
10. What is meant by built up edge and state the causes of it?
b. Analytical type questions <Minimum of ten>
1. The speed, life relationship for a tool is given by VT 1/3 = 200 for a given set of conditions
and time taken to change the tool is 6min. Show that operating at a speed of 75mpm
gives higher output at either 110mpm or 50mpm, if other conditions remain unchanged.
c. Essay type Questions <As per requirements>
1. (a) Explain the factors influencing tool wear and tool life.
(b) What are essential characteristics of cutting fluid?
2. (a) Discuss various types of cutting fluids.
(b) Explain the constructional features of speed gear box and feed gear box.
3. (a) Explain various types of tool materials and their applications.
(b) Explain about Machine ability and Machine ability index.
4. (a) Derive an expression for optimum value of cutting speed.
(b)What is built up edge? Discuss its effects.
5. Briefly discuss about tool signature with an example?

6. Explain about carbon tool steel, high speed steel, and cemented carbides tool material in detail?
7. Derive an expression for optimum value of cutting speed?
8. Describe the Merchants force diagram and state its significance in machining?
9. Explain ORS and ASA system of tool nomenclature
10. Draw a neat sketch of single point cutting tool geometry and explain different angles on the
single point cutting tool?
d. Problems <As per required Number>
1. During an orthogonal cutting a chip length of 160mm was obtained from an uncut chip
length of 350 mm. The cutting tool has 220 rake angles and a depth of cut is 0.8mm.
Determine the shear plane angle and chip thickness.
2. The orthogonal cutting of steel is done with 100 rake tool with a depth of cut 2mm and
feed rate of 0.20 mm/rev. The cutting speed is 200 m/min. The chip thickness ratio is
0.31. The vertical cutting force is 1200 N and the horizontal cutting force is 650 N.
Calculate from the merchant’s theory, the various works done in metal cutting and
shear stress.
3. In an orthogonal cutting experiment with a tool of rake angle α= 70 , the chip thickness
was found to be 2.5mm when the uncut chip thickness was set to 1mm. Find (i) the
shear angle and (ii) the friction angle assuming that Merchant’s formula holds good.
4. A cutting tool at 35m/min gave a life of one hour twenty minutes, when operating on
roughening cuts. What will be the probable life when engaged on light finishing cuts?
Take n=0.125 for rough cut n=0.1 for finishing cut.
5. During a metal cutting test under orthogonal conditions it was found that cutting force is
125kg and feed force is 110kg when cutting at 170mpm .The rake angle is 10 0 and shear
plane angle was found to be at 190.determine
i. Shear velocity
ii. Chip flow velocity
iii. Work done per minute in shearing the metal and work done against friction
iv. Show that the work input is equal to the sum of work done in shearing and
against friction
e. Case study <As per required Number>
4.1.7. Skill Building Exercises/Assignments

- Prepare a model of single point cutting tool with wood material
- Trace various cutting tool materials used for manufacturing of cutting tools
- Prepare a report on various cutting fluids used in machining
4.1.8. Previous Questions (Asked by JNTUK from the concerned Unit)

1. (a) Explain the factors influencing tool wear and tool life.
(b) What are essential characteristics of cutting fluid?
2. (a) Discuss various types of cutting fluids.
(b) Explain the constructional features of speed gear box
3. (a) Explain various types of tool materials and their applications.
(b) Explain about Machine ability and Machine ability index.
4. (a) Derive an expression for optimum value of cutting speed.
(b)What is built up edge? Discuss its effects.
4.1.9. GATE Questions (Where relevant)
1 Minimum shear strain in Orthogonal turning with a cutting tool of Zero Rake angle is
A 0.0
B 0.5
C 1.0
D 2.0
GATE Ans:
2009
2 A Single point cutting tool with Zero Rake angle is used in an Orthogonal machining
process at a cutting speed of 180 m/min, The thrust force is 490 N. If the coeffient of
friction between tool and chip is 0.7 then, the power consumption (in KW) for the
machining operation is________
GATE Ans: 2.1 KW

2015
3 If the Taylor’s Tool life exponent ‘n’ is 0.2 and Tool Changing time is 1.5 Minute.
Then tool life for maximum production rate is ______
GATE Ans: 6 Minutes
2014
4 Better surface finish is obtained with large rake angle, because
A. Area of shear plane decreases resulting in the Decrease in shear force

and cutting force
B. The tool becomes thinner and cutting force is reduced
C. Less heat is accumulated in the cutting Zone
D. The friction between the chip and tool is less
GATE Ans: A
2014
5 In an orthogonal process the tool used has rake angle of Zero degree. The
measured cutting force and thrust force are 500N and 250N. The coefficient of
friction between tool and chip is ______
GATE Ans: 0.5

2016
6 In a single point turning operation with cemented Carbide tool and Steel work
piece, it is found that the taylor’s Exponent is 0.25. If the cutting speed is
reduced by 50%, then the tool life changes by _____ times.
GATE Ans: 16
2016
7 What is the percentage increase in tool life, when cutting speed is halved.
A. 50%
B. 200%
C. 300%
D. 400%
GATE Ans:
2009
8 A single point cutting tool with 120 rake angle is used to machine a steel work
piece. The Depth of cut i.e uncut thickness is 0.81 mm. The chip thickness
under orthogonal cutting is 1.8mm. The shear angle is approximately
A. 220
B. 260
C. 560
D. 760
GATE Ans: B
2011
9 The exponent ‘n’ and constant ‘K’ of a Taylor’s tool life equation are
A. n=0.5, K=540
B. n=1, K=4860
C. n=-1, K=0.74
D. n=-0.5, K=1.155
GATE Ans:
2009
10 Cutting tool is much harder than the work piece. Yet the tool wears out during
the tool work interaction because
A. Extra Hardness is imparted to the work piece due to coolant used
B. Oxide layers on the work piece surface impart extra hardness to it
C. Extra hardness is imparted to the work piece due to severe rate of strain
D. Vibration is induced in the machine tool
GATE Ans: C
2009
4.1.10. Interview questions (which are frequently asked in a Technical

round - Placements)
1) What is the Work & Tool Interfacing mechanism or Mechanism of metal removal on
the work.
2) What do you understand by tool dynamics
3) Why to make machining as a secondary process
4) What are the boundary conditions for the application of machining
4.1.11. Real-Word (Live) Examples / Case studies wherever applicable

1. Temporary fasteners used in daily life
2. Making of shafts ,bearings
4.1.12. Suggested “Expert Guest Lectures” (both from in and outside of

the campus)
1. S.V Ramana Assoc.Prof.Mechanical Department, VIIT, Duvvada.
2. Prof. K.Ramji, College of Engineering, A.U.
4.1.13. Literature references of Relevant NPTEL Videos/Web/You Tube

videos etc.
1) http://nptel.ac.in/courses/112105127/1
2) Chip formation - https://www.youtube.com/watch?v=8SbBC5UWeNI
3) Single point cutting tool geometry- https://www.youtube.com/watch?

v=Mn9jpqI8rao
4) Difference between orthogonal and oblique cutting-

https://www.youtube.com/watch?v=vXFXzs_7O0A
4.1.14. Any Lab requirements; if so link it to Lab Lesson Plan.

