ME2007 MT Module-1 Lectures 1-10

Manufacturing Technology
Dr. R. Seetharam
Assistant Professor
Department of Mechanical Engineering
IIITDM Jabalpur
Dr. R. Seetharam
ME6: Manufacturing Technology
Units: Lecture: 3 Tutorial: 0 Lab: 1 Credit: 4
Evaluation Scheme: Quiz-1 (10%), MID-30%, Quiz-2 (10%), END-30%, Lab Quiz (20%)
Module 1: Machining and Mechanics of Metal Cutting: Introduction to orthogonal & oblique cutting;
Chip information mechanism; heat generation and cutting tool temperature, tool geometry – ASA, ORS, NRS
and relationships, selection of tool angles. Cutting tool material; tool wear; tool life and machinability;
surface finish; cutting fluids. Merchant’s circle diagram, coefficient of friction, stress, strain and strain rate,
shear angle. Lee and Shaffer’s Relationship: Friction in Metal cutting-sticking & sliding.
Module 2: Material Removal Processes: Basic operations of turning, shaping, slotting and planning,
drilling and boring, milling. Introduction multipoint cutting tools; twist drill, helical milling cutter. Practical
machining operations with machining parameters, force magnitudes, power consumption, material removal
rate, time per pass. Cutting Force Measurement: Basic methods of measurement, axially loaded members,
cantilever beam, rings and octagon, dynamometer requirements machine tool dynamometers
Module 3: Economics of Machining: Cutting parameters for minimum production cost criteria; maximum
production and profit rate criterion. Restrictions on cutting conditions (power, speed, force and vibration,
surface finish).
Module 4: Metal Forming: Plasticity: Introduction to stress, strain, stress-strain relationships, Mechanics of
Forming Processes: Rolling, Forging, Drawing, Deep Drawing Extrusion, Punching and Blanking
Module 5: Casting: Design of riser, runner and gating system, mechanism and analysis of solidification
Text/Reference books:
1. M.C. Shaw, Metal Cutting Principles, 2nd Edition Oxford University Press, England 2005.
2. A. Ghosh and A.K. Malik, Manufacturing Science. Affiliated East West press 1985.
3. Mikel P. Groover, “Fundamentals of Modern Manufacturing”, John Wiley & Sons inc
Dr. R. Seetharam
Introduction to Manufacturing Processes
 Definition of Manufacturing
 The word manufacturing is derived from Latin:
 manus = hand, factus = made
 Manufacturing is the economic term for making goods and services available to
satisfy human wants.
 Manufacturing implies creating value to a raw material by applying useful mental

and physical labour.
 The materials are then shaped and formed into different useful components through
different manufacturing processes to fulfil the needs of day-to-day work.
 Manufacturing converts the raw materials to finished products to be used for some
purpose. Dr. R. Seetharam
Manufacturing system:
• A collection of operations and processes used to obtain a desired product(s) or
component(s) is called a manufacturing system.
• The manufacturing system is therefore the design or arrangement of the
manufacturing processes..
Production system:
• A production system includes people, money, equipment, materials and supplies,
markets, management and the manufacturing system.
Dr. R. Seetharam
Production System
Manufacturing System
People, Money, Equipment, Materials and Supplies, Markets, Management

CLASSIFICATION OF MANUFACTURING PROCESSES
Manufacturing processes can be grouped as:

 Casting, foundry or moulding processes.
 Forming or metal working processes.
 Machining/Metal cutting (metal removal) processes
 Joining and assembly
 Surface treatments (finishing).
 Heat treating
Dr. R. Seetharam
CLASSIFICATION OF MANUFACTURING PROCESSES
Manufacturing processes can be grouped as:

 Casting, foundry or moulding processes.
 Forming or metal working processes.
 Machining/Metal cutting (metal removal) processes.
 Joining and assembly
 Surface treatments (finishing).
 Heat treating
Dr. R. Seetharam
Organization of Unit-1
Machining and Mechanics of Metal Cutting:
 Introduction to orthogonal & oblique cutting;

