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LESSON PLAN LP- ME 2252

LP Rev. No: 00

Date: 09/12/2009

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Sub Code &Name : ME 2252 Manufacturing Technology - II

Branch: Mechanical Engg. Semester : IV

UNIT I THEORY OF METAL CUTTING 9(LIntroduction: material removal processes, types of machine tools theory of metal cuttin

chip formation, orthogonal cutting, cutting tool materials, tool wear, tool life, surface finish, cuttinfluids.

Objective: To understand the basic concepts in mechanics of metal cutting, chip formation, varioutool materials and their properties.

Session

No Topics to be covered Time Ref

Teaching

Method

1 Introduction, Need for metal removal process, comparison

of metal machining process with respect to metal forming

process, Classification of machine tools.

50 min

1,2

BB

2 Theory of metal cutting, mechanics of chip formation 50 min BB

3 Types of chip, Continuous chips with built up edge,discontinuous chips, continuous chips without built up

edge, conditions favorable for the formation of various

types of chips

50 min BB

4 Types of metal cutting Orthogonal cutting and oblique

cutting

50 min BB

5 Cutting tool materials, Tool materials properties, Tool

wear and various mechanisms of tool wear

50 min BB

6 Tool life definition, surface finish- properties influencing

surface finish

50 min BB

7 Cutting fluids, properties of cutting fluids 50 min BB

8 Cutting force in single point cutting tool, merchants circleconstruction, velocity triangle in metal cutting

50 min BB

9 Problems related to metal cutting 50 min BB

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Unit II CENTRE LATHE AND SPECIAL PURPOSE LATHES 9(LCentre lathe, constructional features, cutting tool geometry, various operations, taper turnin

methods, thread cutting methods, special attachments, machining time and power estimatioCapstan and turret lathes automats single spindle, Swiss type, automatic screw type, muspindle - Turret Indexing mechanism, Bar feed mechanism.

Objective: - To teach the concept of types of lathe, capstan lathe, turret lathe and automats, variooperations that can be performed in various lathe, various mechanisms adopted.

Session


Teaching

Method

1 Centre lathe constructional features: - Headstock, tailstock,saddle, carriage, bed, tool post, feed rod etc. Cutting toolgeometry- tool nomenclature and tool signature

50 min

1,2

BB

2 Various operations in lathe Turning, facing, taperturning, Grooving, parting off, drilling, boring, threading

operations, undercutting.

50 min BB

3 Various methods of taper turning by swiveling the

compound rest, by form tool, by shifting the tail stock,

taper turning attachment

50 min BB

4 Thread cutting methods by single point cutting tool, taps

and dies. Special attachments used in lathe, Machining

time and power estimation in lathe.

50 min BB

5 Capstan lathe and turret lathe constructional details,

difference between capstan and turret lathe

50 min BB

6 Turret indexing mechanism and bar feeding mechanism in

capstan and turret lathe.

50 min BB

7 Automats introduction, types of automats single spindle

automats and Multispindle automats, Single spindle

automats :- Swiss type and sliding head type automats

50 min BB

8 Multispindle spindle automats; Parallel action and

Multispindle automats,

50 min BB

9 Tool layout for capstan lathe for a given component 50 min BB

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UNIT III OTHER MACHINE TOOLS 9(LReciprocating machine tools: shaper, planer, slotter - Milling: types, milling cutters, operatio

- Hole making: drilling - Quill mechanism, Reaming, Boring, Tapping - Sawing machine: hack sawband saw, circular saw; broaching machines: broach construction push, pull, surface acontinuous broaching machines

Objective: - To teach the basic fundamentals of reciprocating machine tools used to generate thplain surface, the various operations performed, various cutters used and various mechanisminvolved in various machine tools.

Session


Teaching

Method1 Construction details of shaper, planer and slotter 50 min

1, 2

BB

2 Various operations performed in shaper, planer and slotter 50 min BB

3 Mechanisms in shaper, planer 50 min BB

4 Construction details of milling machine, various cuttersused

50 min BB

5 Various operations performed in milling machine 50 min BB

6 Construction details of upright and radial type drilling

machine, quill mechanism for providing the rotary and feed

movement to the tool, various operations performed

50 min BB

7 Sawing machine types and constructional details 50 min BB

8 Broaching machine construction, types of broachingmachine

50 min BB

9 Various operations performed in broaching machine 50 min BB

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UNIT IV ABRASIVE PROCESSES AND GEAR CUTTING 9(LAbrasive processes: grinding wheel specifications and selection, types of grinding process

cylindrical grinding, surface grinding, centreless grinding honing, lapping, super finishing, polishiand buffing, abrasive jet machining - Gear cutting, forming, generation, shaping, hobbing.

Objective:- To teach the fundamentals of finishing process and super finishing process, theirassociated machine tools and the various gear manufacturing process.

Session


Teaching

Method

1 Construction detail of cylindrical grinding machine,

centreless grinding and surface grinding machine.

50 min

1, 2

BB

2 Grinding wheel specification and selection of grinding

wheels

50 min BB

3 Types of components grinded in centreless grinding

machine

50 min BB

4 Gear manufacturing process classification Gear forming

and gear generation process. Gear forming process

indexing mechanism, various types of indexing

50 min BB

5 Gear milling procedure for cutting spur and helical gears

in milling machine.

50 min BB

6 Gear hobbing constructional details Gear hob cutter,

change gear calculations

50 min BB

7 Procedure for cutting spur gear and helical gear in hobbing

machine

50 min BB

8 Gear shaping constructional details, types of gear shaping

process, gear shaping using disc type cutter and gear

shaping using reciprocating cutter

50 min BB

9 Procedure for cutting spur and helical gear in gear shaper. 50 min BB

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UNIT V CNC MACHINE TOOLS AND PART PROGRAMMING 9(LNumerical control (NC) machine tools CNC: types, constructional details, special features

design considerations of CNC machines for improving machining accuracy structural membersslide ways linear bearings ball screws spindle drives and feed drives. Part programmifundamentals manual programming computer assisted part programming.

Objective: - To understand the basic concepts of computer numerical control (CNC) machine toand CNC programming.

Session


Teaching

Method

1 Numerical control machine tools, CNC types, CNC andDNC, construction details,

50 min

2, 3

BB

2 Special features of CNC machine tools, design

considerations on CNC machines for improving machiningaccuracy

50 min BB

3 Introduction to Structural membersslide ways, linearbearings, ball screws

50 min BB

4 Spindle drives and feed drives 50 min BB

5 Part programming fundamentals axis designation,

coordinate system, absolute and incremental mode of

programming

50 min BB

6 Types of controller, manual part programming for simplecomponents

50 min BB

7 Computer assisted part programming, Different statements 50 min BB

8 Computer assisted part programming for simple components 50 min BB

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Course Delivery Plan:

Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

I II I II I II I II I II I II I II I II I II I II I II I II I II I II I II

Units

Text Book

1. Hajra Choudry, Elements of Work Shop Technology Vol. II, Media Promoters. 2002

2. Rao, P.N. Manufacturing Technology, Volume II, Metal Cutting and Machine Tools, Ta

McGrawHill, New Delhi, 2009.

3. M.P.Groover and Zimers Jr., CAD/CAM Prentice Hall of India Ltd., 2004

Prepared by Approved by

Signature

Name S. Ramesh Babu Dr.N.Nallusamy

Designation ASST.PROFESSOR H.O.D.MECHANICAL

Date 09/12/2009 09/12/2009

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ME2252