1. Live demo on chip formation and metal cutting theory
2. Tool grinding of single point cutting tool
3. Cutting motion, feed motion in all the machines
4.1.15. Reference Text Books / with Journals Chapters etc.

1. Production Technology by R.K. Jain and S.C. Gupta.
2. Workshop Technology – B.S.RaghuVamshi – Vol II
3. Production Technology by H.M.T. (Hindustan Machine Tools).
4. Manufacturing technology II, P.N Rao

4.2. 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 – 4.2.1.

Unit
Tool layout and cam design for automats.
Objectives:
- About Lathe & It’s Purpose
- Types of Lathes (Capstan & Turret etc)
- Different Work & Tool Holding devices
- Mechanisms in Lathe Machine
- Methods of Taper Turning operation performed on lathe
- Box and Tool Layouts
- Automatic machines
- Operate lathe, milling machines, drill press, grinding machines, etc.

Lecture Topic Methodology Quick reference
no.
1 Lathe introduction-Engine lathe Chalk & Board
2 Principle of working-Types of lathes- Chalk & Board
specification of lathes
3 Work holders-Tool holders, box tools Chalk & Board
4 taper turning, thread turning, Chalk &
attachments Board,PPT
5 Constructional features of Speed Gear Chalk & Board
Box and Feed Gear Box
6 Turret and capstan lathes, Collect Chalk & Board
chucks and Other work holders
7 Tool Holding devices, Box and Tool Chalk & Board
Layout.
8 Automatic lathes, Classification, Chalk & Board
Single spindle - Multi spindle
9 Tool lay out and Cam Design for Chalk & Board
Automats.
10 Revision of UNIT – 2 PPT
4.2.4.2 Lecture-1

Introduction to Lathe:-
LATHE is the father of machine tools. The main function of a lathe is to remove
metal from a piece of work to give it in required shape and size. The lathe is used to cylindrical
shapes. In a lathe work piece is held and rotated about its axis. Generally single point cutting tool
is used as the cutting tool. The tool is moved parallel to the axis of rotation of work piece to
produce a cylindrical surface.
Principle of Working:-
The lathe can be defined as a machine tool which holds the work between two rigid and strong
supports, called cutters or in a chuck or face plate while the latter revolves. The chuck or the
face plate is mounted on the projected and of the machine spindle. The cutting tool is rigidly
held and supported is a tool post is feed against the revolving work. While the work revolves
about its own axis the tool is made to move either parallel to (or) at as inclination with this axis
to cut the designed material.
Lathe Specification and Sizes:-

The size of a lathe is designated in many different ways. The practice usually differs with
different countries.
A – Maximum length that can be accommodated between centers
B – Swing in gap
C – Height of centers
D – Swing over carriage
E – Swing over bed
Parts of Lathe:-
The lathe carries the following main parts as illustrated by a block diagram in the figure, the
main parts of a lathe are,
1. Bed
2. Headstock
3. Tailstock
4. Carriage
5. Feed mechanism
6. Legs
Bed: - it is the base of the machine. The headstock is mounted on the left end, the carriage in
the middle and the tailstock at the right end of bed. The carriage and the tail stock move over
the bed.
Headstock: - it is mounted on the bed at left end. It carries a hallow spindle. A long bar can
pass through the hole of the spindle. A live center can be attached into the spindle. Chucks and
face plats can be attached to the nose of the spindle.
Tailstock: - it is mounted on the bed on the right end. It is used for supporting the right end
of work. It is also used for holding drill, rammer or tap. It can be moved along the bed and
clamped at any position to support work pieces. The tailstock body is bored and the tailstock
spindle moves through it a dead center can be spindle through it. A dead center can be fixed
into the taper hole of the spindle for supporting the right end of work.
Carriage: - the carriage is used for giving various movements to the tool by hand/power. The
carriage consists of following parts,
1. Saddle
2. Cross slide
3. Compound set
4. Tool post
Saddle: - it is the "H” shaped casting fitted over the bed. It moves along the guide way. It
carries the cross slide and tool post.
Cross slide: - it is attached to the saddle. It carries the compound rest. There is a
micrometer dial on the cross slide hand wheel, with an accuracy of 0.05mm.
Compound Rest: - it will be there in degrees. It is used during taper turning to set the tool
for angular cuts. There is no power feed to the compound rest. The compound slide should be
locked strongly with its base after any setting.
Tool Post: - the tool is clamped in the tool post. The tool post is fitted over the compound
rest. There are four types of tool post,
a) Single screw tool post
b) Open side tool post
c) Four bolt tool post
d) Four way tool post
Feed Mechanism: - the moment of the tool relative to the work piece is termed as feed.
The lathe tool a move parallel to the axis of the lathe, the moment is called longitudinal which is
achieved by moving the cross slide. When the tool moves at an angle to the axis of the lathe is
called angular feed. This is achieved by moving compound slide after sliding at an angle lathe
axis.
Feed Rod: - the feed rod is a long shaft, used to move the carriages/cross side for turning,
facing, boring and all other operations except thread cutting. Power is transmitted from the lathe
spindle to the apron gears through the feed rod via a large number of gears.
4.2.4.2 Lecture-2

Types of Lathes: - According to construction and design we are broadly classify lathes as
follows,
a) Bench Lathe: - it is very small lathe and is mounted on a separately prepared

bench/cabinet. it is used for small and precision work since it is very accurate. it is usually
provided with all the attachments, performing almost all the operations.
b) Speed Lathes: - these lathes may be of bench type or they have been the supporting
legs cast and fitted to the bed. Such lathes are employed for wood turning, polishing, centering
and metal spinning etc; they are named so because of the very high speed at which their
spindle rotates.
c) Engine Lathe: - it is the probably the most widely used type of lathe. the name engine
lathe is a little confusing in modern practice as all the these lathes are now made to have an
individual motor drive. Its construction is more relatively more robust.
d) Tool Room Lathe: - it is nothing but the same engine lathe but equipped with some
extra attachments to make it suitable for a relatively more accurate and precision type of work
carried out in tool room. it carries a much wider range of speeds and feeds. The most commonly
used lengths are 135-180cms.
e) Capstan and Turret Lathes: - these lathes from a very important and useful group
and are vastly used in mass productions. These machines are semi-automatic type and a very
wide range of operations can be performed on them. They carry special mechanisms for
indexing of their tool heads.
f) Automatic Lathes: - these lathes help a long way in enhancing the quality as well as
the quality of production. These fall in the category of heavy duty, high speed, lathes mainly
employed in mass production.
g) Special Purpose Lathes: - a large number of lathes are designed to suit a definite
class of work and to perform certain specified operations only. They obviously prove to be more
efficient and effective as compared to the common engine lathe so far as this specified class
work is concerned.
According to the height of centers (above the bed) lathes can be grouped as,
1. Small lathe – up to 150mm