 Chip information mechanism;
 heat generation and cutting tool temperature,
 tool geometry – ASA, ORS, NRS and relationships, selection of tool angles.
 Cutting tool material; tool wear; tool life and machinability; surface finish;
cutting fluids.
 Merchant’s circle diagram, coefficient of friction, stress, strain and strain rate,
shear angle. Leee and Shaffer’s Relationship: Friction in Metal cutting-sticking
& sliding.
Dr. R. Seetharam
MATERIAL REMOVAL PROCESSES
MRPs
Traditional Advanced
Cutting Finishing
Circular Shape
Other/Prismatic Loose
Bonded
Shape Abrasive Abrasive
• Turning
• Drilling • Milling • Grinding
• Planning • Lapping
• Boring • Honing
• Shaping • Polishing
• Coated Abrasive
• Gear Cutting
• Broaching
Dr. R. Seetharam
NATURE OF RELATIVE MOTION BETWEEN THE
TOOL AND WORKPIECE
Dr. R. Seetharam
OPERATION MOTION MOTION OF FIGURE OF
OF JOB CUTTING OPEARTION
TOOL
Translatory
TURNING Rotary
(Forward)
Translation
BORING Rotation
(Forward)
Rotation As Well
Fixed (No
DRILLING As Translatory
Motion)
Feed
Dr. R. Seetharam
PLANING/ Intermittent
Translatory
Shaping Translation
MILLING Translatory Rotation
Rotary /
GRINDING Rotary
Translatory
WHAT IS THE BASIC DIFFERENCE BETWEEN ?
TURNING DRILLING  Single vs Multi point

BORING AND MILLING  Continuous and Intermittent
PLANING GRINDING
Dr. R. Seetharam
Work Material
Cutting Tool M/C Tool Product
Machining
Conditions
Dr. R. Seetharam
Metal Cutting/Machining
 It is the process of producing a workpiece by removing unwanted material from a

block (Raw) of metal, in the former Chips
 Metal Cutting Plastic

Deformation/Flow Process
 Forces induced during machining

 Temperature induced in the machining
 Tool life
 Power consumption
Dr. R. Seetharam
Classification of Cutting
Orthogonal Cutting Oblique Cutting
Dr. R. Seetharam
Dr. R. Seetharam
Dr. R. Seetharam
Difference between Orthogonal and Oblique Cutting
The cutting edge of the tool is perpendicular to The cutting edge of the tool is not perpendicular
the direction of the feed motion to the direction of the feed motion
The chip flow is expected to in a direction The chip flow angle is more than zero
perpendicular to the cutting edge
In orthogonal cutting, there are only two In oblique cutting, three components of force are
components of force which are mutually considered, that is thrust force, radial force
perpendicular. The components include: cutting and cutting force. (3D Cutting)
force and thrust force
(2D Cutting)
In this cutting, chip flow over the tool. In this cutting, chip flow along the sideways
Heat generation between tool and W/P is high Heat generation between tool and W/P is less
Life of the tool is less Life of the tool is high
Used in grooving, parting, slotting, pipe Used almost in all industrial cutting, used in
cutting etc.. drilling, grinding, milling etc
Dr. R. Seetharam
Mechanism of chip formation
 Machining processes remove material from the work piece surface by producing
chips
Dr. R. Seetharam
 The basic mechanics of chip formation, which is essentially the same for all cutting
operations is represented by two-dimensional model
Dr. R. Seetharam
Assumptions in orthogonal metal cutting
 No contact at the flank i.e. the tool is perfectly sharp.
 Width of the chips remains constant
 Uniform cutting velocity
 Chip does not flow to either side
 The stresses on the shear plane is uniformly distributed
Dr. R. Seetharam
 As
Asthe
thetool
tool is forced
is forced into into the material,
the material, the chipthe chip is
is formed byformed by shear
shear deformation
deformation along a plane called the shear plane
along a plane called the shear plane
 The angle made by shear plane with the surface of the work- shear angle (ᶲ)
Dr. R. Seetharam
Chip Thickness Ratio
where r = chip thickness ratio; to = Uncut thickness of the chip; and
tc = chip thickness after separation
to
r 
tc
 Index- the amount of plastic

