II Jai Sri Gurudev II

Sri Adichunchanagiri Shikshana Trust®

SJB INSTITUTE OF TECHNOLOGY

BGS Health & Education City, Dr. Vishnuvardhan Road, Kengeri, Bengaluru – 560060

MACHINING
SCIENCE
JIGS & FIXTURES
21ME42

Faculty Name : Uday M

Designation : Assistant Professor
2022-2023
TABLE OF
CONTENT

VISION , MISSION

PO'S, PSO'S & PEO'S

BLOOMS TAXONOMY

OBJECTIVES AND OUTCOMES

COURSE SYLLABUS

LECTURE NOTES
VISION
MISSION

Vision of the Institute

To become a recognized technical education center with global
perspective.

Mission of the Institute

To provide learning opportunities that fosters students ethical
values, intelligent development in science & technology and
social responsibility so that they become sensible and
contributing members of the society.

Vision of the Department

• To become a center of excellence and a platform in diversified
fields for the aspirants in Mechanical Engineering.

Mission of the Department

• To impart comprehensive education in the field of mechanical
engineering to produce highly accomplished graduates
• To endow high profile technical & soft skill trainings to foster
professionalism and ethical values among students
• To inculcate innovative thinking among students through
projects and research work
 02.

Program Specific Outcomes (PSO’s)

PSO1: Apply the Knowledge & Skill of Mechanical Engineering on Design,

Manufacturing and Thermal platforms to address the real life problem of
the society.
PSO2: Design and implement new ideas with the help of CAD/CAM and
Industrial Automation tools.

Program Educational Objectives (PEO’s)

PEO-1: Progress their career as a professional in mechanical engineering
and interdisciplinary fields.
PEO-2: Become successful entrepreneur with social responsibilities and
ethical values.
PEO-3: Pursue higher education and involve in research of allied areas in
mechanical engineering.
 BLOOMS
TAXANOMY

03.
 COURSE
OBJECTIVE

04.
Course objectives

To know the various subtractive machining processes in industries.

To calculate the values of various forces involved in the machining
operations.
To understand and determine tool wear and tool life of different
machining processes.
To know various non-conventional machining and hybrid machining
processes.
To know the design of jigs and fixtures for various industrial/
machining members.

Course outcomes

At the end of the course the student will be able to:

Demonstrate the Conventional CNC machines and advanced

manufacturing process operations
Determine tool life, cutting force, and economy of the machining
process.
Analyze the influence of various parameters on machine tools'
performance.
Select the appropriate machine tools and process, the Jigs, and
fixtures for various applications.
 05
SYLLABUS

MODULE 1:
Introduction to Machining Processes and Machine Tools: Subtractive manufacturing processes
and classifications.
Construction, specification operations of machine tools:– Lathe, Shaping, Milling, Drilling,
Grinding Machine.
Introduction to CNC machines: CNC Lathe, Milling, Drilling, Machine Center.

MODULE 2:
Mechanics of Metal Cutting: Single point turning tool geometry (SPTT) influences the chip
formation mechanisms of the Orthogonal and Oblique cutting process. Cutting Force Analysis
(Orthogonal Cutting):Analysis of machining forces and power requirement, ‘Merchant’s model of
Orthogonal Cutting and Theory of Lee & Shaffer’ Chip Velocity, Velocity relationships (simple
numerical); the influence of cutting temperature on machinability. CuttingFluids: Characteristics
of Cutting fluids, Selections, and applying methods of cutting fluids.

MODULE 3:
Machinability and Tool Life Process of cutting tool failure wears and time relationship, tool wear
index, feed marks, the effect of tool wear on the machined surface, surface finish, machinability,
machinability index/rating, tool life & variables affecting tool life, tool materials. Finishing
Process: Importance of surface finishing processes, Grinding, Abrasive Flow Machining, Honing.
Sanding, Abrasive blasting, Polishing, Lapping. Surface Finishing and Protection: Powder Coating,
Liquid Coating, Electroplating, Galvanizing, Anodizing.