2. Medium lathe – up to 150-300mm
3. Heavy duty lathe - above 300mm
4.2.4.2 Lecture-3

Work Holding Devices: - the work holding devices in the lathe are mentioned as
follows,
1. Chucks
2. Face Plate
3. Angle Plate
4. Driving Plate
Chucks: - they provide a very efficient and true device of holding the work on the lathe
during the operation. There is a fairly large variety of chucks in use on lathes, but most common
types are the following,
1. Three-jaw self cutting chuck

2. Four-jaw independent chuck
3. Combination chuck
4. Magnetic chuck
5. Air/Collect chuck
Three-Jaw Self Cutting Chuck: - It is also known as scroll chuck or self centering
chuck. It consists of cylindrical body having three jaws fixed radially at its front.
It is not suitable for unsymmetrical (eccentrically) components. The centering and gripping of the
work piece is done quick since all the three jaws move simultaneously by turning the key.
Four-Jaw Independent Chuck: - It is used for complex and symmetrical shaped work
pieces. it has four jaws, each jaw, each jaw can be moved independently. When the chuck key
is tightened that particular jaw will move.
Magnetic Chuck: - Magnetic chucks are used for holding thin work pieces of magnetic
materials. This cannot be held in the chucks with jaws. The holding power of the chuck is due to
the magnetic flux from the electro magnets/permanent magnets inside the chuck.
Air/Collect Chucks:- Collect chucks are as shown in the above figure, they are used for
selling quickly and for holding accurately small cylindrical work during mass production of parts.
The collect chuck is attached to the spindle.
Face Plate: - It is usually a circular cast iron disc, having a threaded hole at its center so
that it can be screwed to the threaded nose of the spindle. It consists of a number of holes and
slots by means of which the work can be secured. A number of other things like bolts, nuts,
washers, clamping plates and metallic packing pieces etc, are required for holding the work
properly on a face plate. When an eccentric job is held directly on the face plate an angle plate
is used to hold the work. A balance weight is usually fitted to counter balance this electricity.
Angle Plate: - It is employed for holding work in conjunction with a face plate. When the
size/shape of the work is such that it is possible to mount the ark directly on the face plate the
angle plate is secured to the face plate and angle plate is and the work mounted on it. It is
almost an indispensable attachment for most of the operations in face plate work. A useful form
of angle plate is as shown in the figure.
Driving Plate: - It is a circular plate having a projected base its rare. The base has a
headed hole and it can be mounted on the lathe spindle. A driving pin is fitted to the plate. In
transfer motion to the dog fitted with the work piece. Here the work piece is held between the
catch centers & tailstock center as shown in the figure,
Tool Holding Devices: - The following are the different types of tool holding devices,
they are,
1. Straight Cutter Holder

2. Multi Cutter Holder
3. Knee Tool Cutter
4. Flange Tool Cutter
5. Knurling Tool Cutter
6. Form Tool Cutter
Straight Cutter Holder: - This is a simple tool holder constructed to take standard
selection of tool bits. In this type of holder the tool is held perpendicular to the shank. The tool is
gripped in the holder by three set screws. Different operations like turning, facing, boring etc,
can be performed by holding suitable tool holder.
Multi Cutter Holder: - If can accommodate double tools in its body. This Feature enables
turning of two different diameters simultaneously. Turning boring (or) turning and facing tools
can be set in the holder to perform operations at a time.
Knee Holder: - It is useful for simultaneous turning & boring (or) turning & drilling
operations. The tool holder is bolted directly on the turret face.
Flange Tool Holder: - The Twist drills having more taper shanks are usually held in a
socket, which is parallel outside but taper inside.
Knurling Tool Holder: - Knurling tool holder may be mounted on the turrent face or on
the tool posts of cross slide. The holder with knurls is mounted on the cross side can perform
knurling operation on any diameter work.
Form Tool Holder: - The form tool holder is having two set of form tool holders for holding
straight and circular form cutters. In the straight form tool holder the tool is mounted on a
dovetail slide and the height of the cutting edge may be adjusted by moving the tool within the
slide. The height of the circular form tool may be adjusted by rotating the circular cutter.
Centers: - These are required to turn the work between headstock and tailstock. The Centers
which is fitted in the headstock spindle is called "Live Revolving Center". This center rotates
with the work. Another is called "Dead Center", which is kept stationary in the tailstock.
Carries/Dogs: - It is used to transfer motion from the driving plate to the work piece held
between centers. Te work piece is inserted into the hole of the dog and firmly secured in position
by means of set screw as shown in figure,
Mandrels: - These are used for holding work pieces. The mandrel is supported and routed
between the centers as shown in figure. The diameter of mandrel is a little less than that the
inside diameter of the work piece. It is used to one size of bore only & for standard holes. It is
tapered 0.5mm.
These are mostly used for large diameters. These types of mandrels help in reducing the weight
of mandrel.
These mandrels are having external threads for mounting work pieces. The internal thread of
the work piece is same as the external threads on the mandrels.
Step mandrels have steps of different diameters used to drive different. Stepped mandrel work
pieces having different sizes of holes, without replacing the mandrel each type. This type of
mandrel is used for turning of washers and odd size of jobs.
It consists of a tapered pin which is driven into a sleeve that is parallel outside and tapered
inside. This construction makes an expansion to grip varies work pieces with different diameter
that cannot be held in an ordinary mandrel.
Types of Mandrel:-
1. Plain (or) Solid Mandrel
2. Gauge Mandrel
3. Expanding Mandrel
4. Screwed Mandrel
5. Step Mandrel
6. Collar Mandrel
Work Supporting Devices: - The work supporting devices are termed as “Rests”.
The following are the commonly used supporting devices on engine lathe.
a) Steady Rest: - It consists of a cast-iron base that may be made to slide on the lathe
bed. It is clamped on the bed ways on the required position between headstock and
tailstock. The work-piece is supported between 3 jaws and two on the base and one on the
upper flange. It is also used to support the free end of a long work-piece for drilling, lathing,
boring etc;
b) Follower Rest: - It is having two adjustable jaws to support the work-piece. The jaws
always flow the tool giving continuous support to the work-piece and prevent deflection of
the work. The entire work-piece will be turned without disturbing the setting.
4.2.4.2 Lecture-4
Examples include (Repeat the below for all lectures)

Different Methods for Tape Turning On Lathe: - Taper turning is a process of
producing taper on a work-piece. The various methods for taper turning operation are,
1. Tailstock Set Over Method

2. Compound Rest Swiveling Method
3. Taper Turning Attachment
4. Forming tool Method
1) Tailstock Set Over Method: - This method is used for producing small tapers on
long work-piece. Due to the setting of the tailstock, the work-piece center line is shifted at an
angle to the spindle axis. The setup is shown in the above figure.
2) Compound Rest Swiveling Method: - In this steep and short external tapers are
can easily be turned on a lathe by swiveling the compound rest on the carriage through an
angle ”α”, which is equal to half the total included angle of the taper.
Tan α =
α = tan-1
α= taper angle
3) Taper Turning Attachment: - It is a very suitable method of taper turning which
provides a very wide range of tapers. As the attachment travels along the saddle, it is possible
to turn the taper anywhere along the length of the job.
4)Form ing
Tool
Method: - Very short tapers can easily be turned with a form/broad nose tool in which the
cutting edge of the tool is ground to contain the half taper angle “α”.
4.2.4.2 Lecture-5