deformation
Note: Chip thickness after cut always greater than before, so chip ratio
always less than 1.0
Dr. R. Seetharam
Determining Shear Plane Angle (ᶲ)
=
ls
𝑟𝑐𝑜𝑠 ∅𝑐𝑜𝑠 𝛼+𝑟𝑠𝑖𝑛 ∅𝑠𝑖𝑛 𝛼=𝑠𝑖𝑛 ∅
(90- Ф+ )
 Where r =Dr.
chip ratio, = rake angle and Ф =Shear angle
R. Seetharam
Determining Shear Plane Angle (ᶲ)
ls
Shear angle Ф = f(r, α)
 If chip thickness ratio increases then Ф increases
 If Rake angle (α) increases then Ф increases
Note: As the shear angle increases the length of shear plane reduces, hence the shear plane area
reduces and therefore for a fixed shear strength the force required for producing required shear
stress will be less. due to this it is desirable to have higher angle shear angle
Dr. R. Seetharam
Numarical-1
In orthogonal turning of low carbon steel bar of diameter 150 mm with uncoated carbide tool,
the cutting velocity is 90 m/min. the feed is 0.24 mm/rev and the depth of cut is 2 mm. The chip
thickness obtained is 0.48 mm. If the orthogonal rake angle is zero, what is the thickness ratio
and shear angle.
Sol. 0.24
𝑟= = 0.5
D= 150 mm, 0.48
V=90 m/min,
f= 0.24 mm/rev =to,
tc = 0.48
α= 0
Dr. R. Seetharam
Shear Strain in chip formation
 Shear strain in machining can be computed from the following equation, based on the
preceding parallel plate model:
𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛𝑜𝑓 𝑡h𝑒 𝑐h𝑖𝑝

𝑆h𝑒𝑎𝑟 𝑠𝑡𝑟𝑎𝑖𝑛(γ )=
𝐿𝑒𝑛𝑔𝑡h ( 𝐶h𝑖𝑝 𝑡h𝑖𝑐𝑘𝑛𝑒𝑠𝑠)
𝐴𝐶
γ=
𝐷𝐵
𝐴𝐷 + 𝐷𝐶
γ=
𝐷𝐵
𝐴𝐷 𝐷𝐶
γ= +
𝐷𝐵 𝐷𝐵
(a) chip formation depicted as a series of parallel plates sliding relative to each other, (b) one of the
plates isolated toDr.
show shear strain, and (c) shear strain triangle used to derive strain equation.
R. Seetharam
Shear Strain in chip formation
 Shear strain in machining can be computed from the following equation, based on the
preceding parallel plate model:
𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛𝑜𝑓 𝑡h𝑒 𝑐h𝑖𝑝

𝑆h𝑒𝑎𝑟 𝑠𝑡𝑟𝑎𝑖𝑛(γ )=
𝐿𝑒𝑛𝑔𝑡h ( 𝐶h𝑖𝑝 𝑡h𝑖𝑐𝑘𝑛𝑒𝑠𝑠)
𝐴𝐶 tan (90-ϕ) = Cotϕ
γ= α
𝐷𝐵
𝐴𝐷 + 𝐷𝐶 (90- Ф) tan (ϕ-α)

