Department of Mechanical Engineering, GMRIT | Syllabi | Regulation 2019

19ME603 METAL CUTTING AND MACHINE TOOLS

3103
Course Outcomes
1. Explain cutting tool geometry; analyze mechanism of chip formation and forces in orthogonal cutting.
2. Explain tool failure and influence of various process parameters on tool life.
3. Illustrate basic parts and operations of machine tools including lathe, shaper, planer, drilling, boring,
milling and grinding machine.
4. Select a machining operation and corresponding machine tool for a specific application in real time.
5. Identify the need of super finishing operations like honing, lapping and broaching.
6. Design locating and clamping devices to produce a component.
COs POs Mapping
COs PO1 PO2 PO3
1 3 3 2
2 3 2 2
3 3 1 1
4 3 2 2
5 3 3 3
6 - 3 2

3 Strongly linked | 2 Moderately linked | 1 Weakly linked

Unit I
Fundamentals of Machining
Elements of machining, Theory of chip formation, Cutting tool materials, Tool geometry, Classification and
type of machining of tools, Mechanics of orthogonal cutting, Machining parameters and metal removal rate,
Cutting force analysis by Merchant's diagram, work done and power required, Problems, Types of cutting
parameters and coolants.
Tool Signature- Different systems of tool signature
10+4 Hours

Unit II
Rotary Machines
Introduction, Construction and working, Principle of Lathe, Classification of lathes, Specification of a lathe,
work and tool holders, Lathe operations, cutting speed, feed and depth of cut, Machining time, Cutting fluids,
Tool materials and properties.
Drilling and Boring Machines
Introduction, Construction and working, specifications, Classification, Operations performed, Work and tool
holding devices, Twist drill nomenclature, Drill size and materials, Boring Machines.
Cutting speed, feed and depth of cut- rotary machines
12+4 Hours

Unit III
Reciprocating Machines
Shaping, Slotting and Planning Machines
Introduction, Construction and working, Principle parts, Specifications and operations performed, Machining
time calculations.
Milling Machines
Introduction, Construction and working, Classification- horizontal, vertical and universal milling machines,
Machining operations, Milling cutters, Elements of a plain milling cutter, Methods of indexing, Machining time.
Cutting speed, feed and depth of cut- reciprocating machines

14+4 Hours

Unit IV
Grinding Machines
Introduction, Construction and working, Classification- cylindrical and surface grinders, tool and cutter
grinders, Abrasives, Bonds and bonding processes, Specification and selection of a grinding wheel
Finishing operations- lapping and honing
9+3 Hours
 Department of Mechanical Engineering, GMRIT | Syllabi | Regulation 2019

Total: 45+15 Hours

Textbook (s)
1. Hajra Choudhury S. K., Elements of workshop technology Volume No. II Machine Tools, Media
Promotors and Publishers Pvt. Limited, 15th Edition, 2018.
2. Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, John
Wiley & Sons, Inc., 7th Edition, 2019.
3. B. L. Juneja, G. S. Sekhon and Nitin Seth, Fundamentals of Metal Cutting and Machine tools, New Age
International Publishers-2nd Edition., 2005.
4. P N Rao, Manufacturing Technology: Metal Cutting and Machine Tools, MC Graw Hill Education
(India) Pvt. ltd, 4th Edition, 2018.
Reference (s)
1. Winston A. Knight and Geoffrey Boothroyd, Fundamentals of Metal Machining and Machine Tools,
CRC Press, 3rd Edition, 2005
2. Serope Kalpakjian and Stephen Schmid, Manufacturing Engineering and Technology, Prentice Hall
Publication, 7th Edition, 2014
3. Amitabha Ghosh and Ashok Kumar Mallik, Manufacturing Science, East West Press Private Ltd, 2nd
Edition, 2010
4. B. S Raghuwanshi, Workshop Technology Vol-II, Dhanpatrai & Co., 11th Edition, 2013.

SAMPLE QUESTION (S)

Internal Assessment Pattern
Cognitive Level Int. Test 1 (%) Int. Test 2 (%) Assignment Test39 (%)
Remember 45 40 -
Understand 35 40 -
Apply 20 20 40
Analyze - - 45
Evaluate - - 15
Create - - -
Total (%) 100 100 100
Remember
1. What are the adverse effects of the built-up edge formation?
2. What Is an indexing jig? What are the various kinds of indexing devices commonly used?
3. What are the advantages and disadvantages of conical locators?
4. List out the advantages of CNC systems over conventional NC systems.
5. What are the applications of CNC machines? Explain.
6. What is the coordinate system used for CNC milling machine?
7. What is 3-2-1 principle of location? Explain with neat sketch.
8. What are different types of clamping elements? Explain with neat sketches.
Understand
1. Explain the nomenclature of a single point cutting tool.
2. Explain the working principle of a Lathe. What are the operations that can be performed on lathe?
3. Demontrate the Merchant's force diagram and state its significance in machining.
4. Explain the following grinding processes: Form Grinding. Gear tooth grinding, Thread grinding and
Cam grinding and Sketch.
5. Explain the mechanism behind the working of a shaper in detail.
6. Discuss the principles of design of jigs and fixtures.
Apply
1. A steel work piece s to be milled. Metal removal rate is 30 cm3 /mm. Depth of cut is 5mm and width of
cut is 100 mm. Find the table speed.
2. In a turning operation, it was observed that the tool life was 100 min and 50 min at cutting speed of
25m/min and 100 m/min respectively. Find out tool life at 200 m/min under same cutting condition.

39
Assignment Test should contain only questions related to Higher Order Thinking (HOT) Skills pertaining to this course