SPEED GEAR BOX:
The Desired speed of the spindle can be achieved by engaging and disengaging of the different
transmission in gear boxes by sliding key mechanism or by using frictional clutches. When
spindle spindle drives is to be changed frequently change gears are used. Heavy machines tools
make use of jaw clutches with attachment to gear boxes. Frictional clutches are especially used is
small and medium size turret lathes for changing different speeds.
The sliding gear type gear boxes transmits heavy torque and operates at high speeds.
Some of the essential components of the gear boxes are shafts for mounting of gears, bearings to
support the shaft, housing to support bearings, lubricating oil to protect the gears from foreign
particles. Spacers are provided to maintain space between the gears. Enough space is provided
for a gears to easy engaging and disengaging.
For changing the feed in gear boxes, various methods are mechanisms are employed.
Some of them are as follows
1. Sliding gear mechanism
2. Sliding clutch mechanism
3. Gear cone and tumbler gear mechanism
4. Sliding key mechanism
5. Combination of any two or more of the above
Among all these mechanisms, the most common method used is Gear cone and Tumbler
mechanism
Give a diagrams for gear cone and Tumbler mechanism

4.2.4.2 Lecture-6

Turret and Capstan Lathe:
The main operating parts of capstan and turret lathes are
1. Head stock
2. Carriage
3. Turret saddle
4. Bed
5. Legs
Which are illustrated in the block diagram

Turret Lathe Capstan Lathe
1 In Turret (Head) is mounted directly on the Its Turret (Head) is mounted on an Auxiliary
saddle slide, Which moves on the guide ways provided
on the saddle
2 For Feeding the tools to the work the entire In this case the saddle is fixed at a convenient
saddle unit is moved distance from the work and tools are fed by
moving the slide
3 The above arrangement enables a very high In this case, because of the Overhung of the Slide
rigidity because all the cutting forces or Ram, the tool support unit is subjected to
transferred to the lathe Bed bending and deflection, which results in
vibrations.
4 At Turret lathe is capable of handling It is not capable of withstanding heavy cutting

Heavier jobs involving heavy cutting forces loads and severe cutting conditions, hence it is
and severe cutting conditions. used to confine to relatively lighter and smaller
jobs and precision work
5 It may carry either a reach over type or Side The capstan lathe is usually equipped with reach
Hung type carriage over type carriage.
6 It is generally provide with pneumatic and There is no such requirements.

hydraulic chucks.
7 It may carry provision for cross feeding of No such provision is made

hexagonal turret to enable cross feeding.
Classification of Turret Lathes:

They are classified in many ways according to the
i. Type of saddle they carry
ii. Direction of mounting of the turret saddle
iii. Type of job they are capable of handling
iv. Specific operations they have to perform
According to the type of saddle they are classified as
 Ram type Turret lathe or Capstan lathe
 Saddle type turret lathes or combination Turrets
According to the direction of mounting of saddle they are classified as
 Vertical turrets
 Horizontal turrets
According to type of job they are capable of machining are classified as
 Bar Machines
 Chucking machines
4.2.4.2 Lecture-7

Common Tools and attachments used on Turret and Capstan Lathes
The Tools which are common to both Turret and Capstan lathes are
 Work stops or Bar stops
 Centering and Chamfering tools
 Drill and Reamer holders
 Turning tools
 Tap and Die holders
 Box Tools
 Attachment used in cross Slide
Special Attachments:
 Pilot Bar
 Multiple turning head
 Cutter holders
 Adjustable slide tools
Tooling layout
In machining operation the tool layout is predetermined plan that depends upon quantity of
pieces that are to be manufactured. An efficient layout produces parts of greater accuracy as
per the requirements of cost. This accuracy depends upon nature of job, condition of raw
material, number of pieces to be manufactured etc. a perfect tool layout eliminates
unnecessary, precautionary measures which takes away the machining time.
Various rules that must be followed while laying out sequence of operations
1. Standard tools should be used for small batches of work.
2. Special tools must be used for large quantities of work which minimizes the machining
time
3. Overlap working operations whenever required
4. Provide a finish cut with single tool
5. Use central drill before drilling small diameter holes
6. Heavy operations like threading where rigidity is considered should not be performed in
the early stages.
4.2.4.2 Lecture-8

Automatic lathes:
As the name indicates the automatic lathes are those which machine the work pieces automatically. In
more clear terms we can say that all movements of the cutting tool, their sequence of operations, feeding
of raw material, and parting off, unloading finished articles are all done by machines. The automatic
machine thus performs a fully automatic cycle of operations which produces the desired number of
identical parts without any participation of operator.
Classification of Automatic lathes:

The main classification of Automatic machines is as follows
1. According to the type of stock material used
A. Bar Automatics
B. Chucking machines
2. According to the Direction of access of machine spindle
A. Horizontal machines
B. Vertical machines
3. According to the Number of spindles carried by machine
A. Single spindle Automatics
B. Multiple spindle Automatics.
4.2.4.2 Lecture-9

Cam Design for Automats
In order to carry out the Cam Design in automatic lathe, it is very important to carry out the step by step
operations in detail. To achieve the necessary part, Geometry of the Cam, the movement provided to each
tool is examined carefully, with the relative timings.
The following points to be taken care while designing a Cam.
1. Dwell
2. Tool Travel of Throw
3. Overlapping operations
4.2.4.2 Lecture-10

i. Lathe is made of __________ Iron (Ans: Chilled cast Iron )

ii. Lead screw of lathe has ________ Start thread (Ans: Single)
iii. In ________ Operation, Job rotates and the tool is fed longitudinally by giving
the desired depth of cut. (Ans: Turning)
iv. ___________ used for holding and rotating the hollow jobs on machine spindle
(Ans: Mandrel)
v. Front portion of the Lathe carriage is ________ (Ans: Apron)
vi. ________ is the lathe part, which gives rigid supports to the tool during opera-
tions and transmits the power through feed rod and Lead screw.
(Ans: Carriage)
vii. _______ lathe is high speed heavy duty machine tools which is suitable for mass
production (Ans: Automatic)
viii. Main specification of lathe are ____________ and ____________ (Ans: Swing Di-
ameter, Length of Bed)
ix. ________ Chuck is suitable for holding Heavy and large jobs on lathe machine
spindle. (Ans: Air Operated)
x. _________Chuck is used for holding irregular jobs. (Four Jaw Chuck).
xi. _________ Chuck is self-centering chuck. (Three Jaw Chuck)
1. An operation of embossing, Producing a roughened Diamond – shaped pattern