γ=
𝐷𝐵
𝐴𝐷 𝐷𝐶
γ= +
𝐷𝐵 𝐷𝐵
φ
)+ (90- Ф+ )
Dr. R. Seetharam
Velocity Relationship
Vf
α
Vs
ϕ
Vc
Cutting Velocity (Vc): is the speed of the tool relative to the work
Chip Flow velocity (Vf): Represents the speed of the chip relative to the cutting tool and directed
along the tool face.
Shear Velocity (Vs): represents the speed of the chip relative to the work piece and directed
along the shear plane.
Dr. R. Seetharam
Velocity Relationship
(90- ϕ+α)
f
V
α
Vs
ϕ
Vc
(90-α)
Using the sign rules:
𝑉𝑐 𝑉𝑠 𝑉 𝑓
=¿ =¿
𝑆𝑖𝑛( 90 − ∅+𝛼) 𝑆𝑖𝑛(90 −𝛼) 𝑆𝑖𝑛 ∅
𝑉𝑐 𝑉𝑠 𝑉 𝑓
=¿ =¿
𝐶𝑜𝑠(∅ −𝛼 ) 𝐶𝑜𝑠 𝛼𝑆𝑖𝑛 ∅
Dr. R. Seetharam
Chip formation
 Mechanics of metal cutting is greatly depend on the shape and size of
the chips formed.
More realistic view of chip formation, showing shear zone rather than shear plane. Also
shown is the secondary shear zone resulting from tool-chip friction.
Dr. R. Seetharam
Four Basic Type of Chips in Machining are
a) Discontinuous chip
b) Continuous chip
c) Continuous chip with Built-up Edge (BUE)
d) Serrated chip
Dr. R. Seetharam
Discontinuous chip
 When brittle materials like cast iron are cut, the deformed material gets
fractured very easily and thus the Chip produced is in the form of
discontinuous segments
Reasons
 Brittle work materials
 Low cutting speeds
 Large feed and depth of cut
 High tool-chip friction
Dr. R. Seetharam
Continuous chip
 Continuous chips are normally produced when machining steel or ductile
materials at high cutting speeds. The continuous chip which is like a ribbon
flows along the rake face.
Reasons
 Ductile work materials
 High cutting speeds
 Small feeds and depths
 Sharp cutting edge
 Low tool-chip friction
Dr. R. Seetharam
Continuous chip with Built-up Edge (BUE)
 When the friction between tool and chip is high while machining ductile
materials, some particles of chip adhere to the tool rake face near the tool tip.
When such sizeable material piles upon the rake face, it acts as a cutting edge in
place of the actual cutting edge is termed as built up edge (BUE). By virtue of
work hardening, BUE is harder than the parent work material
Reasons
 Ductile materials
 Low-to-medium cutting speeds
 Tool-chip friction causes portions of
chip to adhere to rake face
 BUE forms, then breaks off, cyclically
Dr. R. Seetharam
Serrated chip
• Semi Continuous (saw tooth appearance) chips produced when machining
tool steels or Harden materials at high cutting speeds.
Reasons
 Difficult-to-machine metals such as
titanium alloys, nickel-base and
superalloys
 High cutting speeds
Dr. R. Seetharam
Heat generation during machining operation
Zones of Heat Generation
Chip-Tool Interface
Shear Zone
Work
Tool-Work Interface
Dr. R. Seetharam
Zones of Heat Generation

18% of Energy is
converted to heat
Secondary Heat Zone

Primary Heat Zone
80% Energy is
converted to heat
Work 2% of Energy is
converted to heat
Tertiary Heat Zone
Dr. R. Seetharam
Shear Zone:
 The maximum heat is generated in this zone due to the shearing of the metal
 The major heat is generated in this zone is carried away by the chip and remaining (less than
10%) is taken by work piece.
Friction Zone: (Chip-tool interface)

 In this zone as the chip moves upwards along the tool face, a good amount of heat generated
due to friction at the chip tool interface, which further rises the temperature of chip
 A part of the heat generated in the zones goes to the tool
Work-tool Interface:
 Due to friction between work and tool, the heat is generated. This heat is carried away
partially by the tool and partially workpiece.
 Heat distribution between chip, work and tool are 75% 20% and 5% respectively
Dr. R. Seetharam
Cutting Tool Temperature
 From the figure all the three heat zones are meeting at one point known as tip of tool. The tip of tool
may experience very high temperature. When the temperature of tip of tool goes behind hot
hardness temperature of the tool material then the tool tip is losing hardness considerably.
 The tip of the tool may deform plastically and it can’t perform the machining operation properly.
 To avoid the plastic deformation failure of the tool, it is required to measure the temperature of
tip of the tool
 If it goes beyond hot hardness temperature of tool material, adjust the process parameters
(cutting velocity, feed and depth of cut), and maintain the tool temp. below hot hardness temp.
Dr. R. Seetharam
Methods of Measurement Temperature of tip of the tool
1. Tool Work Thermocouple:

