Introduction, system of Tool nomenclature, Tool Geometry, Mechanism of Chip, formation and
forces in orthogonal cutting, Merchant’s force diagram. (3 Hours)
Oblique Cutting: Normal chip reduction coefficient under oblique cutting, true shear angle,
effective rake, influx region consideration for deformation, direction of maximum elongation, effect
of cutting variables on chip reduction co-efficent, forces system in oblique cutting, effect of wear
land on force system, force system in milling, effect of helix angle. (7 hours)
Fundamentals of Dynamometry, Theoretical determination of forces, angle relations, heat and
temperature during metal cutting; distribution, measurement, analysis, theoretical estimation of work
piece temperature, hot machining (7 hours)
Fundamental factors, which effect tool forces: Correlation of standard mechanised test. (Abuladze –
relation), nature of contact and stagnant phenomenon, rates of strains, shear strain and normal strain
distributions, cutting variables on cutting forces. (7 Hours)
Cutting Tools: Tools materials analysis of plastic failure (from stability criterion), Analysis failure by
brittle fracture, wear of cutting tools, criterion, flank and crater wear analysis, optimum tool life, tool
life equations, (Taylor’s woxen etc) Tool life test, machining optimisation, predominant types of
wear; abrasive, adhesive, diffusion wear models, wear measurements and techniques, theory of tool
wear oxidative mathematical modelling for wear, test of machinability and influence of metallurgy
on machinability. Economics of Metal machining (9Hours)
Abrasive Machining: Mechanics of grinding, cutting action of grit, maximum grit chip thickness,
energy and grit force temperature during grinding, wheel wear, grinding, process simulation, testing
of grinding wheels, mechanics of lapping and honing, free body abrasion. (7 Hours)