on a smooth surface of a cylindrical job to provide effective gripping is (Ans: B)
A) Grooving B) Knurling C) Honing D) Reaming
2. In an Engine Lathe, the cutting tool is fed against work piece axis in: (Ans:C)
A) Longitudinal direction only B) Cross direction only
C) Both longitudinal and cross directions D) Vertical direction only.
3. Two main specifications of a Centre lathe is: (Ans:A)
A) Swing diameter over bed and length of bed
B) Swing diameter over bed and carriage
C) Speed and feed ranges
D) Swing diameter over bed and maximum length of the job can accommodate in
between centers.
4. A Centre Lathe is specified by: (Ans: D)
A) The swing diameter over bed B) The length of bed
C) The diameter of the hole in H.S. spindle D) All of the above
5. Slow speed in headstock spindle is necessary in: (Ans: D)
A) Spinning B) Turning
C) Thread cutting D) Knurling
E) Both (i) and (ii) F) Both (iii) and (iv).
6. Standard taper used in Lathe centers is:(Ans: B)
A) Brown and Sharp B) Morse
C) Jarno D) Metric taper.
7. A Lathe machine having four steps cone pulley drive with one back gear will
have: (Ans: D)
A) Eight direct speeds B) Four direct speeds
C) Eight indirect speeds D) Four direct and four indirect speeds.
8. When a turning tool travels parallel to the Lathe axis, the movement of tool is
known as:(Ans:A)
A) Longitudinal feed B) Cross feed
C) Angular feed D) None of the above.
9. The included angle of Lathe centers for general work is:(Ans: C)
A) 25° B) 40°
C) 60° D) 75°.
10. The different H.S. spindle speed of all geared - head drive on a lathe form:(Ans:C)
A) Harmonical progression B) Arithmetical progression
C) Geometrical progression D) None of the above.
11 The cutting edge width of a parting off tool varies from (Ans:D)
A) 416 mm B) 825mm
C) 1535mm D) 38mm.
c. True or False questions <Minimum of ten>
i. Operations like Knurling, Thread cutting etc.. Require High speeds? (Ans: False)
ii. In Automatic lathe, all the operations are performed by the machine itself without
the participation of the operator. (True)
iii. Bed of lathe machine is made of Mild steel? (Ans: False)
iv. Morse tapers are used in live and dead centers? (Ans: True)
v. In stepped pulley, Spindle speeds are varied in Arithmetic progression. (Ans: True)
vi. Chucks, steady rests, Driving plate and carriers are the examples of lathe parts (Ans:
False)
vii. If the center is mounted on head stock and rotated with it is known as the live Cen-
tre (Ans: True)
viii. Lead is equal to the product of pitch and number of start.(Ans: True)
ix. Knurling is the process of embossing , producing a roughened surface on a smooth
surface of a cylindrical job to provide effective gripping (Ans: True)
x. Reaming is a single point cutting tool will not follow previous drilling hole and will
trace its own path. (Ans: False)

a. Objective type of questions(Very short notes) <Minimum of ten>
1. Write Type of Lathes with Sketch?
2. Give specifications of lathe?
3. Mention various types of Taper turning methods on Lathe?
4. Mention different types of Work holding devices?
5. Mention different types Tool holding devices?
6. Mention types Of chucks with neat sketch?
b. Analytical type questions <Minimum of ten>
c. Essay type Questions <As per requirements>
i. What type of work holding devices are generally used in a lathe? Give the typical ap-
plications, comparative accuracies, precautions and dis advantages for each type of
work holding device.
ii. How is a lathe specified? Explain with a neat sketch the relevance of each of the
specification points.
iii. What are the types of surfaces that can be generated in a center lathe? Show how
these are achieved with the help of neat sketches.
iv. Explain the methods used for generation of threads in a lathe.
v. What are the precautions and settings to be done for cutting single start threads on
a center lathe? Give a practical method that will allow the cutting tool to follow the
thread.
vi. What are the various methods available for taper turning in a lathe? Explain their
specific advantages and limitations.
vii. Explain the procedure for turning a job, which is very long. List the various opera-
tions and tools (cutting and holding) required for the operation.
viii. What are the various methods available for supporting long components and frail
components in a lathe? Explain with sketches.
ix. Draw a setup required for cutting external threads on a center lathe. Explain clearly
the various methods that are followed for the purpose of engaging the cutting tool
for giving the depth of cut in threading.
x. What the types of lathes? Give their applications.
d. Problems <As per required Number>
e. Case study <As per required Number>
- Prepare a model of single point cutting tool with wood material
- Trace various cutting tool materials used for manufacturing of cutting tools
- Prepare a report on various cutting fluids used in machining

1. What are the differences between capstan and turret lathes?
2. Explain various types of chucks in detail?
3. Discuss the constructional features of speed gear box.
4. Explain briefly the following operations with neat sketches:
(i) Knurling (ii) Forming
5. Explain briefly the following lathe accessories:
(i) Driving Plate (ii) Lathe Centres.
6. Explain the different types of tool post with neat sketches.
7. A shaft 500mm long has a taper of 100mm/m for a distance of 200mm from one
end. The maximum diameter of the shaft is 150mm. Determine the amount of set
over required.
8. Calculate the gears for cutting metric threads of the following pitches:
(i) 4mm pitch (ii) 5.25mm pitch.The lead screw of the lathe contains 6TPI. The lathe
supplied with 20 to 120 teethin steps of 5 and an additional gear wheel of having 127
tee
No – No specific questions related to Lathe were asked in GATE in recent

times

round - Placements)
1. What are the various operations can be performed on a lathe?
1. Turning 6. Thread cutting 11. Grooving

2. Facing 7. Drilling
3. Forming 8. Boring
4. Knurling 9. Recessing
5. Chamfering 10. Tapping
2. What is the function of cutting fluids?

a. It is used to cool the cutting tool & the work piece.
b. It improves the surface finish as stated earlier.
c. It causes the chips to break up into small parts.
d. It protects the finish surface from corrosion.
e. It prevents the corrosion of work & machine.
Write down the steps involved in making above product.

the campus)
1. A Guest Lecture on “Production of Components on Automatic Lathe”
2. CNC Programming of Lathe and Milling machines

videos etc.
1. NPTEl link http://nptel.ac.in/courses/112105127/17
2. Introduction to Lathe machine - https://www.youtube.com/watch?v=fVd52INbgYc
3. Parts of Lathe - https://www.youtube.com/watch?v=dj64QvvbGXM
4. Taper Turning video - https://www.youtube.com/watch?v=y-bEIA6C5gg
5. Threading Operation on lathe - https://www.youtube.com/watch?v=73E75eZU3Do
6. Automatic Lathe - https://www.youtube.com/watch?v=YneXChaRRP4

 Different operations on lathe machine Lathe machine.
4.2.15. Reference Text Books / with Journals Chapters etc.