• Here one end of the Thermocouple is kept near to the type of tool and other end of
Thermocouple kept at 0 centigrade.
• So that EMF generated in the circuit is measured by voltmeter and is directly
proportional to temperature of tip of tool EMF  (T1-T2)
Limitations:
 Thermocouples can be used for measurement of temperatures up to 800 oC accurately,
beyond which the accuracy is poor
 This type of thermocouples can be used for measurement of temperature of
stationary tool
Dr. R. Seetharam
Methods of Measurement Temperature of tip of the tool
2. Optical Pyrometer
• pyrometer is a non-contact type of temperature measuring method
• It can be used for measurement of higher temperature
3. Calorimetric Set up:

 This is used for measurement of temperature of moving or rotating type of
tool
Dr. R. Seetharam
Machining Operation
1. Single Point Cutting Tool 2. Multi Point Cutting Tool
Single Point Cutting Tool: Multi Point Cutting Tool:

 One cutting edge is available.  More than one cutting edge is
 Ex: Lathe , Shaping and etc. available.

 Ex: Drilling, milling and etc.
Dr. R. Seetharam
Single Point Cutting Tool (Tool Geometry)
 The cutting edges in the form of two straight line and meet at single point - Nose
Dr. R. Seetharam
Dr. R. Seetharam
αb – Back rake angle:
 Angle between face of the tool and

line parallel to the base of the tool.
 Purpose is to guide the direction of chip
Top View
flow
Nose radius
αb – Back rake angle
Shank
Flank
End View Front View

Dr. R. Seetharam
αs – Side rake angle:
 Angle between face of the tool and line

perpendicular to the base of the tool
 Purpose is to guide the direction of chip flow
Top View
Nose radius
αs–Side rake angle

Shank
Flank
End View Front View

Dr. R. Seetharam
γe– End clearance angle:

 Angle between a plane perpendicular to the
base and the end flank.
 Provides the clearance between tool and
work peace. Top View
 Prevent the cutting tool from the rubbing.
Nose radius

Shank
Flank
End View Front View

Dr. R. Seetharam γe– End clearance angle
γs– Side clearance angle:
 Angle between side flank and line passing

through the tip perpendicular to the base.
 Permits the tool to be fed side ways into the
job. Top View
 So that it can cut without rubbing.
Nose radius

Shank
Flank
End View
Front View
Dr. R.
γ –Seetharam
Side clearance angle γe– End clearance angle
s
Φs – Side cutting edge angle:
 Angle between side cutting edge and line extending the

shank.
 It avoids the formation of built-up edge, controls the
direction of chip flow. Top View
Nose radius
Φs – Side cutting edge angle αb – Back rake angle

Shank
Flank
End View
Front View
Dr. R.
γ –Seetharam
s
Φe – End cutting edge angle:
 Angle between end cutting edge and line

passing through the tip, perpendicular to the
tool axis.
Φe – End cutting edge angle
 Prevents or avoids the chatter and vibration Top View
of the tool
Nose radius

Shank
Flank
End View
Front View
Dr. R.
γ –Seetharam
s
r – Nose radius:
 Provided to increase the surface finish and strength of the cutting tip of the tool.

Top View
Nose radius

Shank
Flank
End View
Front View
Dr. R.
γ –Seetharam
s
Tool Nomenclature or designation
αb – αs – γe– γs–Φe –Φs – r
Nose radius
Side cutting edge angle

