Metal Cutting and Forming

Maharaja Education Trust (R), Mysuru
Maharaja Institute of Technology Mysore

Belawadi, Srirangapatna Taluk, Mandya – 571 477
Approved by AICTE, New Delhi,
Affiliated to VTU, Belagavi & Recognized by Government of Karnataka
Lecture Notes on
METAL CUTTING AND FORMING (18ME45A)
Prepared by
Department of Mechanical Engineering

Maharaja Education Trust (R), Mysuru
Belawadi, Srirangapatna Taluk, Mandya – 571 477
Vision/ ‫ﰰ‬෭
“To be recognized as a premier technical and management institution promoting extensive

education fostering research, innovation and entrepreneurial attitude"
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Mission/ l Í෭
 To empower students with indispensable knowledge through dedicated teaching and

collaborative learning.
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 To advance extensive research in science, engineering and management disciplines.

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 To facilitate entrepreneurial skills through effective institute - industry collaboration and

interaction with alumni.
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 To instill the need to uphold ethics in every aspect.

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 To mould holistic individuals capable of contributing to the advancement of the society.

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Vision / 璀ॴ
“To excel in technical education by producing Mechanical Engineers who are

competitive, contributing and sustainable in the global socio technological front.”
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Mission / l Íॴ
1. To enrich teaching-learning experience through distinguished practices

and ever improving infrastructure
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2. To enhance student performance through consistent guidance, motivation

and mentoring
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3. To develop distinct skills, leadership qualities and creative thinking among

the learners through sensible endeavors
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Program Outcomes
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems
and design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and
research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to complex engineering
activities with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need
for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and
write effective reports and design documentation, make effective presentations, and give and
receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member and
leader in a team, to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological change.
Course Overview
Subject: Metal Cutting and Forming Subject Code: 18ME45A
Metal cutting and forming are two different Processes for shaping components with desired
features and characteristics. Each process has its own distinguish features and capabilities.
Metal cutting is a process in which excess material is removed in the form of a chip to obtain the
desired size and shape of the product with various metal cutting machines like Lathe , drilling
machine, Milling machine, grinding machine, Boring machine, shaper, planer etc. and various types
of cutting tools are also used. The course emphasis on the nomenclature of various cutting tools, its
classification, cutting tool materials, process of chip formation and calculation of various forces
developed during the cutting action and its operating parameters. The course also outlines the tool
wear mechanisms, calculation of tool life, machining parameters and choices of cutting speed in
improving the productivity and tool-life with minimum cost and maximum production.
Metal forming is a process in which the desired shape and size of the component is obtained
through various plastic deformation process like forging, rolling, extrusion, drawing and various sheet
metal operations like deep drawing, Roll bending etc…By utilizing the concept of sheet metal dies to
prepare the various components like plain washer, fuel tank, cans, cup etc through the arrangement of
compound, combination and progressive dies.
Course Objectives
The objectives of this course is to make students to learn
1. To enrich the knowledge pertaining to relative motion and mechanics required for various
machine tools.
2. To introduce students to different machine tools to produce components having different
shapes and sizes.
3. To develop the knowledge on mechanics of machining process and effect of various
parameters on machining.
4. To acquaint with the basic knowledge on fundamentals of metal forming processes
5. To study various metal forming processes.
COs Description
Make use of fundamentals of manufacturing process to describe the constructional
C205.1
features and working of various machine tools and different metal working process
Identify the metal cutting process and its process parameters, cutting tool geometry term
C205.2
to solve real time metal cutting problems
Calculate the Forming loads in bending and drawing process and angle of bite in rolling
C205.3
Process
C205.4 Apply mechanics of machining process to evaluate machining time.
Analyze tool wear mechanisms and equations to enhance tool life and minimize
C205.5
machining cost.
Prof. G C Ramesh Prof. KrishnaPrasad S Prof. KrishnaPrasad S

Faculty Faculty Course Coordinator
Facilitator NBA Coordinator HOD

Syllabus
Module 1: Introduction to Metal cutting: Orthogonal and oblique cutting. Classification of
cutting tools: single, and multi point; tool signature for single point cutting tool. Mechanics of
orthogonal cutting; chip formation, shear angle and its significance, Merchant circle diagram. 08
Numerical problems. Cutting tool materials and applications. Introduction to basic metal cutting Hours
machine tools: Lathe- Parts of lathe machine, accessories of lathe machine, and various operations
carried out on lathe. Kinematics of lathe. Turret and Capstan lathe.
MODULE 2: Milling: Various Milling operations, classification of milling machines, Vertical &
Horizontal milling, up milling & down milling. Indexing: need of indexing, simple, compound &
differential indexing. Drilling: Difference between drilling, boring & reaming, types of drilling
08
machines. Boring operations & boring machines. Shaping, Planing and Slotting machines- Hours
machining operations and operating parameters. Grinding: Grinding operation, classification of
grinding processes: cylindrical, surface &centerless grinding
Module 3: Introduction to tool wear, tool wear mechanisms, tool life equations, effect of process
parameters on tool life, machinability. Cutting fluid-types and applications, surface finish, effect of
10
machining parameters on surface finish. Economics of machining process, choice of cutting speed Hours
and feed, tool life for minimum cost and production time. Numerical problems. .
Module 4:Mechanical Working of Metals Introduction to metal forming processes &
classification of metal forming processes. Hot working & coldworking of metals. Forging: Smith
forging, drop forging & press forging. Forging Equipment, Defects in forging. Rolling: Rolling 08
process, Angle of bite, Types of rolling mills, Variables of rolling process, Rolling defects. Hours
Drawing & Extrusion: Drawing of wires, rods & pipes, Variables of drawing process. Difference
between drawing & extrusion. Various types of extrusion processes.
Module 5: Sheet Metal Operations: Blanking, piercing, punching, drawing, draw ratio, drawing
force, variables in drawing, Trimming, and Shearing. Bending –– types of bending dies, Bending 08
force calculation, Embossing and coining. Types of dies: Progressive, compound and combination Hours
dies.
Index
SL. No. Contents Page No.
1-51
1 Module 1: Introduction to Metal cutting
52-118
2 Module 2: Milling, Drilling,Shaping and Grinding
119-159
3 Module 3: Introduction to tool wear
160-199
4 Module 4: Mechanical Working of Metals
200-220
5 Module 5: Sheet Metal Operations
Maharaja Institute of Technology Mysore Department of Mechanical Engineering
Metal Cutting and Forming (18ME45A) Module 1 Introduction to Metal Cutting Page 1
Metal Cutting and Forming (18ME45A) Module 2 Milling Drilling shaping and Grinding Page 52
Maharaja Institute of Technology Department of Mechanical Engineering
Metal Cutting & Forming (18ME45A) Module 3 Introduction to Tool Wear Page 119
Metal Cutting & Forming (18ME45A) Module 4 Metal Working of Metals Page 160
Maharaja institute of technology Mysore Department of Mechanical Engineering
Metal Cutting and Forming (18ME45A) Module 5 Sheet Metal Forming Page 200

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Maharaja Institute of Technology Mysore