Contents

• 1. Metal Removal Processes

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  Introduction, Classification of Metal Removal Process, Mechanics of Metal Cutting, Concept of Generatrix and Directrix, Elements of Metal Cutting Process, Cutting Tool, Classification of Cutting Tools, Single Point Cutting Tools Geometry, Tool Angle, Tool Nomenclature in ASA, ORS and NRS, American Standards Association (ASA), Orthogonal Rake System (ORS), Normal Tool Reference System (NRS), Interrelation between the Different type of Nomenclature, Interrelation between ASA and ORS System, Interrelationship Between ORS and NRS, Mechanism of Chip Formation, Relation of Orthogonal Cutting Forces (Merchant Theory), Types of Chips, Discontinuous or Type I Chips, Continuous, Flow or Type II Chips, Continuous Chips with Built-up Edge or Type III, Non-homogeneous Chips or Type IV, Chip Breakers, Orthogonal and Oblique Cutting, Cutting Forces, Measurement of Cutting Forces, Power Required for Machine Tool, Theories on Mechanics of Metal Cutting, Thermal Aspects of Machining, Measurement of Chip-tool Interface Temperature, Friction in Metal Cutting, Tool Geometry, Milling Cutters, Drills, Solved Examples, Summary, Review Questions.
   
  2. Machinability

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  Introduction, Evaluation of Machinability, Tool Life, Taylor’s Tool Life Equation, Factors Affecting Tool Life, Mechanism of Tool Failure, Types of Tool Failure, Machinability Index, Factors Affecting Machinability, Tool Wear, Types of Tool Wear, Mechanism of Tool Wear, Shearing at High Temperature, Diffusion Wear, Adhesive Wear (Attrition Wear), Fatigue Wear, Abrasive Wear, Oxidation Wear, Chemical Decomposition, Electrochemical Effect, Measurement Method of Tool Wear, Control of Tool Wear, Tool Materials and its Applications, Tool Coating, Machining Time (th), Determination of Cycle Time, Economics of Machining, Cutting Fluids, Types of Cutting Fluids, Properties of Cutting Fluids, Selection of Cutting Fluids, Methods of Application, Advantages of Cutting Fluid Applications, Disadvantages of Using Cutting Fluids, Precautions in Handling of Cutting Fluids, Solved Examples, Summary, Review Questions.
   
  3. General Purpose Machine Tools

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  Introduction, Lathe, Lathe Design, Size and Specification of Lathe, Classification of Lathes, Lathe Accessories, Lathe Attachments, Lathe Tools, Lathe Operations, Machining Parameters (Lathe), Drilling Machine, Principle of Operation and Parts of Drilling Machine, Types of Drilling Machines, Drilling Machine Operations, Machining Parameters (Drilling), Specification of a Drilling Machine, Drill Tools, Milling Machines, Principle of Milling, Specifications of a Milling Machine, Types of Milling Machine, Types of Milling Cutters, Milling Operations, Machining Parameters (Milling), Milling Machine Attachments, Shaper (Shaping Machine), Working Principle of Shaper, Classification of Shapers, Type of Shapers, Principle Parts of a Shaper, Shaper Size and Specifications, Operations Performed on a Shaper, Quick Return Motion Mechanism (Crank and Slotted Lever Type), Shaping Tools, Machining Parameters (Shaper), Planning Machine (Planer), Classification of Planning Machines, Principal Parts of a Planer, Machine Size and Specifications, Planning Operations, Planer Tools, Broaching Machine, Classification of Broaching Machines, Specifications of a Broaching Machine, Application of Broaching, Machining Time Calculation, Boring Machines, Classification of Boring Machines, Solved Examples, Summary, Review Questions.
   
  4. Special Purpose Machine Tools

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  Introduction, Turret Lathe, Capstan or Ram Type Lathe, Turret or Saddle Type Lathe, Principal Parts of a Capstan and Turret Lathe, Size and Specifications of Turret Lathe, Machining Operations Performed on Turret and Capstan Lathes, Comparison between Capstan and Turret Lathe, Automatic Lathes, Classification of Automatic Lathe, Single Spindle Automatics, Multi-spindle Automatic Machine, Operational Planning and Turret Tool Layout (Sequence of Operations), Hydraulic Tracer Attachment, Principle of Copying Machine, Mechanical Copying Machines, Electric Tracing System, Automatic Tracing System, Summary, Review Questions.
   
  5. Abrasive Processes

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  Introduction, Natural Abrasives, Synthetic Abrasives, Bonding Material, Vitrified Bond, Silicate Bond, Shellac Bond, Resinoid Bond, Rubber Bond, Oxychloride Bond, Some Basic Terms and Their Meaning, Nomenclature, The Standard Marking System for Conventional Grinding Wheel, Marking System for Superabrasive Grinding Wheel, Selection of Grinding Wheels, Wheel Mounting, Glazing and Loading of Grinding Wheels, Truing and Dressing of Grinding Wheels, Theory of Grinding, Reasons for Grinding, Method of Grinding, Parameters of Grinding Operation, Grinding Machines, Surface Grinding Machines, Cylindrical Grinder, Centreless Grinding, Surface Finishing, Honing, Lapping, Superfinishing, Polishing, Buffing, Summary, Review Questions.
   
  6. Thread and Gear Manufacturing Processes

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  Introduction, Classification of Threads, Elements of Screw Thread, Manufacturing of Threads, Gear Manufacturing Process, Materials used in Gear Manufacturing Process, Gear Manufacturing Process, Gear Generating Processes, Gear Hobbing, Gear Shaping, Gear Finishing Processes, Gear Shaving, Gear Grinding, Gear Lapping, Shot Blasting, Phosphate Coating, Gear Testing, Summary, Review Questions.
   
  7. High Velocity Forming Methods and Industrial Safety

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  Introduction, High Velocity Forming Methods, Principle, Requirement of High Velocity Forming Method, Advantages of HVF, High Energy Rate Forming Method (HERF), Open Type Forming, Closed Type Forming, Requirement of Explosive Forming, Parameters of Explosive Forming, Hydro Forming, Working, Advantages of Hydro Forming, Disadvantages of Hydro Forming, Electro Hydraulic Forming, Difference between Explosive and Electro Hydraulic, Working, Process Variables, Advantages, Applications, Magnetic Pulse Forming, Operating Principle, Process Variables, Applications, Industrial Safety, Objective of Industrial Safety, Safety Precautions, Human Factor in Machine Equipment Safety, Personal Safety, Hand Tool Safety, Machine Safety, Noise Control Techniques, Precaution to be Taken by the Operator for Safe Working on Different Machines Tools, Lathes, Shaper, Grinding Machine, Drilling Machine, Milling Machine, Summary, Review Questions.
   
  P. Paper