AKTU Syllabus

Unit-2
Metal cutting: Single and multi-point cutting; Orthogonal cutting, various force
components: Chip formation, Tool wear and tool life, Surface finish and integrity,
Machinability, cutting tool materials, cutting fluids, Coating; Turning, Drilling,
Milling and finishing processes, Introduction to CNC machining, Additive
manufacturing, Rapid prototyping and rapid tooling
 Manufacturing Process
Manufacturing is a process of converting raw material into finished product
by using various processes, machines and energy, it is a narrow term.
𝑴𝒂𝒏𝒖𝒇𝒂𝒄𝒕𝒖𝒓𝒊𝒏𝒈
Raw Materials Finished Products
𝑷𝒓𝒐𝒄𝒆𝒔𝒔𝒆𝒔

Production
Production is a process of converting inputs into outputs it is a broader
term.
 Classification of Manufacturing Process

𝐼. 𝐶𝑎𝑠𝑡𝑖𝑛𝑔

𝐼𝐼. 𝑆ℎ𝑎𝑝𝑝𝑖𝑛𝑔 𝑜𝑟 𝐹𝑜𝑟𝑚𝑖𝑛𝑔 𝑍𝑒𝑟𝑜 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝑆ℎ𝑎𝑝𝑒, 𝑁𝑜 𝑐ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑚𝑎𝑠𝑠.

𝐼𝐼𝐼. 𝑅𝑒𝑚𝑜𝑣𝑎𝑙 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 (𝑀𝑎𝑐ℎ𝑖𝑛𝑖𝑛𝑔): 𝑁𝑒𝑔𝑎𝑡𝑖𝑣𝑒 𝑃𝑟𝑜𝑐𝑒𝑠𝑠

𝐼𝑉. 𝐽𝑜𝑖𝑛𝑖𝑛𝑔 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 (𝑊𝑒𝑙𝑑𝑖𝑛𝑔): [ +𝑣𝑒 𝑃𝑟𝑜𝑐𝑒𝑠𝑠]

𝑉. 𝑅𝑒𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑣𝑒 𝑚𝑎𝑛𝑢𝑓𝑎𝑐𝑡𝑢𝑟𝑖𝑛𝑔
𝑴𝒂𝒄𝒉𝒊𝒏𝒊𝒏𝒈 (−𝑣𝑒 𝑝𝑟𝑜𝑐𝑒𝑠𝑠. )
 𝑴𝒂𝒄𝒉𝒊𝒏𝒊𝒏𝒈 (−𝑣𝑒 𝑝𝑟𝑜𝑐𝑒𝑠𝑠. )
“𝑰𝒕 𝒊𝒔 𝒂 𝒎𝒂𝒏𝒖𝒇𝒂𝒄𝒕𝒖𝒓𝒊𝒏𝒈 𝒑𝒓𝒐𝒄𝒆𝒔𝒔 𝒊𝒏 𝒘𝒉𝒊𝒄𝒉 𝒓𝒆𝒎𝒐𝒗𝒂𝒍 𝒐𝒇 𝒎𝒆𝒕𝒂𝒓𝒊𝒂𝒍 𝒕𝒂𝒌𝒆𝒔
𝒑𝒍𝒂𝒄𝒆 𝒊𝒏 𝒐𝒓𝒅𝒆𝒓 𝐭𝐨 𝒐𝒃𝒕𝒂𝒊𝒏𝒆𝒅 𝒅𝒆𝒔𝒊𝒓𝒆𝒅 𝒔𝒉𝒂𝒑𝒆 𝒂𝒏𝒅 𝒔𝒊𝒛𝒆 𝒐𝒇 𝒂𝒏 𝒐𝒃𝒋𝒆𝒄𝒕".
𝑫𝒓𝒂𝒘𝒃𝒂𝒄𝒌 𝒐𝒇 𝒎𝒂𝒄𝒉𝒊𝒏𝒊𝒏𝒈: −
 𝑆𝑙𝑜𝑤 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 𝐿𝑜𝑤 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦
 𝐿𝑜𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑜𝑟𝑚 𝑜𝑓 𝑐ℎ𝑖𝑝𝑠

𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝑇𝑜𝑜𝑙: 𝑝𝑜𝑤𝑒𝑟 𝑤𝑖𝑡ℎ 𝑐𝑢𝑡𝑡𝑒𝑟

(𝐸𝑥. −𝐿𝑎𝑡ℎ𝑒 , 𝑆ℎ𝑎𝑝𝑒𝑟, 𝑀𝑖𝑙𝑙𝑖𝑛𝑔 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 𝑒𝑡𝑐. )
𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑇𝑜𝑜𝑙: 𝐶𝑢𝑡𝑡𝑒𝑟 𝑜𝑛𝑙𝑦 (𝐸𝑥. −𝐷𝑟𝑖𝑙𝑙 𝑏𝑖𝑡, 𝑚𝑖𝑙𝑙𝑖𝑛𝑔 𝑐𝑢𝑡𝑡𝑒𝑟 𝑒𝑡𝑐. )
 𝑂𝑟𝑡ℎ𝑜𝑔𝑜𝑛𝑎𝑙 𝐶𝑢𝑡𝑡𝑖𝑛𝑔
𝛼: 𝑅𝑎𝑘𝑒 𝑎𝑛𝑔𝑙𝑒
𝛶: 𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒 𝑜𝑟 𝑅𝑒𝑙𝑖𝑒𝑓 𝑎𝑛𝑔𝑙𝑒
𝛹 ∶ 𝐿𝑖𝑝 𝑎𝑛𝑔𝑙𝑒 𝑜𝑟 𝑤𝑒𝑑𝑔𝑒 𝑎𝑛𝑔𝑙𝑒 𝑜𝑟
𝑘𝑛𝑖𝑓𝑒 𝑎𝑛𝑔𝑙𝑒 𝑜𝑟 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑎𝑛𝑔𝑙𝑒.
𝜙 ∶ 𝑆ℎ𝑒𝑎𝑟 𝑎𝑛𝑔𝑙𝑒
𝑡𝑐 = 𝑐ℎ𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
𝑡 = 𝑢𝑛𝑐𝑢𝑡 𝑐ℎ𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
𝑜𝑟 𝑈𝑛𝑑𝑒𝑓𝑜𝑟𝑚𝑎𝑒𝑑 𝑐ℎ𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠

(𝑡𝑐 > 𝑡 ) − 𝐷𝑢𝑒 𝑡𝑜 𝑝𝑙𝑎𝑠𝑡𝑖𝑐 𝑑𝑒𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛.

(𝑠ℎ𝑒𝑎𝑟 𝑓𝑎𝑖𝑙𝑢𝑟𝑒)
𝑡=𝑑 𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 𝐹𝑜𝑟 “𝑜𝑟𝑡ℎ𝑜𝑔𝑜𝑛𝑎𝑙 𝑐𝑢𝑡𝑡𝑖𝑛𝑔”
𝑡 = 𝑓𝑠𝑖 𝑛 𝜆 𝑇𝑢𝑟𝑛𝑖𝑛𝑔
𝑓 = 𝑓𝑒𝑒𝑑 𝜆 = 𝑝𝑟𝑖𝑛𝑐𝑖𝑝𝑎𝑙 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒 𝑎𝑛𝑔𝑙𝑒
𝑏 = 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡.

