Manufacturing Technology

ME3493

MANUFACTURING TECHNOLOGY

COURSE OBJECTIVES:

1. To study the concepts and basic mechanics of metal cutting and the factors affecting machinability

2. To learn working of basic and advanced turning machines.

3. To teach the basics of machine tools with reciprocating and rotating motions and abrasive finishing processes.

4. To study the basic concepts of CNC of machine tools and constructional features of CNC.

5. To learn the basics of CNC programming concepts to develop the part programme for Machine centre and turning centre

UNIT – I

MECHANICS OF METAL CUTTING

Mechanics of chip formation, forces in machining, Types of chip, cutting tools – single point cutting tool nomenclature, orthogonal and oblique metal cutting, thermal aspects, cutting tool materials, tool wear, tool life, surface finish, cutting fluids and Machinability.

UNIT – II

TURNING MACHINES

Centre lathe, constructional features, specification, operations – taper turning methods, thread cutting methods, special attachments, surface roughness in turning, machining time and power estimation. Special lathes - Capstan and turret lathes- tool layout – automatic lathes: semi-automatic – single spindle: Swiss type, automatic screw type – multi spindle

UNIT – III

RECIPROCATING MACHINE TOOLS

Reciprocating machine tools: shaper, planer, slotter: Types and operations- Hole making: Drilling, reaming, boring, tapping, type of milling operations-attachments- types of milling cutters– machining time calculation - Gear cutting, gear hobbing and gear shaping – gear finishing methods Abrasive processes: grinding wheel – specifications and selection, types of grinding process – cylindrical grinding, surface grinding, centreless grinding, internal grinding - micro finishing methods

UNIT – IV

CNC MACHINES

Computer Numerical Control (CNC) machine tools, constructional details, special features – Drives, Recirculating ball screws, tool changers; CNC Control systems – Open/closed, point-to-point/continuous - Turning and machining centres – Work holding methods in Turning and machining centres, Coolant systems, Safety features.

UNIT – V

PROGRAMMING OF CNC MACHINE TOOLS

Coordinates, axis and motion, Absolute vs Incremental, Interpolators, Polar coordinates, Program planning, G and M codes, Manual part programming for CNC machining centers and Turning centers – Fixed cycles, Loops and subroutines, Setting up a CNC machine for machining.

TOTAL 45 PERIODS

OUTCOMES:

At the end of the course the students would be able to

1. Apply the mechanism of metal removal process and to identify the factors involved in improving machinability.

2. Describe the constructional and operational features of centre lathe and other special purpose lathes.

3. Describe the constructional and operational features of reciprocating machine tools.

4. Apply the constructional features and working principles of CNC machine tools.

5. Demonstrate the Program CNC machine tools through planning, writing codes and setting up CNC machine tools to manufacture a given component.

TEXT BOOKS:

1. Kalpakjian. S, “Manufacturing Engineering and Technology”, Pearson Education India,7th Edition, 2018.

2. Michael Fitzpatrick, Machining and CNC Technology, McGraw-Hill Education; 4^th edition, 2018.

REFERENCES:

1. Roy. A. Lindberg, Processes and materials of manufacture, PHI / Pearson education, 2006.

2. Geofrey Boothroyd, “Fundamentals of Metal Machining and Machine Tools”, McGraw Hill, 1984.

3. Rao. P.N “Manufacturing Technology,” Metal Cutting and Machine Tools, Tata McGraw- Hill, New Delhi, 2009.

4. A. B. Chattopadhyay, Machining and Machine Tools, Wiley, 2nd edition, 2017.

5. Peter Smid, CNC Programming Handbook, Industrial Press Inc.; Third edition, 2007.