End cutting edge angle
Side clearance angle
End clearance angle
Side rake angle

Back rake angle
Dr. R. Seetharam
Type of System
a) ASA System (American Standards Association)

b) ORS System (Orthogonal Rake System)
Dr. R. Seetharam
ASA System (American Standards Association)
Dr. R. Seetharam
Z Y  : Transverse Plane
x : Longitudinal Plane y
y
0 R
αb
0 S.F
1
X
4 2 x 4
S E.F
1
B
x
R : Reference 0 R
Plane αs
Angle Measure Measure E.F
w.r.t In 2
αb R y y 4
S.F
αs R x
Dr. R. Seetharam
αb – Back rake angle: It is the angle made by the rake face of the tool with respect
to the horizontal plane measured in the length direction.
αs – Side rake angle: It is the angle made by the rake face of the tool with respect
to the horizontal plane measured in the width direction.
Dr. R. Seetharam
y
0 R
0 S.F
1
X x γe 4
4 2 E.F
S
1
B
x
R : Reference 0 R
Plane
Angle Measure Measure
E.F
w.r.t In 2
γe x y y γs 4
S.F
γs y x
Dr. R. Seetharam
γe–End clearance angle: It is the angle made by the end flank and plane
perpendicular to the base and angle is measured in plane parallel to the tool
axis.
γs–Side clearance angle: It is the angle made by the side flank and plane
perpendicular to the base and angle is measured in plane perpendicular to the
tool axis.
Dr. R. Seetharam
R
y
Φs
x
X Φe
S
B
R : Reference
Plane
Angle Measure Measure
w.r.t in
Φe x R
Dr. R. Seetharam
Φs y R
Φe – End cutting edge angle: It is the angle between end cutting edge and line
passing through the tip perpendicular to the tool axis and angle is measured in
a plane parallel to base.
Φs – Side cutting edge angle: It is the angle between side cutting edge and line
extending the shank. And angle is measured in a plane parallel to base.
Dr. R. Seetharam
Angle Measured Measured
w.r.t In
αb R y
αs R x
γe x y
γs y x
Φe x R
Φs y R
Dr. R. Seetharam
ORS System (Orthogonal Rake System)
ORS System- Tool Reference System
i – αo – – –Φe –λ – r
Nose radius
Principal cutting edge angle
End cutting edge angle
Side clearance angle

End clearance angle
Orthogonal rake angle

Inclination angle
Dr. R. Seetharam
λ - Principal cutting edge angle
Φs O :Orthogonal Plane
λ
Φs + λ= 90o λ= 90o
If Φs= 0o R
λ= 90o
C : Cutting Plane
Dr. R. Seetharam
i - Inclination angle
Angle made by side cutting edge with respect horizontal plane, and angle measured in
cutting plane
C
i R
Dr. R. Seetharam
αo – Orthogonal Rake Angle
It is the angle of inclination of the rake face from reference plane (horizontal ), and angle
measured in orthogonal plane
o
αo R
Dr. R. Seetharam
Inter Conversion Between ASA to ORS
=
It can be written as
tan 𝑖=𝑠𝑖𝑛 λ tan 𝛼 𝑏 −cos λ tan 𝛼 𝑠
tan 𝛼 𝑜 ¿ 𝑐𝑜𝑠 λ tan 𝛼 𝑏+ sin λ tan 𝛼 𝑠
Φs + λ= 90 If Φs= 0 λ= 90
tan 𝑖=¿ tan𝛼 𝑏 ¿