2. Workshop Technology – B.S.RaghuVamshi – Vol II
4. Manufacturing technology II, P.N Rao
Extra questions from Raghuwanshi book

1. What is the significance of Capstan, Turret and automatic lathes in a production shop?
2. Compare the merits and demerits of Turret and capstan lathes with an engine lathe.
3. What is the difference between a Capstan and Turret lathe? Explain with the help of suitable sketches.
4. Describe in brief the different types of Headstocks used on semi-automatic and automatic machines.
5. What is Turret saddle? Describe its function in Brief.
6. How do you classify Turret lathes? Give a brief description of the different types you know?
7. What do you know about bar and chunking machines? Describe?
8. How are the Sizes of Turret and capstan lathes specified?
9. What are the primary and secondary motions of Turret and Capstan lathes? Explain.
10. What are the attachments used commonly on Capstan and Turret Lathes?
11. Describe with sketches the following attachments used on Turret and Capstan lathes:
i. Micrometer Bar stop
ii. Roller steady centering tool
iii. Combined bar stop and centering tool
iv. Combined centering and facing tool
v. Chamfering tool
12. What is knee Tool holder? Describe with the help of a sketch the knee tool with Micrometer
Adjustment.
13. Write short notes on the following:
i. Drill and Reamer Holders
ii. A Self releasing Tap holder
iii. A Self-Operating Die Head
iv. Boring tools
i. Reaming Tools
14. What are the ‘Box Tools’? Describe with sketch a Roller steady Box tool for Turning.
15. Sketch and describe Concentric Knurling Tool.
16. Why a pilot bar is used on a Turret lathe? Sketch and describe a Multiple Turning Head.
17. How the tools are mounted on Capstan and Turret lathes?
18. Describe, with the help of a neat sketch, the working of a Collet chuck.
19. Describe a suitable method of feeding the bar stock on capstan and turret lathes.
20. With the help of a suitable diagram, explain the working of Turret indexing and stop drum
mechanisms used on Turret and capstan lathes.
21. What are Automatic lathes? Where their use is preferred and why?
22. How automation affects the production rate?
23. What considerations will you make in selecting a particular type of lathe for particular job?
24. Give broad classification of automatic machines, mentioning their main features.
25. What do you understand by the term ‘Manufacturing Process’? What is Interchangeability?
26. How the bars and blanks should be selected for machining on Automatic and semi- automatic lathes?
27. Describe ‘Single Spindle Bar Automatic’ in detail.
28. What are Multi spindle Automatic machines and how do you classify them?
29. What are Automatic Transfer Machines?
30. What is Automatic Loading device and what is its purpose?
31. How will you proceed to ‘set up’ a machine before staring the Operation?
32. Why Lubrication and Cooling is done?
1.1. Unit – III - shaping ,slotting and planning machines
UNIT SYLLABUS
SHAPING, SLOTTING AND PLANNING MACHINES: Principles of working – principal parts –
specifications, operations performed, machining time calculations.
DRILLING & BORING MACHINES: Principles of working ,specifications, types, operations performed – tool
holding devices – twist drill– Boring Machines – fine Boring Machines – jig boring machine, deep hole Drilling
Machine

- Principles of shaping, slotting and planning machines and principal parts, specifica-
tions.
- Tool and work holding devices and operations performed
- Machining time calculations
- Principles and types of drilling and boring machines
- Twist drill nomenclature
- Details of jig boring machine and deep hole drilling machine
- List out various principal parts of shaper, slotter and planner
- Give an outline of planner machine
- Explain the working of a hydraulic quick return motion mechanism of a shaper
- Give an expression for calculating the cutting speed of shaper and planner machine
- Explain the nomenclature of twist drill with neat sketch
- List out specifications of shaper and planner
- Give an outline of deep hole drilling machine and jig boring machine
Lecture no. Topic Methodology Quick reference

1 Principles of working- Principle Chalk and board Concern material
parts- Specification
2 Operations performed Chalk and board ,OHP sheets
3 Machining Time calculations, Chalk and board
Problems.
4 Drilling and Boring Machines- Chalk and board
Introduction
5 Principles of Working of Drilling Chalk and board
and Boring.
6 Types and Operations Performed. PPT
7 Tool handling devices PPT
8 Twist drills, Boring Machines, Fine Chalk and board
Boring
9 Jig boring machine,Deep hole Chalk and board
drilling machine
10 Revision Chalk and board
1.1.4.1. Lecture-1
Examples include (Repeat the below for all lectures)
 Provide Seminar details (Title, mode of student participa-

tion, duration, outcomes)
 Add a snapshot of models used
 Any other innovative teaching methodologies
 Include case study if applicable
 Any internet links / video lecture links relevant to the lec-

ture
 Any other relevant material / links / journal publications /

videos / experiments etc.
1. maximum size of a block can be machined by a shaping
machine________________
2. ________________maximum size of a block can be machined by a planing ma-
chine.
3. ___________is a process of removing materials in the form of chips from a
work piece by mechanical action of many small abrasive particles bonded to-
gether in a wheel.
4. The boring machine is one of the most _________________ machine tools.
5. Vertical boring machine is similar in job tool motion as in
vertical_________________
6. Dd
7. Dd
8. Dd
9. Dd
10. dd
1. Reciprocation type of machine tools intended primarily to reduce hodizontal,
vertical or Inclined Flat surfaces (Ans:A)
A. Shaper B. Planner C. Slotter D. Grinder
2. Flat thin work piece is held on a planner by (Ans:C)
A.Magnetic Chucks B. V-Blocks C. Toe dogs and Stops D. V-Blocks, Clamps
and T-Bolts
3. The Tool in a ____________ removes metal during it’s vertical cutting stroke
(Ans:D)
A.Grinder B. Shaper C.Planner D.Slotter
4. Gear Shaping is related to (Ans: B)
A. Form tooth process B. Hob
C. Templates D. None of the above
5. Soda water is used as lubricant for drilling (Ans:D)
A.Brass B. Bronge C. Cast Iron D. Malleable carbon
6. Operation of forming internal threads is known as (Ans:B)
A.Reaming B. Tapping C. Knurling D. Spot facing
7. The relation between Torque, Diameter of Drill and Feed is given by(Ans:A)
A.T=C*f0.75*d1.8 B.T=C*f1.8*d0.75 C. T=C*f0.5*d2.5 D. T=C*f2.5*d0.25
8. Select the machine in which three surfaces can be machined at a time
9. (i) Open housing planer (ii) Double housing planer (iii) Pit planer (iv) Edge or
plate planer.
10. In an universal planer metal is removed during
(i) Forward strokes (ii) Return strokes (iii) Both forward and Return strokes (iv)
None of the above
c. True or False questions <Minimum of ten>

1. In selecting grade, harder wheel is used for softer materials.(T)
2. Centre less grinder is suitable for production purpose.(F)
3. A grinding wheel is designated or specified by a line with letters and figures
which show the characteristics of a wheel.(T)
4. Boring Machine is designed for machining of large and heavy work pieces in
mass production work of machine frame, cylinder machine housing etc.(F)
5. Horizontal Boring machine requires less floor space than vertical boring ma-
chine.(F)
6.

d. Objective type of questions(Very short notes) <Minimum of ten>
1. Discuss the working principle and operation of a slotter?

