Machine Tools and Machining (ME 30604); Spring Semester 2023

Name of the text book:

1. Machining and Machine Tool, A. B. Chattopadhyay, Willey India, 2011, 1st edition,
ISBN no: 978-81-265-3098-4
2. Machining and Machine Tool, A. B. Chattopadhyay, Willey, 2017, 2nd edition, ISBN
no: 978-81-265-6474-3

Both the chapter and in many places the article number of interest has been included for the
benefit of the students. Articles/ chapter for self study have been separately indicated. It may
be noted that while this course includes but is not limited to the following.

Introduction 1

Both 1st edition and 2nd edition: Chapter 1

• What is manufacturing?
• Classification of manufacturing
• What is machining?
• Process parameters
• Material Removal rate (MRR)
• Constraints in machining.

Introduction 2

1st edition: Chapter 11, Chapter 18+19+20 (Self-study) and 21.1+21.2+21.3.1

2nd edition: Chapter 11, Chapter 19+20 (Self-study) and 21.1+21.2+21.3.1

• Classification of lathe (self study)

• Primary idea about lathe, milling and shaping
• External features and kinematic chain of a lathe
• Gear boxes – speed gear box and feed gear box
• Norton Cone and Meander Drive (only characteristics)
• Apron – sliding apron and swivelling apron, and apron constant,
• Work holding in lathes
• Machining operations using lathe
• Basics of longitudinal feed, cross feed and thread cutting

1
Tool geometry

Both 1st and 2nd edition: Articles 2.1 + 2.2+ 2.3 (till page 41) + 2.4 (till page 58) + 2.4.1.2

• Single point turning tool

• All axes
• Tool in hand nomenclature
• ASA and ORS systems
• Master line
• MRS system
• Conversion of angles from one system to other
• Inclination angle of the auxiliary cutting edge
• WRS (Tool in Use) systems
• Primary idea of straight fluted and helical fluted slab milling cutter and drill
geometry.

Chip formation

Both 1st edition and 2nd edition: Articles 3.1 + 3.2 + 3.3 + 3.4 + 3.4.1 – 3.4.6 + 3.4.7.1. +
3.4.7.2 (1st para) + 3.4.7.3 + 3.4.8 + 3.6

• Schematic
• Depiction of s, t, a1, a2, b1, b2, Vc, Vf
• 3D depiction &3D pipe turning depiction
• 2D special case ø = 90°
• Definition and schematic for ζ
• Cutting ratio =1/ ζ
• Piispanen model
• Why does chip thicken?
• Relation between β, γo and ζ
• Kronenberg’s model
• Velocity triangle
• Cutting strain
• Strain rate
• Effect of Vc and S on ζ
• BUE; effect of γo on ζ
• Chip deviation – λ, nose radius and restricted cutting effect
• Orthogonal machining
• Pure orthogonal machining
• Derivations of chip deviation
• Concept of effective rake
• Chip formation in slab milling
• Contact length- Abuladze’s model
• Chip formation in brittle material
• Irregular chips
• Segmented chips in high speed machining, and certain work materials
Cutting forces

2
Both 1st edition and 2nd edition: Articles 4.1 + 4.2 + 4.3 + 4.6 + 4.7 + 4.8 + 4.8.1 + {4.8.2
(self-study)}

• Cutting force components

• Power estimation
• Merchant’s Circle Diagram
• Angle relationships
• Specific cutting energy
• Significance of cutting force components
• Primary idea of forces in drilling and milling
• Measurements (self study)

Cutting temperature

Both 1st edition and 2nd edition: Articles 5.1 + 5.2 + 5.3 + 5.4.1 + 5.4.2.2 + 5.4.2.3 + 5.4.3
+ 5.4.4 + {5.5 (self-study)}

• Heat sources in machining

• Power calculation
• Temperature calculations (mainly shear plane temperature)
• Effect of process parameters on cutting temperature
• Control of temperature
• Temperature measurement

Tool Wear, Tool Life & Tool Materials

Both 1st edition and 2nd edition: Articles 6.1 + 6.2 + 6.3 + 6.4 + {6.5 (self-study)} + for
machinability 8.1 + 8.2.1 + {8.2.2 (self-study)}

• Tool wear types

• Tool wear mechanism
• Role of parameters
• Tool life test
• Taylor’s primary and modified equation
• Tool materials
• Machinability

Machining Time and Machining Economics

Both 1st edition and 2nd edition: Articles 7.1 + 7.2 + 7.3 + 7.4.1 + 7.4.2 + 7.4.3 + 7.4.4

• Machining time tm, and cycle time tc

distance travelled
• tm =
feed rate
Volume of material removed
• tm =
mrr
distance
• tm = 
feed rate

3
 • Calculation for straight turning,
• Taper turning (CNC and centre Lathe)
• Facing (in CNC and centre Lathe)
• Drilling, side and face milling, face milling, end milling,
• Machining cost per piece calculation

Surface roughness (self study; to be dealt in the lab course)

Both 1st edition and 2nd edition: Articles 8.6.1 + 8.6.2 + 8.6.3 + 8.6.4 + 8.6.5 + 8.6.6

Machine Tools

Both 1st and 2nd edition: Articles 15.1 + 15.2 + 15.3 + 21.3.2 (drilling) + 21.3.4 (milling)

• Speed change mechanisms

• Norton and Meander drives
• thread cutting
• kinematic schemes of drilling and milling