9/1/2011

AnalysisofPreviousIESPapers
Production Materials Total Question

By IES-2011 31 28 59

IES-2010 33 19 52
Swapan KumarMondal IES 2009
IES-2009 38 16 54

IESOfficer(Railway) IES-2008 25 15 40

IES-2007 34 15 49
NTPCLtd(5Years)
IES-2006 23 13 36
TeachingExperience(12Years) IES-2005 28 12 40

GATEpercentile99.96 Average 30 17 47

Noofquestionsasked

AnalysisofPreviousGATEPapers WhyPPTandVideoneeded?
Production Materials Total Marks

GATE-2011 13 1 14 out of 100

GATE-2010 13 1 14 out of 100

GATE
GATE-2009
2009 16 2 18 out of 100

GATE-2008 26 0 26 out of 150

GATE-2007 25 2 27 out of 150

GATE-2006 25 1 26 out of 150

GATE-2005 19 1 26 out of 150

Average 15.22 % 0.9 % 16.57 %

NoofMarksasked

DiscussedQuestionsareavailableat
www.scribd.com
Email:bestmadeeasy@gmail.com
Password:reliancejain

Thenopen"MyDocumentanddownload
desiredfile.

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 9/1/2011

ClassificationofManufacturingProcess

TheoryofMetalCutting y Shapingorforming

y Joiningprocess

y Removalprocess

y Regenerativemanufacturing

BySKMondal

RegenerativeManufacturing BasicPrincipleofRegenerative
Manufacturing
y Production of solid products in layer by layer from
raw materials in different forms.

y Very rapid, accurate used for Rapid prototyping

and tooling. Advantages:
ProcessisIndependentofPartFeature
NoBlanksareRequires
Toolless process
EasilyAutomationPossible

Machining
Machiningaimto
y Machining is an essential process of finishing by
y Fulfillitsfunctionalrequirements
which jobs are produced to the desired dimensions
y Improveitsperformance
and surface finish byy g
graduallyy removing
g the
excess material from the preformed blank in the y Prolongitsservice.

form of chips with the help of cutting tools moved

past the work surface. Machining is a removal
process.

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DrawbackinMachining
y Loss of material in the form of chips.
Machinetool
y A machine tool is a nonportable power operated
and reasonably valued device or system of device
in which energy is expended to produce jobs of
desired size, shape and surface finish by removing
excess material from the preformed blanks in the
form of chips with the help of cutting tools moved
past the work surface.

IAS2009main
Why even a battery operated y Name four independent variables and three
pencil sharpener cannot be dependent variables in metal cutting.
[5marks]
accepted as a machine tool?
IndependentVariables DependentVariables
y Ans.
A In
I spite
i off having
h i allll other
h major
j features
f off
Startingmaterials Forceorpowerrequirements
machine tools, the sharpener is of low value.
(tool/work) Maximumtemperaturein
Toolgeometry cutting
CuttingVelocity Surfacefinish
Lubrication

RackangleandClearanceangle RackSurfaceandFlank
y The surface along which the chip moves upward is
called Rack surface of tool.

y The other surface which is relieved to avoid

rubbing with the machined surface, is called
Flank.

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RakeangleandClearanceAngle The nomenclature of different

y Rake angle () Angle of inclination of rake
angle and surface in turning
surface from reference plane i.e. normal to
horizontal machined surface.

y Clearance angle ( ) :Angle of inclination of

clearance or flank surface from the finished
surface.

DiscussiononRackangle Positiverake

y Reducecuttingforce

y Reducecuttingpower

Positiverakeanglesisrecommended Negativerake
y Machininglowstrengthmaterial
y Increase edge strength
y Lowpowermachine
y Increases life of the tool
y Longshaftofsmalldiameter
y Increases the cutting force
y Set uplacksstrengthandrigidity
y High cutting speeds
y Lowcuttingspeed
y Requires ample power

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Negativerakeanglesisrecommended
Zerorake
y Machininghighstrengthalloy
y To simplify design and manufacturing of the form
y Heavyimpactloads
tools.
y Highspeedcutting
Hi h d i y Increases tool strength
y Withrigidset up
y Avoids digging of the tool into the workpiece

y Brass is turned with zero rake angle

Clearanceangle
y Provided to avoid rubbing of the tool (flank) with
TypesofMachining
the machined surface.

y Reduce tool wear

y Increase tool life.

y Must be positive (30 150)

OrthogonalCutting
1. Cutting edge of the tool is perpendicular to the
direction of cutting velocity.
2. The cutting edge is wider than the workpiece
width and extends beyond the workpiece on
p
either side. Also the width of the workpiece is Geometry of single point turning tool
Geometryofsinglepointturningtool
much greater than the depth of cut.
3. The chip generated flows on the rake face of the
tool with chip velocity perpendicular to the
cutting edge.
4. The cutting forces act along two directions only.