o = x
tan 𝛼 𝑜 ¿ tan 𝛼 𝑠
=
Cutting Edge
C = y
Dr. R. Seetharam
i=
Inter Conversion Between ASA to ORS
Φe= end cutting edge angle is same in ASA and ORS system
Dr. R. Seetharam
Orthogonal machining process
If Φs= 0, i = =0
If Φs= 0, i = ≠ 0
o = x
i R
Dr. R. Seetharam
Numarical-2
In machining operation chip thickness ratio is 0.3 and back angle of tool is 10 o . what is the
value of shear strain
Sol.
α= 10o
r=0.3 0.3 𝑐𝑜𝑠10
𝑡𝑎𝑛 Ф=
)+ 1 −0.3 sin 10
Ф=17.31o
)+
Shear strain 3.34
Dr. R. Seetharam
Numarical-3
The rake angle of a cutting tool is 15o and shear angle 45° and cutting velocity 35 m/min. What is
the chief velocity along the tool face.
Sol.
α= 15o
𝑉 𝐶 𝑠𝑖𝑛𝜑
Ф=45 o 𝑉 𝑓=
cos ⁡(𝜑 − 𝛼)
VC= 35m/min 35 𝑠𝑖𝑛 45
𝑉 𝑓=
cos ⁡(45 −15)
𝑚
𝑉 𝑓 =28.57 .
𝑚𝑖𝑛
Dr. R. Seetharam
Numarical-4
In orthogonal cutting, the depth of cut is 0.5 mm cutting speed of 2 m/sec. If the chip thickness
is 0.75 mm, the chip velocity is.
Sol.
t1= 0.5
t2=0.75
VC= 2 m/sec
Volume of the material before cut = Volume of the material after cut
𝑡1
V1w1t1 = V2w2t2 𝑉 𝑓 =𝑉𝑐
𝑡2
Vcw1t1 = Vfw2t2 0.5
𝑉 𝑓 =2 𝑋
w1 = w2t 0.75
1.33m/sec
Dr. R. Seetharam
Effect of Tool Geometry on Machining
Rake Angle: Rake angle is provided for ease of chip flow and overall machining.
 The size of the angles depend upon the material to be machined.
 Rake angle may be positive, or negative or even zero.
Dr. R. Seetharam
Positive rake –A tool has a positive rake when the face of the tool slopes away from the cutting
edges and slants towards the back or side of the tool. In most cases, tools are provided with a
positive rake
 Helps reduce cutting force requirement and thus cutting power requirement. (Imagine cutting
by blunt knife v/s sharp knife)
 Positive rake angle makes the tool sharp and pointed, but reduce the strength of cutting edge.
(Very sharp pencil tip breaks)
 It helps the formation of continues chip in ductile material and contributes to avoiding the
formation of built-up edge chip.
 Higher value of rake angle weakens the cutting edge of the tool, so the maximum value of
positive rake angle is 45 degrees beyond which increasing the rake angle causes tool to fails
abnormally.
Dr. R. Seetharam
Zero Rake angle. – It is used during machining of brass workpiece and also during
thread operation
 During brass work piece machining, the surface obtain is very good with zero rake
angle
 During thread cutting if positive rake angle is used the chip may flow sideward and
trying to shear off the thread, zero rake angle is used the chip flow straight
upwards.
Dr. R. Seetharam
Negative Rake angle. – A tool has a negative rake when the face of the tool slopes
away from the cutting edges and slants upwards the back or side of the tool.
 Negative rake angle are used with tools which are weak in tension
 When the cutting tools is provided with negative rake angle, the main force
component is directed at the strongest rake section of the tool
 Cutting tools with negative rake angle are stronger and are used to cut high
strength alloys
 However the uses of an increased negative rake angle leads to increase cutting force
during machining, this causes vibrations, reducing machining accuracy and raises
power consumption in cutting
 So maximum negative rake angle used is 10o
Dr. R. Seetharam
Side Rake angle. –
 It is also guides the direction of the chip away from the job
 The amount that a chip is bent depends upon this angle
 With increase in side rake angle, the amount of chip bend decreases
 Larger side rake angle produces smooth surface finish.
 As side rake angle increases, strength decreases, forces decreases, power
consumption decreases and tool life increases.
 Side Rake angle- 5 to 10o
Dr. R. Seetharam
End clearance Angle
 It minimize rubbing contact between tool and machined surface.
 If this angle very large, the cutting edge of the tool will be unsupported and will
break up.
 If this angle is very small the tool will rub on the job, cutting will not proper and
poor finish will be obtained on the job.
 It values varies from 5 to 15o
Shank
Flank
Front View
γe– End clearance angle
Dr. R. Seetharam
Side clearance Angle
 This angle permits the tool to be fed side-ways into the job so that it can cut without
rubbing
 If this angle very large, the cutting edge of the tool will be unsupported and will
break up.
 If this angle is very small the tool cannot fed into the job, it will rub against the job
and will get overheated and become blunt and the finish obtained on the job will be
poor.
 It values varies from 5 to 15o
End View
Dr.
Dr. R. Seetharam
Seetharam γs– Side clearance angle
End & Side Cutting Edge Angles
 Cutting edge angles are mainly influencing the surface finish produced on the work
piece.
𝑓
 Φe= 8 to 20 o 𝑅𝑡 =
tanФ 𝑠 +𝐶𝑜𝑡 Ф 𝑒
 Φs= 0 to 90o
 If the value of Фs increases then R decreases. Thus better surface finish will be
obtained.
Top View
Nose radius
Φs – Side cutting edge angle
Dr.
Dr. R. Seetharam
Seetharam
Nose Radius
 It is provided to obtain better surface finish and strength of the cutting tip of the tool
 With increase of nose radius, the contact area between tool and workpiece increases,
therefore higher force is required to machine the job which leads to vibration and make
the surface finish poor
 The nominal value of nose radius – 0.2 to 1.2 mm
𝑓2
S urface F inish 𝑅 𝑡 =
8𝑟 Top View
Nose radius
Dr. R. Seetharam