𝑅𝑎𝑘𝑒 𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑜𝑟 𝐹𝑎𝑐𝑒: −

 𝑇ℎ𝑒 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑙𝑜𝑛𝑔 𝑤ℎ𝑖𝑐ℎ 𝑡ℎ𝑒 𝑐ℎ𝑖𝑝 𝑚𝑜𝑣𝑒𝑠 𝑢𝑝𝑤𝑎𝑟𝑑 𝑖𝑠 𝑐𝑎𝑙𝑙𝑒𝑑 𝑅𝑎𝑘𝑒 𝑠𝑢𝑟𝑓𝑎𝑐𝑒
𝑜𝑓 𝑡𝑜𝑜𝑙.
𝐹𝑙𝑎𝑛𝑘 𝑜𝑟 𝑅𝑒𝑙𝑖𝑒𝑓 𝑆𝑢𝑟𝑓𝑎𝑐𝑒: −
 𝑇ℎ𝑒 𝑜𝑡ℎ𝑒𝑟 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 𝑟𝑒𝑙𝑖𝑒𝑣𝑒𝑑 𝑡𝑜 𝑎𝑣𝑜𝑖𝑑 𝑟𝑢𝑏𝑏𝑖𝑛𝑔 𝑤𝑖𝑡ℎ 𝑡ℎ𝑒 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑑
𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑖𝑠 𝑐𝑎𝑙𝑙𝑒𝑑 𝑓𝑙𝑎𝑛𝑘 𝑜𝑟 𝑅𝑒𝑙𝑖𝑒𝑓 𝑠𝑢𝑟𝑓𝑎𝑐𝑒.
𝑅𝑎𝑘𝑒 𝐴𝑛𝑔𝑙𝑒 ∝ : −
 𝐴𝑛𝑔𝑙𝑒 𝑜𝑓 𝑖𝑛𝑐𝑙𝑖𝑛𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑅𝑎𝑘𝑒 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑟𝑜𝑚 𝑟𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑝𝑙𝑎𝑛𝑒,
𝑖. 𝑒. 𝑛𝑜𝑟𝑚𝑎𝑙 𝑡𝑜 ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑑 𝑠𝑢𝑟𝑓𝑎𝑐𝑒.
 𝐼𝑡 𝑎𝑙𝑙𝑜𝑤𝑠 𝑐ℎ𝑖𝑝 𝑓𝑙𝑜𝑤 𝑑𝑖𝑟𝑒𝑐𝑡𝑖𝑜𝑛.
 𝐼𝑡 𝑅𝑒𝑑𝑢𝑐𝑒𝑠 𝑡ℎ𝑒 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜 𝑠ℎ𝑒𝑎𝑟 𝑡ℎ𝑒 𝑚𝑒𝑡𝑎𝑙 & 𝑟𝑒𝑑𝑢𝑐𝑒
𝑡ℎ𝑒 𝑝𝑜𝑤𝑒𝑟 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛.
 𝐼𝑡 𝑖𝑚𝑝𝑟𝑜𝑣𝑒𝑠 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑖𝑛𝑖𝑠ℎ.
𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒 𝑜𝑟 𝑅𝑒𝑙𝑖𝑒𝑓 𝑎𝑛𝑔𝑙𝑒 𝛾 : −
 𝐴𝑛𝑔𝑙𝑒 𝑜𝑓 𝑖𝑛𝑐𝑙𝑖𝑛𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑓𝑙𝑎𝑛𝑘 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑓𝑖𝑛𝑖𝑠ℎ𝑒𝑑 𝑠𝑢𝑟𝑓𝑎𝑐𝑒.
 𝐼𝑡 𝑟𝑒𝑑𝑢𝑐𝑒𝑠 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝑡𝑜𝑜𝑙 𝑤𝑒𝑎𝑟.
 𝐼𝑡 𝑖𝑚𝑝𝑟𝑜𝑣𝑒𝑠 𝑙𝑖𝑓𝑒.
 𝐸𝑥𝑐𝑒𝑠𝑠𝑖𝑣𝑒 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒 𝑤𝑒𝑎𝑘𝑒𝑛𝑠 𝑡ℎ𝑒 𝑡𝑜𝑜𝑙. 𝐼𝑡 𝑀𝑢𝑠𝑡 𝑏𝑒 + 𝑣𝑒 3° 𝑡𝑜 15°
Lip angle or wedge angle or knife angle or cutting angle (𝛹) :-
 It depends on the rake and clearance angle provided on the tool.
 It determines the strength of the cutting edge.
 A larger angle permits machining harder materials, allows heavier depth
of cut, increases tool life.
𝑆ℎ𝑒𝑎𝑟 𝑎𝑛𝑔𝑙𝑒(𝜙):-
 It is defined as the angle between the shear plane and the cutting
direction.
 The shear plane is the surface along which the material being cut
deforms plastically and shears off to form a chip.
 𝑶𝒓𝒕𝒉𝒐𝒈𝒐𝒏𝒂𝒍 𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝑶𝒃𝒍𝒊𝒒𝒖𝒆 𝒄𝒖𝒕𝒕𝒊𝒏𝒈
Cutting edge of the tool is Cutting edge of the tool is inclined to
perpendicular to the direction of the direction of cutting velocity
cutting velocity
Chips flow straight up the face of the Chips flow sideways, along the face of
tool the tool.
Forces are two-dimensional. Forces are three-dimensional.
𝑇ℎ𝑒 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒 𝑖𝑠 𝑤𝑖𝑑𝑒𝑟 𝑡ℎ𝑎𝑛 𝑡ℎ𝑒
𝑤𝑜𝑟𝑘𝑝𝑙𝑒𝑐𝑒 𝑤𝑖𝑑𝑡ℎ

