Unit 1 Metal Cutting Principles and Machine Tools

12 lecture hours

• Machine tools classification
• working and auxiliary motions in machine tools
• Primary cutting motions in machines tools
• Elements of Metal cutting
• Orthogonal and Oblique cutting
• Classification of tools and tool Materials
• Systems of Cutting- Tool Nomenclature: British Maximum Rake System
• ASA system
• German System
• International Standards: Tool in hand and tool in Use systems
• Setting system
• Mathematical relationship between tool and Working systems
• Calculation of Tool Angles and Working Angles
• Chip formation: Types of chip and effect of cutting parameter
• Chip thickness and Shear Plane angle measurement
• Velocity relationship
• Chip control and chip breakers
• Concept of different forces in metal cutting: Merchant circle diagram
• Stress and Strain in chip
• Work done in Cutting
• Power calculation in cutting
• Concept of Tool life
• Tool Wear
• cutting fluid
• Machinability and Economics of metal cutting

Unit 2 Metal Cutting Lathes

• The Lathe and its working Principle
• Different Parts of Lathe
• Lathe Accessories and Attachments
• Change of speed and Speed ratios
• Feed Mechanism and change gears
• Apron and Apron Mechanism
• Specifications of Lathe
• Different Operations on Lathe
• Reaming knurling
• Parting off and form turning on lathe
• Chip disposal devices
• Estimating machining time calculations
• Turret and Capstan lathes as compared with a centre lathe
• Main parts of Turret and capstan lathe and classification
• Primary and secondary motions
• common tools
• attachments and feeding mechanism
• Safety Precautions associated in Lathe. 10 Subject Code: 3142509 *to be covered in laboratory

Unit 3 Shapers, Slotters and Planers

• Classification of Shapers
• Slotters, and Planer Machine
• Attachments extending the processing capacities of Shapers
• Slotters, and Planer
• Different Parts and Tooling requirements
• Working Principle and Mechanism
• Machining time calculations
• Safety Precautions associated with Shapers

Unit 4 Drilling, Reaming and Boring Machines

4 lecture hours

• Drilling Machine: Purpose and field of application of drilling machines
• Classifications of Drills
• Twist drill
• Twist drill parts and terminology
• Types of drilling machines
• Specifications of Drilling machines
• Driving Mechanism of Drill
• Drilling and allied operation
• Estimating of machining time
• Drill Grinding
• Reaming: Reamer terminology
• Types of reamer
• reaming operations
• Boring Machine: Purpose and filed of application
• Classification Boring Machines
• Operations performed on Boring machines
• Safety Precautions associated with Drilling
• Reaming and Boring machines

Unit 5 Milling Machines

• Working Principles
• Purpose and types of Milling machines
• Size and specifications of Milling machines
• Types of Milling machines
• Different types of milling operations
• milling cutters and attachments extending the processing capabilities
• Cutting Speed and Feed
• Estimating machining time
• Indexing or Dividing heads
• Helical and spiral milling operation and its set up
• Safety Precautions associated with Milling machine

Unit 6 Sawing and Broaching Machines

3 lecture hours

• Metal sawing classification
• Blade specification
• Machine Size and specification
• Cutting speed
• Blade failure and their preventions
• Types of broaching machines
• Broach constructions and elements of broach
• Method of broaching
• Tooth load on broach
• Broaching speed and machining time calculation
• Advantage and limitations of broaching
• Safety Precautions associated with Sawing and Broaching machine

Unit 7 Abrasives and Grinding Machines

6 lecture hours

• Common form of abrasive tools
• Grinding wheels and wheel material
• Abrasive and bond material
• symbolic representation of bonds
• Grain and Grit
• common wheel shapes
• Method of specifying grinding wheels
• trueing and Dressing of grinding wheels
• Classification of grinding machines
• Grinding operations
• Centreless grinders: Through feed
• Infeed and End feed grinding
• Special grinding machines
• Size and specifications of grinding machines
• Method of grinding
• Sharpening of tools
• feed and depth of cut in grinding
• Machining time calculations
• Safety Precautions associated with Grinding

Unit 8 Installation and Testing of Machine Tools

• Foundations for the machine tools
• different types of machine foundations: Block, Box, Wall
• Frame types
• Factor effecting the type and size of foundation
• Transportation and Erection: Types of Lifting and transporting equipment: pulley blocks
• levelling and aligning
• Machine tool testing: Alignment and practical test
• Acceptance tests
• site for testing
• degree of accuracy
• measuring equipment
• Common geometrical tests
• mode of tolerances and understanding of test charts. 04 (Lab Teachi ng) Total Hours 45+4* Subject Code: 3142509