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Classification: (According to the SystemofDescriptionofToolGeometry

number of major cutting edges y (I) Machinereferencesystem:ASAorANSI

(points) involved.) y (II) Toolreferencesystem:ORSandNRS

y Single point: turning,
turning shaping,
shaping planning,
planning slotting
tools etc. y (III)Workreferencesystem: WRS

y Double point: drilling tools

y Multipoint: Milling, broaching, hobbing tools etc.

ASinglepointcuttingtool

ASAorANSIsystem Endcuttingedgeangle,ECEA

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 9/1/2011

BackRakeangle Siderakeangle(axialrake)
y It is the angle between the face of the tool and the y It is the angle between the face of the tool and the base
of the shank or holder, and is usually measured in a
base of the shank or holder, and is usually
plane perpendicular to the base, to the sidecutting
measured in a plane through the sidecutting edge, edge
and at right angles to the base y Increase
I in
i the
th side
id rake
k anglel reduces
d the
th chip
hi
thickness in turning.
y It affects the ability of the tool to shear the work
material and form the chip.

Sidereliefangle Endreliefangle
y It is the angle between the portion of the side flank y It is the angle between the portion of the end flank
immediately below the sidecutting edge, and a immediately below the end cutting edge, and a line
line drawn through this cutting edge drawn through this cutting edge perpendicular to
perpendicular to the base. the base. It is usually measured in a plane

y It is measured in a plane perpendicular to the side perpendicular to the end flank.

flank. y The End Relief Angle prevents friction on the flank

of the tool.

Sidecuttingedgeangle,SCEA(CS) SCEAandLeadAngle
y Itistheanglewhichpreventsinterferenceasthetoolenters
theworkmaterials.(Normally15 30o )
y Largerthisangle,thegreaterthecomponentofforcetending
toseparatetheworkandthetool.(MayinduceChatter)
y Atitsincreasedvalueitwillhavemoreofitslengthinaction
foragivendepthofcut.
y Atitsincreasedvalueitproducethinnerandwiderchipthat
willdistributethecuttingheat.(increasetoollife)
y ZeroSCEAisdesirablewhenmachiningcastingandforging
withhardandscalyskins,becauseoftheleastamountoftool
edgeshouldbeexposedtothedestructiveactionoftheskin.

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 9/1/2011

Noseradius
Lipangle y It is curvature of the tool tip.
y Lip angle or cutting angle depends on the on the
rake and clearance angle provided on the tool and y It provides strengthening of the tool nose and better
determine the strength of the cutting edge. surface finish.
y A larger
l lip
l angle l permits machining
h off harder
h d
metals, allow heavier depth of cut, increase tool y But too large a nose radius will induce chatter.
life, better heat dissipation.
y If nose radius increased cutting force and cutting power
y Larger lip angle reduce cutting speed
(Disadvantage) increased.

Tooldesignation(ANSI)orASA
Toremembereasilyfollowtherule
y rake,relief,cuttingedge
y Sidewillcomelast
y finishwithnoseradius(inch)
b s e s Ce Cs R
OrthogonalRakeSystem(ORS)
i 1 Ce R
( ) side relief ()
y Inclination angle (i) side rake
end relief ( 1) End cutting edge (Ce)
Approach ( ) nose radius (mm)
y Approach angle () = 90 - CS
y [Sometimes is called principal cutting edge
angle (Orthogonal cutting)]
y For Pure orthogonal cutting, i = 0
y For Oblique cutting, i 0

InterconversionbetweenASA&ORS Criticalcorrelations
When = 90 s =
When i = 0 n =
When i = 0 and = 90 s = n =
(P orthogonal
(Pure h l cutting)
i )

is principal cutting edge angle

i is inclination angle
s is side rake angle ( ASA)
is orthogonal rake angle (ORS )
n is normal rake angle (NRS)

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 9/1/2011

Causeofchipformation Mechanismofchipformationin
Yieldinginductilematerial ductilematerial
Brittlefracture inbrittlematerial

Mechanismofchipformationin Typesofchip
brittlematerial y Continuouschip

y Discontinuouschip

y ContinuouschipwithBUE
Co t uous c p t U

y Serratedchip

Fig.Developmentandpropagationofcrack
causingchipseparation.