MODULE 4:
Advanced Machining Process; Importance and classification of advanced machining process;
Process principal, process parameters, and application of: - Abrasive Jet Machining (AJW), Water
Jet Machining (WJM), Abrasive Water Jet Machining (AWJM); Ultrasonic Machining
(USM);Electrical Discharge Machining (EDM); Wire Electrical Discharge Machining (WEDM); Electro
Chemical Machining (ECM). Laser Beam Machining (LBM), Electron Beam Machining (EBM), and
Plasma Arc Machining (PAM). Hybrid Machining Process: Importance of hybrid machining
process; Process principal, process parameters, and application of: - Electrochemical Discharge
Machining (ECDM), Ultrasonic Assisted Electric Discharge Machining (UAEDM), Electrochemical
Discharge Grinding (EDG), Powder Assisted Electric Discharge Machining (PAEDM).

MODULE 5:
Jigs and Fixtures: Importance of jigs and fixtures; the difference between jigs and fixtures; types
of jigs and fixtures; essential features of jigs and fixtures, Materials used. Factors to be considered
for the design of Jigs and Fixtures; Jigs: Template, Plate, Channel, Diameter, Leaf, Rung, Box,
Fixtures: Turning, Milling, Broaching, Grinding, Boring, Indexing, Tapping, Duplex, Welding, and
Assembly fixtures.
MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Module 2
Mechanics of Metal Cutting
Single point turning tool geometry

Single point turning tools are used in lathe machines for cutting and shaping materials such as
metal, plastic, and wood. The geometry of a single point turning tool is critical to its
performance, as it determines how the tool will interact with the material being cut. The key
components of a single point turning tool include:

1. Cutting edge: The cutting edge is the part of the tool that comes into contact with the
material being cut. It is typically ground to a specific geometry to achieve the desired
cutting performance.

2. Tool tip: The tool tip is the part of the tool that is in contact with the workpiece. It is
typically ground to a specific geometry to achieve the desired cutting performance.

3. Rake angle: The rake angle is the angle between the cutting edge and the surface of the
workpiece being cut. A positive rake angle means that the cutting edge is tilted upward,
while a negative rake angle means that the cutting edge is tilted downward. A positive
rake angle is typically used for cutting soft materials, while a negative rake angle is
typically used for cutting hard materials.

4. Relief angle: The relief angle is the angle between the cutting edge and the surface of the
tool behind the cutting edge. It is used to prevent the tool from rubbing against the
workpiece and causing excessive heat and wear. A larger relief angle provides more
clearance for the tool and reduces the risk of rubbing.

5. Nose radius: The nose radius is the radius of the tool tip. A larger nose radius provides
greater strength and durability to the tool, while a smaller nose radius provides greater
precision and accuracy.

Dept. of Mechanical Engineering, SJBIT Page 1

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

The geometry of a single point turning tool can be adjusted to achieve different cutting
performance characteristics, such as higher cutting speeds, improved surface finish, and longer
tool life. The optimal geometry for a single point turning tool depends on the material being cut,
the desired cutting performance, and the specific application

The geometry of a single point turning tool (SPTT) has a significant influence on the chip
formation mechanisms that occur during the machining process. The SPTT geometry affects how
the chip is formed, the thickness of the chip, and the force required to remove material from the
workpiece.

The rake angle of the SPTT is particularly important in chip formation. A positive rake angle
will cause the chip to be formed more easily and will produce thinner chips, while a negative
rake angle will produce thicker chips. The relief angle of the SPTT also affects chip formation,
as it can help prevent the chip from rubbing against the tool and workpiece, which can lead to
excessive heat and wear.

The nose radius of the SPTT also affects chip formation. A larger nose radius can produce a
smoother surface finish and reduce the risk of chatter, but it can also increase the force required
to remove material from the workpiece. A smaller nose radius can produce a more precise cut
and require less force, but it can also increase the risk of tool wear.

Orthogonal cutting and oblique cutting

Orthogonal cutting and oblique cutting are two different cutting processes that are used in
machining operations such as turning, milling, drilling, and grinding.