2. Discuss the working principle and operation of a shaper?
3. How is metal removal rate in a shaping machine calculated?
4. How is the size of a planer specified?
5. Mention different operations performed on slotter machine?
6. What is planer? Illustrate and describe its working principle?
7. How do you specify a drilling machine?
8. What is tap? How the taps are classified?
9. Write short notes on elements of vertical boring machine.
10. How do you specify a radial drilling machine?
e. Analytical type questions <Minimum of ten>
1. A 40mm HSS drill is used to drill a hole in C.I block 80mm thick. Determine the time re-
quired to drill the hole if feed is 0.2mm/rev. Assume an over travel of drill as 5mm. The cut-
ting speed is 22m/min.
f. Essay type Questions <As per requirements>
1. Draw the block diagram of a slotting machine and explain briefly its principal parts.
2. Explain briefly “Twist drill nomenclature” with neat sketches.
3. Explain briefly a Jig boring machine with a neat sketch.
4. Explain briefly the deep hole drilling machine.
5. Mention some differences between slotting and shaping machines.
6. Classify drilling machines with neat sketch.
7. Explain different work holding and tool holding devices.
8. Explain different operations performed on shaping machine with neat sketch.
9. Explain clearly with a neat sketch the construction of a horizontal boring machine.
g. Problems <As per required Number>
1. Calculate the machining time required for machining a surface 600mm x 800 mm on a shap-
ing machine. Assume cutting speed as 8m/min. The return to cutting time ratio is 1:4 and
feed is 2mm/double stroke. The clearance at each end is 70mm.
2. Calculate the power required to drill 25mm diameter hole in Al plate at a feed of 0.2mm/rev
and at a drill speed 400 rpm. Determine also the volume of metal removed per unit energies.
3. Calculate the machining time required for making 18 holes on M.S plate of 20mm thickness
with the data: Drill diameter =30mm, Cutting speed=25m/min and Feed=0.15mm/rev.
h. Case study <As per required Number>

-Prepare a model of a shaft with keyways
-Prepare a report on shaper, planner and slotting machines regarding sizes,

specifications and different operations performed
- Trace different angles in twist drill bit

1. Discuss the nomenclature of a twist drill
2. Explain clearly what is meant by jig boring?
3. Classify planers with neat sketch?
4. Explain the mechanism behind the working of a shaper in detail
5. Describe the different types of slotters
6. Differentiate among shaping, planning and slotting machines with respect to

their features, applications and working.
7. With the help of block diagram, explain the principle parts of a double hous-
ing planer.
S.No. Question(Answer)
Yr. of
GATE
question
appeared
1.

round - Placements)
1. What is the working principle of shaper?
2. Differentiate between shaper and planer machines?
3. Define flute?
4. How you specify planer machine?
5. What is the maximum length of work piece in shaper machine?

1. Shafts with key slots
2. Holes on surfaces of objects
3. Horizontal surfaces long length objects

the campus)
NOT REQUIRED

videos etc.
1. http://www.nptel.ac.in/courses/112105127/pdf/LM-22.pdf -
complete unit pdf from nptel
2. https://www.youtube.com/watch?v=X_BofN7_gsw -shaping
operation
3. https://www.youtube.com/watch?v=36davgmq2Kg - slotting op-

eration
4. https://www.youtube.com/watch?v=G0fsXxAAsD8 - planer op-

eration
Reference Text Books / with Journals Chapters etc.

Textbooks:
2. Workshop Technology – B.S.Raghuwanshi – Vol II
REFERENCES:
1. Metal cutting Principles by M.C. Shaw

2. Metal cutting and machine tools by Boothroyd
4. Production Engineering, K.C Jain & A.K Chitaley, PHI Publishers
5 a) Explain briefly the following with neat sketches:

(i) Straddle milling (ii) Dove-tail milling.
b) Discuss briefly the vertical milling machine.
5 a) Describe schematic diagram of universal milling machine.

b) Determine the indexing crank movement for milling square bolt by simple
Indexing.
5 a) Discuss the differential indexing method with a neat sketch.

b) Explain briefly the following with neat sketches:
(i) Form milling (ii) Gang milling.
5 a) What are the types of cutters? Explain.

b) Draw the block diagram of a horizontal milling machine and explain briefly its
various parts.
6 a) Explain briefly the lapping process. Give the examples of lapping work.
b) Discuss briefly the following: (i) Mounting of wheels (ii) Wheel truing.
6 a) Explain the process of precision grinding with a neat sketch. [8M]

b) What are the various methods of centreless grinding? Explain.
5. Unit-wise course material
5.1. Unit – IV- milling machines
UNIT SYLLABUS
MILLING MACHINES: Principles of working – specifications – classification of Milling
Machines – Principle features of horizontal, vertical and universal Milling Machine, machining
operations, types of cutters, geometry of milling cutters – methods of indexing, accessories to
milling machines.

- Working principle of milling machine
- Methods of indexing mechanism
- classification
- operations done on milling machine
- geometry of milling cutter

- apply indexing mechanism for manufacturing of gears on milling machine
- Nomenclature of milling cutter
- Classification of milling machines

Lecture
Topic Methodology Quick reference
no.
Principles of working – Specifications
1 Chalk and Board
– Classifications.
2 Principle features of Horizontal, Chalk and Concern material
Vertical and Universal Milling
Board ,OHP sheets
Machine.
3 Machining Operations Chalk and Board book
Types of Cutters CH-4,pg.no.
book
Geometry of Milling Cutters CH-4,pg.no.-
Chalk and
5 B.S Raghuwanshi txt.
Board,PPT
book
6 Methods of Indexing Chalk and Board Concern material
Methods of Indexing CH-4,pg.no.-
book
Methods of Indexing, problems CH-4,pg.no.-
book
CH-4,pg.no.-
Accessories to milling machines(work Chalk and
9 B.S Raghuwanshi txt.
and tool holding devices) Board,PPT
book
10 Revision Chalk and Board Concern material
Teaching material of each topic

6. Reference text books/web material etc.,
<Please provide a detailed list of textbooks and reference materials relevant for the entire
subject. Note: Please do not copy all the lecture level references. You are requested to
avoid any references which may only be relevant to 1 or 2 lectures>
Textbooks:
1.Production Technology by R.K. Jain and S.C. Gupta.
2. Workshop Technology – B.S.Raghu Vamshi – Vol II
REFERENCES:
2. Metal cutting Principles by M.C. Shaw
2. Metal cutting and machine tools by Boothroyd
4. Production Engineering, K.C Jain & A.K Chitaley, PHI Publishers
Web-links (including videos):
1.http://www.nptel.ac.in/downloads/112105127/#
2.
Please add if you have more…
Reference Journals:
1.
2.
Please add if you have more…

7. Mid Question Paper + Schemes of Evaluation.
<Please include at least three mid 1 and three mid 2 papers with scheme of evaluation for
each of them. Note: All of the papers are to be included here in this section as softcopy.
Please do not attach scanned hardcopies at the end.>
MID – I EXAMINATION
Subject: METAL CUTTING AND MACHINE TOOLS
EACH QUESTION CARRIES 5Marks
1) Explain single point cutting tool nomenclature with a neat sketch .

