Production Engineering

(MET 351)
B.Tech. (6th Sem) Spring 2024
Department of Mechanical Engineering
NIT Srinagar

Course In-charge
Dr. Noor Zaman Khan
 Syllabus
UNIT I
• Introduction to machining; Orthogonal cutting; Oblique cutting; Types of chips;
Mechanics of chip formation; chip breakers; Mechanics of Metal Cutting:
Merchant's circle diagram; Determination of cutting and thrust forces; Coefficient
of friction; strain rate; Measurement of shear angle, Thermal aspects of machining,
Numerical problems.

UNIT II
• Mechanisms of tool wear; Types of tool wear, Tool life: Variables affecting tool
life-Cutting conditions; Tool angles specification systems; Tool materials;
Desirable Properties of Cutting Tool; Determination of tool life; Machinability,
Economics of machining.
• Abrasive Machining Process: Introduction; Grinding: Characteristics of a grinding
wheel; Specification of grinding heels; Mechanics of grinding process; Grinding
operations; Wheel wear; Surface Finish; Selection of grinding wheels.
 Syllabus
UNIT III
• Metal Forming: Hot and cold working, Rolling; Forging; Extrusion; Sheet metal
working. Introduction to high energy rate forming processes, their advantages and
application. Electromagnetic forming, Explosive forming, Electrohydraulic forming.
UNIT IV
• Metrology: Introduction to Metrology, Accuracy and Precision. Limits, fits and
tolerances, need of providing tolerance, unilateral and bilateral system, Taylor’s
principles of gauge design, Sine bars and gauge blocks manufacturing method and
their applications, Numerical problems.
 Books
Text Book:
1. Ghosh, A. and Malik, A.K., “Manufacturing Science”, Affiliated East Press, New-Delhi.

Reference Books:
• Campbell, J.S., Principles of Manufacturing Materials and Processes, McGraw-Hill, New-
York,
• Engineering Metrology and Measurements by N.V. Raghavendra and L. Krishnamurthy, 1st
Edition, Oxford University Press
• Rao, P.N., Manufacturing Technology, Volume 2, McGraw-Hill Education, New Delhi.
• Lindberg, R.A., Processes and Materials of Manufacturing, Allyn and Bacon, Boston
 Course Outcomes
At the end of the course, a student should be able to:
• CO1: Determine the shear angle and cutting force in machining and understand the basics
of metal cutting.
• CO2: Estimate tool life and explain the tool wear mechanisms and abrasive machining
process.
• CO3: Analyze the forming process behavior for conventional and advanced metal forming
processes.
• CO4: Understand the basics of limits, fits and tolerances in manufacturing.
Numerical 1.2
• During orthogonal machining with tool of α rake angle, chip thickness
0.39 mm and uncut thickness is 0.15 mm when the shear angle is
21.6𝑜 . Determine the value of rake angle.
 Velocities in metal cutting
1. Cutting velocity: Relative velocity of the tool and the work piece (𝑉𝑐 )
2. Shear velocity: The flow velocity of chip with respect to the work (𝑉𝑠 )
3. Chip velocity: The flow velocity of chip with respect to the tool (𝑉𝑓 )
Velocities in metal cutting
Numerical 1.3
Rake angle = 15𝑜 , Shear angle = 45𝑜 , Cutting Velocity = 35 m/min. Determine Chip
flow velocity with respect to the tool.
Numerical 1.3
• α = 15𝑜 , φ = 45𝑜 , 𝑉𝑐 = 35 m/min, 𝑉𝑓 = ?
MECHANISM OF CHIP FORMATION
(types of chips)
1. Continuous chips
2. Continuous chips with built up edge
3. Discontinuous chips
Continuous chips : Generally formed with ductile material and high cutting speed.
• The uncut layer deforms into a chip after it goes through a severe plastic deformation in the primary shear
zone.
• the chip flows over the rake surface of the tool and the strong adhesion between the tool and the newly
formed chip surface results in some sticking.
• the chip material at this surface and the adjacent layers undergoes a further plastic deformation since, despite
the sticking, it flows. This zone is referred to as the secondary shear zone.
• Under suitable conditions, the machining operation is smooth and stable and produces continuous ribbon-like
chips.
• As a result, the surface produced is smooth and the power consumption is not unnecessarily high.
• Continuous chips are not necessarily desirable as they tend to become tangled around tool holder, fixture and
work piece. This problem is reduced by chip breakers.
• At high speed, temp increases, ductility increases, fracture tendency decreases, so it will resist failure and
support the material flow.
Continuous chips with built up edge

• At a somewhat high speed, the temperature increases and

the tendency of the plastically deformed material to adhere
to the rake face increases and a lump is formed at the
cutting edge. This is called a built-up edge (BUE).
• A built-up edge consists of layers of material from the
workpiece that gradually deposited on the tool-tip and
hence termed as built-up.
• It grows up to a certain size but ultimately breaks due to the
increased force exerted on it by the adjacent flowing
material.
• After it breaks, the broken fragments adhere to the finished
surface and the chip surface results in a rough finish.
• With a further increase in the cutting speed or when a
cutting fluid is used, the built-up edge disappears.
 Discontinuous chips
• When the machining is performed at a very low speed or the work material is brittle, the
shearing operation on the work material does not continue without causing a fracture.
• The ruptures occur intermittently, producing discontinuous chips. Figure 4.11 shows the
progress of the formation of discontinuous chips.
• The resulting surface is rough
 Conditions for the various types of chips
(1) Continuous chips without BUE: (3) Discontinuous chips:
• Ductile material • Low cutting speed
• Small depth of cut • Brittle work material
• Low feed rate. • Small rake angle
• High cutting speed
• Large depth of cut
• Large rake angle
• Suitable cutting fluid
• Continuous process

(2) Continuous chips with BUE: • continuous chips without BUE are most
desirable
• Stronger adhesion between chips and tool face
• Low rake angle
• Large depth of cut
• Medium cutting speed
• High feed rate
• Zone-I: Discontinuous chips, initially poor surface finish. It improves
with increase in velocity and chips become semi d Discontinuous.
• Zone-II: BUE is formed, continue till recrystallization temp is reached.
• Zone-III: Continuous chips without BUE.