Orthogonal cutting is a cutting process where the cutting edge of the tool is perpendicular to the
direction of motion of the workpiece. This cutting process is used in turning and facing
operations, where the workpiece rotates and the tool moves along a straight line to remove
material. In orthogonal cutting, the chip thickness is equal to the depth of cut, and the chip is
typically thicker than in oblique cutting.

Oblique cutting, on the other hand, is a cutting process where the cutting edge of the tool is at an
angle to the direction of motion of the workpiece. This cutting process is used in operations such
as milling and drilling, where the tool rotates and moves in a circular or spiral path to remove
material. In oblique cutting, the chip thickness is smaller than the depth of cut, and the chip is
typically thinner than in orthogonal cutting.

The choice between orthogonal and oblique cutting depends on the specific application and the
desired outcome. Orthogonal cutting is typically used when a high material removal rate is
required, while oblique cutting is used when a smoother surface finish is desired. Additionally,
oblique cutting can be used to create complex shapes and contours that cannot be achieved with
orthogonal cutting.

Dept. of Mechanical Engineering, SJBIT Page 2

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 3

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Cutting Fluids

Cutting fluids are liquids or gases that are used to cool and lubricate cutting tools during
machining operations. Some common characteristics of cutting fluids include:

1. Cooling: Cutting fluids help to dissipate heat generated during cutting, which helps to
prevent damage to the cutting tool and workpiece.

2. Lubrication: Cutting fluids provide lubrication between the cutting tool and the
workpiece, which helps to reduce friction and wear.

3. Chip evacuation: Cutting fluids help to flush away chips and debris from the cutting
zone, which helps to prevent chip buildup and clogging of the cutting tool.

4. Corrosion inhibition: Cutting fluids contain additives that help to prevent corrosion of the
cutting tool and workpiece.

5. Bacterial growth prevention: Cutting fluids can be prone to bacterial growth, which can
lead to unpleasant odors and degraded performance. Some cutting fluids contain biocides
to help prevent bacterial growth.

6. Environmental considerations: Cutting fluids can have negative environmental impacts if

they are not properly disposed of. Some cutting fluids are designed to be more
environmentally friendly, such as those that are water-based or biodegradable.

7. Application method: Cutting fluids can be applied to the cutting zone in a variety of
ways, including flood, mist, and spray. The application method can affect the
performance of the cutting fluid and the efficiency of the machining operation.

8. Compatibility: Cutting fluids should be compatible with the materials being machined,
the cutting tools being used, and any other additives or chemicals in the machining
process.

Selection of cutting fluids

The selection of cutting fluids for a specific machining operation depends on various factors such
as the type of material being machined, the cutting tool being used, the machining process, and
environmental considerations. Here are some key factors to consider when selecting cutting
fluids:

1. Material being machined: Different materials require different cutting fluids. For
example, water-based cutting fluids are generally suitable for machining aluminum,
whereas oil-based cutting fluids may be required for machining steel.

Dept. of Mechanical Engineering, SJBIT Page 4

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

2. Cutting tool: The type of cutting tool being used can also influence the selection of
cutting fluids. For example, carbide cutting tools may require a different type of cutting
fluid compared to high-speed steel tools.

3. Machining process: The type of machining process being used can also affect the
selection of cutting fluids. For example, a high-speed machining process may require a
cutting fluid with higher cooling and lubricating properties.

4. Environmental considerations: The environmental impact of the cutting fluid should also
be considered, including factors such as disposal and emissions. Water-based cutting
fluids are generally considered more environmentally friendly compared to oil-based
fluids.

5. Health and safety: The potential health and safety hazards associated with the cutting
fluid should also be considered. For example, some cutting fluids may contain hazardous
chemicals or emit harmful fumes.

6. Performance requirements: The performance requirements of the machining operation

should also be considered. For example, a high-precision machining operation may
require a cutting fluid with higher lubricating properties.

7. Cost: Finally, the cost of the cutting fluid should also be considered, as this can vary
depending on the type of fluid and the size of the machining operation.

Applyingmethods of cutting fluids.

Cutting fluids can be applied to the cutting zone in a variety of ways, including:

1. Flood cooling: This method involves flooding the entire workpiece and cutting zone with
cutting fluid. It is typically used for large-scale machining operations and can provide
effective cooling and lubrication.

