Production Engineering

(MET 351)
B.Tech. (6th Sem) Spring 2025
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.
Manufacturing Processes
• Converting raw material into finished product of higher value
Manufacturing
• Manufacturing is a process of converting raw material of low utility into a finished
product.

Classification
• Casting process – Melting and solidification. (Sand mould C, Die C, Centrifugal
C, Investment C)
• Machining process- Removal of excess material (Turning, Milling, Drilling,
Boring, Shaping, Planning, Gear cutting etc)
• Forming process- Plastic deformation (Forging, Drawing, Deep drawing, Rolling,
Bending, Extrusion)
• Welding process- Heat and/or pressure (Gas, Arc, high energy beam welding, solid
state welding)
• Rapid Prototyping- layer by layer (SLS, FDM, LOM)
 Manufacturing
• Manufacturing is a process of converting raw material of low
utility into a finished product.

Classification
• Casting process
• Machining process
• Forming process
• Welding process
• Rapid Prototyping

8
 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.
 Basics of Machining
The important parameters involved are
(i) the thickness of the uncut layer (𝑡1 ),
(ii) the thickness of the chips produced (𝑡2 ),
(iii) the inclination of the chip-tool interface
with respect to the normal of the machined
component (the face of the tool in contact with
the chip is commonly known as the rake face),
i.e., the rake angle (α)
(iv) the relative velocity of the workpiece and
the tool (ν).
A clearance angle between the job and the flank
surfaces is also provided to make cutting
possible.
 Orthogonal And Oblique Machining
• Orthogonal machining: When the cutting edge is straight and the relative
velocity of the work and the tool is perpendicular to the cutting edge, this type
of machining is known as orthogonal machining.
• It should be noted that the machining operation can be represented by a two-
dimensional figure only when all the work and chip material particles move in
the planes parallel to the plane of the paper.
• There is no component of velocity or motion in the direction perpendicular to
the plane of the paper.
• Oblique machining: When the relative velocity of the work and the tool is not
perpendicular to the cutting edge, this type of machining is termed as an oblique
machining.
• All the work and chip material particles do not move in parallel planes; thus, a
two-dimensional representation becomes difficult.
 Mechanics of chip formation
• The plane OS where the shear occurs is known as the shear plane and its
inclination with the machined surface (φ) is called the shear angle.
• A direct determination of the shear angle φ is quite difficult but 𝑡1 and 𝑡2 can be
easily measured.
• To establish a relation among 𝑡1 ,𝑡2 , α and φ, let us drop two perpendiculars SM
and SN from S on the extension of the machined surface and the tool’s rake face.
• Further, SP is drawn parallel to OM and Q is the intersection of SP with the
normal drawn at O to OM.
Mechanics of chip formation
• Considering the two right-angled triangles A SNO and A QPO, we get

• Value of r is always less than unity

• Chip compression ratio = 1/r
Magnitude of Shear strain
Magnitude of Shear strain
 Numerical 1.1
During orthogonal machining with a cutting tool having a 10° rake angle, the chip
thickness is measured to be 0.4 mm, the uncut thickness being 0.15 mm. Determine the
shear plane angle and also the magnitude of the shear strain.
Numerical 1.1
During orthogonal machining with a cutting tool having a 10° rake angle, the chip
thickness is measured to be 0.4 mm, the uncut thickness being 0.15 mm. Determine
the shear plane angle and also the magnitude of the shear strain.
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, and 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.
• High cutting speed
• Small rake angle
• Large rake angle • Large depth of cut
• Suitable cutting fluid
• Continuous process

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