Scheme: Cutting tool figure-2m, Nomenclature (Minimum 5 parts definitions) -3m
2) Explain the working principle and description of lathe with neat sketch and types of lathes?
Scheme: Working principle -2m, Lathe sketch and parts-1m, Types of lathes-2m
3) Draw the schematic diagram of shaper and explain different operations performed on shaped with neat sketch.
Scheme: Shaper sketch with parts-2m, Operations (minimum of 3 operations with sketch) -3m
1. What is mechanics of metal cutting and explain merchants force diagram and establish relation between
cutting forces and shear forces.
Scheme: Merchants circle diagram-3m, Force equations-2m
2. a) Explain turret and capstan lathes
Scheme: Types of lathes with sketches-5m (minimum of 3 types)
b) List out various attachments of lathe
Scheme- Various attachments with sketch -5m (Minimum of 3 types)
3. a) Draw the schematic diagram of a slotter machine
Scheme: slotter machine sketch with parts -5m
b) Differentiate between shaper, slotter and planer machines
Scheme: Differences between 3 machines -5m (at least 5 differences)
1. What are the various cutting fluids? Explain.

Scheme: Different cutting fluids-5m
2. What are the different types of taper turning methods? Explain them with neat sketch?
Scheme: Each type with figure carries 2m
3. Draw the block diagram of a jig boring machine and discuss the functions of various elements of it.
Scheme: line diagram-2m, Functions-3m
MID – II EXAMINATION
1) Describe the various operations that can be performed on a milling machine with neat sketch.
Scheme: Operations with neat sketch 1m (5 operations to be performed)
2) Write the advantages and limitations of center less grinding machine.
Scheme: Advantages-2m, Limitations-3m
3) (a) What are the applications of CNC machines and explain the constructional features of CNC machine?
Scheme: applications-1m , Features-1m
(b)Explain the working principle of CNC machine and classify them?
Scheme: Working principle-1m, Classification-2m
1) Explain with help of line diagram, the construction and working principle of vertical milling machine
Scheme: block diagram-2m,construction and working principle-3m
2) Specify the grinding wheel with example and explain the factors for selection of grinding wheel.
Scheme: specifications-3m,factors for selection-2m
3) (a) What are the different types of motion controls in CNC machines?
Scheme: types of motion-3m
(b) Explain about the function of CNC controller?
Scheme: functions-2m
1) Explain the work holding and tool holding devices in milling along with neat diagrams.
Scheme: work holding devices-3m,tool holding devices-2m
2) Explain the following with neat drawing
a .Lapping, b. Honing, c. Broaching
Scheme: definition with diagram each 2m
3) (a)Distinguish between jigs and fixtures with diagrams and give typical examples?
Scheme: differences -3m (minimum 4 points)
(b)What are the safety factors related to design of jigs and fixtures?
Scheme: design factors-2m (minimum 4 points)
8. Fast track material for Back-Log students.
Please include the following:
 A quick reference document (a maximum of 4 pages) to study the basic concepts

related to the subject
 A minimum of 3 unique question papers with 8 questions each along with detailed
solutions. These question papers need NOT have complex questions. The idea is to
make the student clear the exam. Hence, please include only basic and average
complexity questions after studying which a student can clear the exam
 Each student is expected to write each of the papers a minimum of 10 times
 Please include all the papers (softcopies) and solutions in this section. Please do
NOT attach handwritten sheets at the end.
9. Sample Question Papers with solutions (Minimum 3)
 A minimum of 3 unique question papers with 8 questions each along with detailed
solutions. These question papers should follow bloom’s taxonomy. They should also
include basic, average and complex questions so that all the students including the
toppers get benefitted by practicing with these papers. The basic objective is to help
students get top marks so that they can end up in merit list!
10. Virtual Labs if required
 Please provide the details of any virtual labs if applicable. Please provide the links to
the videos etc. Please do NOT embed videos as it will increase the size of the
documents.
Not Required
11. Mapping of Assignments / Question Papers with course objective
learning outcomes.
Course Assignment 1 Assignment 2 Assignment 3 Assignment 4 Assignment 5

objective
Yes / No Yes / No Yes / No Yes / No Yes / No

L AAAAA
P
e Y
s Y
s Y
s Y
s Y
s
Yes / No Yes / No Yes / No Yes / No Yes / No
P
l Y
e e e e Y
Y Y Y e
S
l e e e e e
o
12. Bloom’s Taxonomy checklist
Bloom's Digital Taxonomy Checklist

Check the skills that apply to determine the level at which the student is working
Remembering Understanding Applying Analyzing Evaluating Creating

bookmarking comparing building classifying appraising animating
choosing diagramming constructing dissecting blogging constructing
defining explaining developing distinguishing critiquing designing
finding interpreting editing examining defending developing
labeling outlining experimenting with inspecting disproving elaborating
listing relating modeling linking influencing imagining
matching summarizing playing mashing interpreting inventing
recalling tagging solving simplifying measuring publishing

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COURSE FILE

Metal Cutting and Machine Tools

III B. Tech – I SEMESTER

S.NO. Content Page No.

1 Course Objectives & Outcomes

4 Unit wise course Material (As per given format)

Unit-I: Fundamentals of Machining

Unit-II: Lathe Machines

Unit-III: Shaping, Slotting and Planning Machines

Unit-IV: Milling Machines

Unit-V: Finishing processes

Unit-VI: Jigs and Fixtures

5 Reference text books/web material etc.,

6 Mid Question Paper + Schemes of Evaluation.

7 Fast track material for Back-Log students.

8 Sample Question Papers with solutions

9 Virtual Labs if required

The objectives of the course are:

1. The course provides students with fundamental knowledge and principles in

3. To demonstrate the fundamentals of machining processes and machine tools.

4. To develop knowledge and importance of metal cutting parameters.

5. To develop fundamental knowledge on tool materials, cutting fluids and tool

6. To apply knowledge of basic mathematics to calculate the machining

1.2. Course Outcomes

After completing this Course, the student should be able to:

2) Operate lathe, milling machines, drill press, grinding machines, etc.

4) Select appropriate machining processes and conditions for different metals.

5) Learn machine tool structures and machining economics.

6) Write simple CNC programs and conduct CNC machining.

CNC MACHINE TOOLS: CNC Machines, working principle, classification,

12 Lathe introduction-Engine lathe

21 Principles of working- Principle parts- Specification

31 Principles of working – Specifications – Classifications.

46 Introduction- Principles of Design of Jigs and Fixtures-

4.1.1. Unit Objectives:

- Metal Cutting and Theory of Machining

- Types of machining process

- How to calculate machining forces

- Relation between cutting forces

- How to calculate tool life

4.1.2. Unit Outcomes:

- Apply tool life relation equation based on mechanics of metal cutting.

- Nomenclature of single point cutting tool

4.1.4. Teaching Material / Teaching Aids as per above lecture plan.

 Include / Attach PPT / Handout (typed)

Basic Elements of Machining:-

The basic elements of all machining operations are,

Methods of Metal Cutting:-

Tool Signature: - After tool Nomenclature and geometry

Nomenclature and Geometry of Single Point tools:-

Which are shown in the following figures,

 Add a snapshot of models used

 Include / Attach PPT / Handout (typed)

1.Bake rake angle(80)

2.Side rake angle(140)

3.End relief angle(60)

4.Side relief angle(60)

5.End cutting edge(60)

6.Side cutting edge angle (150)

7.Nose radius (4 mm)

It consists of two system named as follows

i. Material of the tool holder i. Back rake angle(αb)

ii. Diameter of the tool holder ii. Side rake angle(αs)