2. Mist cooling: In this method, cutting fluid is atomized into fine mist and sprayed onto the
cutting zone. It is commonly used for high-speed machining operations and can provide
effective cooling and lubrication while minimizing fluid consumption.

3. Through-tool delivery: Cutting fluid is delivered directly through the cutting tool and
onto the cutting zone. This method can provide targeted cooling and lubrication and is
commonly used for drilling and boring operations.

4. Minimum quantity lubrication (MQL): In this method, a small amount of cutting fluid is
delivered to the cutting zone in a finely atomized spray. MQL can reduce fluid
consumption and minimize environmental impact while still providing effective cooling
and lubrication.

Dept. of Mechanical Engineering, SJBIT Page 5

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

5. Dry machining: Some cutting operations can be performed without the use of cutting
fluids, which can reduce fluid consumption and minimize environmental impact.
However, dry machining can increase tool wear and reduce tool life, particularly for
high-speed machining operations.

Analysis of machining forces and power requirements

Machine tools with enough power must be selected

• With known cutting forces, machine tools can be designed to avoid excessive distortion and
maintain desired tolerances

• Engineers can determine if the workpiece will withstand the cutting forces without distortion

• The tool holder, workholding device, and machine tool must be sufficiently stiff to minimize
deflections caused by the thrust force so that the tool is not pushed away from the workpiece
(reducing depth of cut and causing dimensional inaccuracy)

• Cutting forces can be measured by mounting on the tool:

• Dynamometers

• Force transducers (piezoelectric crystals)

• Cutting forces can also be calculated if you know the power consumption of the machine

• Duller tools require higher forces and power

Merchant’s circle diagram

Assumptions for Merchant’s circle diagram

The assumptions for the merchant circle diagram are as follows.

 The cutting tool must be sharp.

 There is no contact between the cutting tool and the clearance edge.

 The chip formation is in continuous form and without a built-up edge.

 The thickness of the uncut chip is constant.

 The workpiece moves with a uniform velocity during the cutting process.

 The width of the workpiece is always lesser than the cutting tool width.

 Shear occurs on a shear plane where the stress is uniformly distributed.

Dept. of Mechanical Engineering, SJBIT Page 6

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 7

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 8

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 9

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 10

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 11

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 12

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 13

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 14

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 15

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

THEORYOFLEEAND SHAFFER
The theory of Lee and Shaffer is based on slip line field theory and
appliessimplifiedplasticityanalysistotheproblemoforthogonalmetalcutting.Thefollowingassumptionsar
emadeonthebehaviourofworkmaterialunderstress.
1. The material is rigid plastic. The stress-strain curve is shown in Fig.a.
2. The behavior of material is independent of rate of deformation.
3. The effect of temperature increase during deformation is negligible.
4. The inertia effects resulting from acceleration of material during deformation are
negligible.
Stress

Strain

Fig.a Stress-stain curve for a rigid-plastic material.

Chip

tc
Tool
B R
C 45°
β

t 45°-β
ф
A
Workpiece
Fig.b Slip-line field for orthogonal cutting

Dept. of Mechanical Engineering, SJBIT Page 16

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Dept. of Mechanical Engineering, SJBIT Page 17

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Chip Velocity

Dept. of Mechanical Engineering, SJBIT Page 18

MACHINING SCIENCE AND JIGS & FIXTURES 21ME42

Suggested Learning Resources:

Textbook:

1. Shaw, M C, (2014), Metal Cutting Principles, Oxford University Press.

2. McGeough, J A, (1988), Advanced Methods of Machining, Springer.

3. Boothroyd, G., and Knight, W. A., Fundamentals of Machining and Machine Tools, CRC
Press.

4. Chattopadhyay, A B, (2013), Machining and Machine Tools, Wiley India.

5. Mikell P. Groover, (2019), Fundamentals of Modern Manufacturing: Materials, Processes, and

Systems, Wiley

Publications.

6. Rao P. N., Manufacturing Technology II, Tata McGraw Hill.

Dept. of Mechanical Engineering, SJBIT Page 19