ME2007 MT Module-1 Lectures 1-10

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ME2007 MT Module-1 Lectures 1-10

Uploaded by

Copyright:

Available Formats

Manufacturing Technology

 The word manufacturing is derived from Latin:

 manus = hand, factus = made

 Manufacturing implies creating value to a raw material by applying useful mental

People, Money, Equipment, Materials and Supplies, Markets, Management

Manufacturing processes can be grouped as:

Manufacturing processes can be grouped as:

 Introduction to orthogonal & oblique cutting;

MILLING Translatory Rotation

WHAT IS THE BASIC DIFFERENCE BETWEEN ?

TURNING DRILLING  Single vs Multi point

Cutting Tool M/C Tool Product

 It is the process of producing a workpiece by removing unwanted material from a

 Metal Cutting Plastic

 Forces induced during machining

Orthogonal Cutting Oblique Cutting

Orthogonal Cutting Oblique Cutting

Orthogonal Cutting Oblique Cutting

Life of the tool is less Life of the tool is high

 Index- the amount of plastic

𝑟𝑐𝑜𝑠 ∅𝑐𝑜𝑠 𝛼+𝑟𝑠𝑖𝑛 ∅𝑠𝑖𝑛 𝛼=𝑠𝑖𝑛 ∅

𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛𝑜𝑓 𝑡h𝑒 𝑐h𝑖𝑝

𝐷𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛𝑜𝑓 𝑡h𝑒 𝑐h𝑖𝑝

𝐴𝐷 + 𝐷𝐶 (90- Ф) tan (ϕ-α)

c) Continuous chip with Built-up Edge (BUE)

Zones of Heat Generation

Zones of Heat Generation

Secondary Heat Zone

Tertiary Heat Zone

Friction Zone: (Chip-tool interface)

1. Tool Work Thermocouple:

proportional to temperature of tip of tool EMF  (T1-T2)

3. Calorimetric Set up:

1. Single Point Cutting Tool 2. Multi Point Cutting Tool

Single Point Cutting Tool: Multi Point Cutting Tool:

 Ex: Lathe , Shaping and etc. available.

αb – Back rake angle:

 Angle between face of the tool and

αb – Back rake angle

End View Front View

αs – Side rake angle:

 Angle between face of the tool and line

αb – Back rake angle

αs–Side rake angle

End View Front View

γe– End clearance angle:

αb – Back rake angle

αs–Side rake angle

End View Front View

γs– Side clearance angle:

 Angle between side flank and line passing

αb – Back rake angle

αs–Side rake angle

Φs – Side cutting edge angle:

 Angle between side cutting edge and line extending the

Φs – Side cutting edge angle αb – Back rake angle

αs–Side rake angle

Φe – End cutting edge angle:

 Angle between end cutting edge and line

αs–Side rake angle

Φe – End cutting edge angle

αs–Side rake angle

αb – αs – γe– γs–Φe –Φs – r