ConditionsforformingDiscontinuouschip
Typesofchipdependson
ofirregularsizeandshape
workmaterialbrittle(greycastiron)
y Work material (ductile, brittle)
ofregularsizeandshape
y Cutting tool geometry (rake angle, cutting angle workmaterial ductilebuthardandworkhardenable
etc.) feed large
toolrake negative
y Cutting velocity and feed rate.
cuttingfluid absentorinadequate
y Types of cutting fluid and method of application.

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 9/1/2011

ConditionsforformingContinuous ConditionsforformingContinuous
chipwithoutBUE chipwithBUE
y work material ductile y Workmaterial ductile

y Cutting velocity high y Cuttingvelocity medium

y Feed low y Feed medium

y Rake angle positive and high y Cuttingfluid absentorinadequate.

y Cutting fluid both cooling and lubricating

Built up Edge(BUE)formation Built up Edge(BUE)formation

y In machining ductile material with long chip tool
contact length, lot of stress and temperature develops in
the secondary deformation zone at the chip tool
interface.
y Under such highg stress and temperature
p in between two
clean surfaces of metals, strong bonding may locally take
place due to adhesion similar to welding.
y Such bonding will be encouraged and accelerated if the
chip tool materials have mutual affinity or solubility.
y The weld material starts forming as an embryo at the
most favorable location and thus gradually grows.
Contd.
y WiththegrowthoftheBUE,theforcealsogradually
increasedduetowedgingactionofthetooltipalong
withtheBUEformedonit.
y Whenevertheforceexceedsthebondingforceofthe
BUE theBUEisbrokenorshearedoffandtakenawayby
BUE,theBUEisbrokenorshearedoffandtakenawayby
theflowingchip.Thenagainstartsformingandgrow.
y ThisBUEchangesitssizeduringthecuttingoperation.
y Itfirstincreases,thendecreases,andthenagain
increases.
y Lowcuttingspeedalsocontributestotheformationof
BUE.

EffectsofBUEformation ReductionorEliminationofBUE
Harmfuleffect Increase
y Itunfavourably changestherakeangleatthetooltip Cuttingspeed
causingincreaseofcuttingforcei.e.powerconsumption. Rakeangle
y Inducevibration. Ambientworkpiecetemperature.
y Poorsurfacefinish.
Reduce
Feed
Goodeffect
Depthofcut
y BUEprotectsthecuttingedgeofthetooli.e.increases
toollife. Use
y Cuttingfluid
y Changecuttingtoolmaterial(ascermets).

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 9/1/2011

SerratedChips Whenisforcedchipbreakingnecessaryandwhy?
y Serrated chips also called segmented or non Whenchipscontinuouslyformandcomeoutvery
homogeneous chips are semicontinuous chips hot,sharpandatquitehighspeed

with zones of low and high shear strain.

Underthecondition
y Metals with low thermal conductivity and y softductileworkmaterial
strength that decreases sharply with temperature, y flatrakesurfacewithpositiveornearzerorake
For
such as titanium exhibit this behaviour, the chips
y Safetyandconvenienceoftheoperator
have sawtooth like appearance. y easycollectionanddisposalofchips

Shearangle() Proof
t l V sin 1
r= = c = c = =
tc l V cos ( )
r cos
and tan =
1 r sin

Fororthogonalcutting
Cuttingshearstrain()

1
==e
= cot + tan ( )
2

cos
Fromthisexpressionwewillget

(Thevalueofcanbereducedby) =
y usingtoolhavinglargepositiverake sin cos ( )
y Reducefrictionbyusinglubricant.

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Proof Velocitiesinmetalcutting
(i) The velocity of the tool relative to the work
piece (V) called the cutting speed.

(ii) The velocity of the chip relative to the work,

work Vs
called the shear velocity.

(iii) The velocity of the chip up the face of the tool

Vc, called chip velocity.

