Geometry of Cutting Tools:
Single point and multi point cutting tools like drills, milling cutters, tool nomenclature, tool point reference systems, tool angle specification systems – ISO and ASA systems, Chip breakers Indexable inserts, tool holders for indexable inserts, Recommended tool angles, Effect of cutting parameters on tool geometry.
Tool Materials and their Properties:
Characteristics of tool materials, types of tool materials – carbon tool steels, high speed steels, cast alloys, cemented carbides, ceramics, diamonds, SIALON, CBN, UCON, recommended cutting speeds for the above tools, and their applications.
Mechanics of Metal Cutting:
Mechanism of chip formation, Orthogonal & Oblique cutting, types of chips, built-up edge, Determination of shear plane angle, forces on the chips, forces in orthogonal cutting, Merchant circle diagram and analysis, Theory of Lee & Shaffer, coefficient of friction, power & energy relationship, velocity relationship, shear-strain, factors affecting forces and power, problems.
Measurement of Cutting Forces:
Reasons for measuring cutting forces, Classification of cutting force dynamometers – mechanical, hydraulic, pneumatic, optical, inductance, piezoelectric, and strain gage type dynamometers, Dynamometers for lathe, drilling, and milling.
Thermal Aspects in Metal Cutting Process:
Heat sources in metal cutting and temperature distribution in metal cutting, Measurements of chip – tool interface temperature – thermocouple technique and calorimeter technique.
Tool Wear, Tool life:
Mechanisms of tool wear, Sudden & gradual wear, crater wear, flank wear, tool failure criteria, tool life equations, effect of process parameters on tool life, tool life tests, conventional & accelerated tool wear measurement, machinability index, problems on tool life.
Cutting Fluids:
Basic actions of cutting fluids (mechanisms), Function and requirements of cutting fluids; Methods of application of cutting fluids, Types of commonly used cutting fluids, chemical coolants, effect of additives, selection of cutting fluids.
Economics of Machining:
Introduction, elements of total production cost, optimum cutting speed and tool life for minimum cost, optimum cutting speed and tool life for maximum production, problems.