𝐻𝑒𝑎𝑡: −[𝑐ℎ𝑖𝑝 > 𝑡𝑜𝑜𝑙 > 𝑤𝑜𝑟𝑘𝑝𝑙𝑒𝑐𝑒

 𝐶𝑙𝑎𝑠𝑠𝑖𝑓𝑖𝑐𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡𝑜𝑜𝑙
(𝐴𝑐𝑐𝑜𝑟𝑑𝑖𝑛𝑔 𝑡𝑜 𝑛𝑜. 𝑜𝑓 𝑚𝑎𝑗𝑜𝑟 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒𝑠 𝑝𝑜𝑖𝑛𝑡𝑠 𝑖𝑛𝑣𝑜𝑙𝑣𝑒𝑠 : −
1. 𝑆𝑖𝑛𝑔𝑙𝑒 𝑃𝑜𝑖𝑛𝑡: −
𝑇𝑢𝑟𝑛𝑖𝑛𝑔, 𝑠ℎ𝑎𝑝𝑖𝑛𝑔, 𝑝𝑙𝑎𝑛𝑛𝑖𝑛𝑔, 𝑠𝑙𝑜𝑡𝑡𝑖𝑛𝑔 𝑡𝑜𝑜𝑙𝑠, 𝑝𝑎𝑟𝑡𝑖𝑛𝑔 𝑡𝑜𝑜𝑙𝑠 𝑒𝑡𝑐.
𝑜𝑛𝑒 𝑐ℎ𝑖𝑝 𝑎𝑡 𝑎 𝑡𝑖𝑚𝑒
2. 𝐷𝑜𝑢𝑏𝑙𝑒 𝑃𝑜𝑖𝑛𝑡: −
𝐷𝑟𝑖𝑙𝑙𝑖𝑛𝑔 𝑡𝑜𝑜𝑙, . 𝑇𝑤𝑜 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒
3. 𝑀𝑢𝑙𝑡𝑖𝑝𝑜𝑖𝑛𝑡: −
𝑀𝑖𝑙𝑙𝑖𝑛𝑔, 𝑏𝑟𝑜𝑎𝑐ℎ𝑖𝑛𝑔, 𝑠𝑎𝑤, 𝑔𝑟𝑖𝑛𝑑𝑖𝑛𝑔 𝑤ℎ𝑒𝑒𝑙 𝑒𝑡𝑐. 𝑚𝑢𝑙𝑡𝑖𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑒𝑑𝑔𝑒
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