MF4103 Theory of Metal Cutting Syllabus:

MF4103 Theory of Metal Cutting Syllabus – Anna University PG Syllabus Regulation 2021

OBJECTIVES:

1. To make the students to familiar with the basic principles of metal cutting
2. To familiarize the students various cutting tool materials and its wear mechanisms during the machining operation.
3. Differentiate between single point and multi point cutting tools
4. To study the heat generation during machining and the necessity for cutting fluid
5. To study the effect of vibrations during machining

UNIT I INTRODUCTION

Need for rational approach to the problem of cutting materials-observation made in the cutting of metals-basic mechanism of chip formation-thin and thick zone modes-types of chips-chip breaker-orthogonal Vs oblique cutting force velocity relationship for shear plane angle in orthogonal cutting-energy consideration in machining-review of
Merchant, Lee and Shafter theories-critical comparison.

UNIT II SYSTEM OF TOOL NOMENCLATURE

Nomenclature of single point cutting tool and nomenclature of multi point cutting tools – Twist Drill – milling cutter – System of tool nomenclature and conversion of rake angles-nomenclature of multi point tools like drills, milling conventional Vs climb milling, mean cross sectional area of chip in milling-specific cutting pressure.

UNIT III THERMAL ASPECTS OF MACHINING

Heat distribution in machining-effects of various parameters on temperature-methods of temperature measurement in machining-hot machining- Cutting fluid – properties – types of cutting fluids – Selection of cutting fluids.

UNIT IV TOOL MATERIALS, TOOL LIFE AND TOOL WEAR

Essential requirements of tool materials-development of tool materials-ISO specification for inserts and tool holders- Tool geometry – Mechanisms of tool wear – Abrasion – Adhesion – Diffusion – Types of tool wear – flank
wear – crater wear – Tool life – Tool life equations – factors affecting tool life – Illustrative problems- conventional
and accelerated tool life tests-concept of machinability index-economics of machining.

UNIT V WEAR MECHANISMS AND CHATTER IN MACHINING

Processing and Machining – Measuring Techniques – Reasons for failure of cutting tools and forms of wear mechanisms of wear-chatter in machining-factors affecting chatter in machining-types of chatter-mechanism of chatter.

COURSE OUTCOMES:

At the end of the course students will be familiar with
● Basics of orthogonal cutting, oblique cutting and chip formation
● Different tool materials, tool life and tool wear mechanisms
● Necessity for a cutting fluid and cutting efficiency
● Single and Multipoint cutting tools
● Effect of vibrations and surface roughness during machining

REFERENCES

1. Bhattacharya.A., Metal Cutting Theory and practice, Central Book Publishers, India,2012..
2. Boothroid D.G. & Knight W.A., Fundamentals of machining and machine tools, Marcel Dekker, Newyork, 2005.
3. Shaw.M.C.Metal cutting principles, Oxford Clare don press, 2012.
4. B L Juneja and G S Sekhon., Fundamentals of Metal Cutting and Machine Tools, 2017.