Joyjeet ghose, bit, mesra, lecture notes on pe5005 definition of manufacturing the word manufacturing is derived from latin. This process is most important since almost all the products get their final shape and size by metal removal, either directly or indirectly. The filler metal, and the means of protecting it and the. Milling processes milling is a metal removal process by means of using a rotating cutter having one or more cutting teeth as illustrated in figure. Introduction of machining or metal cutting lecture 17. However, the cutting force becomes unstable with the variation coinciding with the fracturing cycle. Within a limited time of 10 hours, this course would elaborate on the theory of metal cutting supplemented with numerical problems. Multiple cutting edge tools more than one cutting edge motion relative to work usually achieved by rotating drilling and milling use rotating multiple cutting edge tools. Lecture notes design and manufacturing ii mechanical. Usually, the portion that is fractured away is in small sized pieces, called chips. When you need an experts advice for metal cutting, this is the place to go. Metal cutting notes free pdf download faadooengineers.
Manufacturing process study notes handwritten free pdf. The tool should be having sufficient toughness withstand the shock and vibration. Included in this category are robots, highspeed machinery, and highspeed rotating shafts for ships or land vehicles. Today i will tell you about types of chips in metal cutting form during machining process. The monitoring and control of turning operations in a metalcutting system are examined. Tool geometry, chip formation, cutting force calculations and measurement, tool wear and other aspects will be given due attention.
It is a combination properties of strength and ductility. Metal finishing systems l 18007472637 introduction to buffing buffing is the process used to shine metal, wood, or composites using a cloth wheel impregnated with cutting compounds or rouges. Kim 2 cutting processes objectives product quality. Plastic properties of metals are used during the process of metal forming. Chapter 4 metal matrix composites princeton university. Sheetmetal characteristics elongation the capability of the sheet metal to stretch without necking and failure. The machining of material is highly dependable on chips. Tig welding has become a popular choice of welding processes when high quality, precision welding is required. Sheet metal forming involves forming and cutting operations performed on metal sheets, strips, and coils. We are here to provides you the best study notes from best coaching like made easy, ace academy etc and lecture notes from best institutions like mit open course, iit nptel, crec tirupati, washington, middle east technical university etc.
The equipment is relatively simple, inexpensive, and portable. Manufacturing technology theory of metal cutting metal cutting or machining is the process of producing a work piece by removing unwanted material from a block of metal, in the form of chips. In this article we mainly focus on sheet metal cutting operations and. More than 90% of smelted metal is processed by different methods of metal forming. Singlepoint tools one cutting edge turning uses single point tools point is usually rounded to form a nose radius 2. Before discussing on this topic, first you should know about machining process. Merchant circle diagram is used to analyze the forces acting in metal cutting. Economics of metal cutting 1 free download as powerpoint presentation.
Longer term applications metal matrix composites with high specific stiffness and strength could be used in applications in which saving weight is an important factor. The process uses shielding from an externally supplied. The cloth buff holds or carries the compound, while the compound does the cutting. If the tool having sufficient amount of toughness, the fine edge of cutting tool does not break down or chip formation. This course would encompass a comprehensive study of metal cutting and machine tools. Shielded metal arc welding is one of the most widely used processes, particularly for short welds in production, maintenance and repair work, and for field construction.
Metal forming is the main method of making metal products and semifinished products. Metal forming processes indian institute of technology. Metal cutting and machine tools iitkgp 31,285 views. Contentcommon features of machining processes, geometry of single point tool and tool signature, concept of speed, feed and depth of cut applicable to various machining processes. Metal cutting cutting processes work by causing fracture of the material that is processed. Sheet metal tools 1 roper whitney hand punch punches up to 14 hole through 16 ga. J s campbell, principles of manufacturing materials and processes. Metal casting processes indian institute of technology. Mainly sheet metal process can be divided into three types. Cutting conditions milling cutters plain milling cutters form milling cutters face milling cutters end milling cutters cutting conditions.
This is nothing but cutting of sheets by shearing action. Manufacturing implies creating value to a raw material by applying useful mental and physical labour. Mrr, tool wear physics of cutting mechanics force, power tool materials design for manufacturing 2. After that, the steel sheet is being placed on the left between the knives, until it reach delimiter. Kim 3 orthogonal cutting in a lathe rake angle shear angle t o. Lubrication and cooling effects provided by cutting fluids coolants result in the following benefits of metalworking. No cutting tool is perfectly sharp, and in the idealized picture as shown in figure 2 the cutting edge is represented by a cylindrical surface joining the tool flank and tool face. Nptel mechanical engineering manufacturing processes ii. Common cutting processes include sawing, shaping or planing, broaching, drilling, grinding, turning and milling. Tig welding is a commonly used high quality welding process. Do you need help with calculating starting values, figure out what causes and solves poor tool life or do you need tips on how to optimize your machining processes. Metal cutting complete seminar report ebook free download ppt. Mechanics of machining metal cutting cutting temperature.
Single point cutting tool geometry indian institute of. Cutting action is carried out by feeding the workpiece against the rotating cutter. Metal beneath the surface undergoes shear deformation. In tig welding an arc is formed between a non consumable tungsten electrode and the metal being welded. The resultant too force in metal cutting is distributed over the areas of the tool that contact the chip and workpiece. Lecture 3 theory of metal cutting linkedin slideshare.
The capacity of lathe tool dynamometer is 500kg, sensitivity is 1 kg, cross interference of 2%, natural frequency is 800 cps min. Sources of heat in metal cutting for example, in a typical study of machining mild steel at 30 mmin at about 750 deg of cutting temperature at toolchip interface, the distribution of total energy developed at the shear zone is as follows energy at chip 60 percent. Cutting metalworking fluids lubricate the workpiecetool metaltometal contact zone preventing tool galling and seizure, which assures good surface finish. Sheet metal forming massachusetts institute of technology. Oblique cutting characteristics cutting edge at an angle. Mechanics of machining metal cutting analytical and experimental determination of cutting forces. The surface areatovolume ratio of the starting metal is relatively high. Machining is a process of cutting metal work piece by means of a tool to convert it into desire shape. To investigate the performance of cutting, the measurement of cutting forces is essential.
Find materials for this course in the pages linked along the left. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. Runners and gates are made by cutting the parting surface with a gate cutter. Economics of metal cutting 1 machining mathematical. From the uniaxial tensile test, one can understand material behavior considerably. Tool wear sensing and metalremoving rate control are considered from a systemstheory viewpoint. A material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. A gate cutter is a piece of sheet metal bent to the desired. The analysis of three forces system, which balance each other for cutting to occur. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing.
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