Derivetheexpressionforvelocitiesin
ShearStrainRate
metalcutting.ESE2004(Conv.)
(Note:itisnotshearstrainitisrateof
shearstraini.e.flow)

d Vs
= =
dt thickness of shear zone ( ts )

DeterminationofUndeformedchip
thicknessinTurning:(VIMP)
Forsinglepointcuttingtool
t = f sin
d
b=
Where
sin
t=Uncutchipthickness
f=feed
=90 Cs=approachangle
Cs=sidecuttingedgeangle

11
 9/1/2011

Whenacutismadetheforcesactingonthemetalchipsare:

Force & Power in Metal Cutting

BySKMondal

Fc andFt Theforcerelations (VIMP)

The two orthogonal components (horizontal and
vertical) Fc and Ft of the resultant force R can be
F = Fc sin + Ft cos
N = Fc cos Ft sin
measured by using a dynamometer.
The horizontal component is the cutting force (Fc)
and the vertical component is the thrust force (Ft)
Fn = Fc sin + Ft cos
Fs = Fc cos Ft sin
F
and = = tan
N

MerchantforcecircleDiagram(MCD) MerchantAnalysis
Assumption

( ) It is based on single shear plane theory.

1
 9/1/2011

LimitationsofMerchantsTheory
FromMerchantForceCircleDiagram
1. Merchant theory is valid only for orthogonal cutting.
2. By the ratio F/N, the Merchant theory gives apparent

= +
(not actual) coefficient of friction.

4 2 2

ModifiedMerchantTheory TheoryofLeeandShaffer
They applied the theory of plasticity for an ideal-rigid-plastic material.
s = so + ks where, s is the normal stress on shear plane.
They also assumed that deformation occured on a thin-shear plane.
Fn They derive.
s =
As
= +
4
and h 2 + - = cot ( k )
d then 1

OtherRelations Compareturningwithorthogonalcutting
y ByStabler

y Bydimensionalanalysis

where, k, a, b, k1, a1 and b1 are empirical constants to be

established from the experimental data
f is feed and d is depth of cut.

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 9/1/2011

y Fc: primary cutting force acting in the direction of MetalRemovalRate(MRR)

the cutting velocity, largest force and accounts for
99% of the power required by the process.
y Ff: feed force acting in the direction of the tool feed. Metalremovalrate(MRR)=Ac.V =btV
This force is about 50% of Fc, but accounts for only a
small percentage of the power required because feed
Where
h
rates are usually small compared to cutting speeds.
y Fr: radial or thrust force acting perpendicular to the Ac =crosssectionareaofuncutchip
machined surface. This force is about 50% of Ff and V=cuttingspeed= DN
60
contributes very little to power requirements
because velocity in the radial direction is negligible.

PowerConsumedDuringCutting FrictioninMetalCutting

Fc V
Where
Fc =cuttingforce
DN
V=cuttingspeed= 60

HeatandTemperatureinMetalCutting Determinationofcuttingtemperature
Analytically using mathematical models (equations) if
available or can be developed. This method is simple,
quick and inexpensive but less accurate and precise.

Experimentally this method is more accurate, precise

and reliable.

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 9/1/2011

ExperimentalMethodsare Dynamometersformeasuringcuttingforces
y Calorimetricmethod Measurement of cutting force(s) is based on three basic
principles :
y Decolourising agent
(a) measurement of elastic deflection of a body
y Toolworkthermocouple subjected to the cutting force
y Movingthermocoupletechnique (b) measurementt off elastic
l ti deformation,
d f ti i.e.
i strain
t i
y Embeddedthermocoupletechnique induced by the force
y Usingcompoundtool
(c) measurement of pressure developed in a medium by
the force.
y IndirectlyfromHardnessandstructuraltransformation

y Photocelltechnique

y Infraraydetectionmethod

DesignrequirementsforTool force TypesofDynamometers

Dynamometers The dynamometers being commonly used nowadays
Sensitivity for measuring machining forces desirably accurately and
The dynamometer should be reasonably sensitive for precisely (both static and dynamic characteristics) are
precision measurement
Either
Rigidity Strain gauge type
The dynamometer need to be quite rigid to withstand the Or
forces without causing much deflection which may affect the
machining condition piezoelectric type
Strain gauge type dynamometers are inexpensive but less
Cross sensitivity accurate and consistent, whereas, the piezoelectric type
The dynamometer should be free from cross sensitivity such are highly accurate, reliable and consistent but very
that one force (say PZ) does not affect measurement of the expensive for high material cost and stringent
other forces (say PX and PY) construction.

StrainGaugeDynamometers
The strain, induced by the force changes the electrical
resistance, R, of the strain gauges which are firmly
pasted on the surface of the toolholding beam as
R
= G
R
where, G = gauge factor (around 2.0 for conductive
gauges)
The change in resistance of the gauges connected in a
wheatstone bridge produces voltage output V, through
a strain measuring bridge (SMB)