Name of the Content Developer: S.

ARUN KUMAR Affiliation: ANNA UNIVERSITY

Medium of Instruction: ENGLISH Department: MECHANICAL ENGG.
Course: B.E. (MECH) Semester: IV
Subject: ME 8451 Manufacturing Technology - II

ME 8451
MANUFACTURING TECHNOLOGY-II
Name of the Content Developer: S.ARUN KUMAR Affiliation: ANNA UNIVERSITY
Medium of Instruction: ENGLISH Department: MECHANICAL ENGG.
Course: B.E. (MECH) Semester: IV
Subject: ME 8451 Manufacturing Technology - II

UNIT-I THEORY OF METAL CUTTING 9

Mechanics of Chip Formation, Single Point Cutting Tool, Forces in Machining, Types of Chip, Cutting
Tools– Nomenclature, Orthogonal Metal Cutting, Thermal Aspects, Cutting Tool Materials, Tool
Wear, Tool Life, Surface Finish, Cutting Fluids and machinability.

UNIT-II TURNING MACHINES 9

Centre lathe, constructional features, specification, operations – taper turning methods, thread
cutting methods, special attachments, machining time and power estimation. Capstan and turret lathes-
tool layout – automatic lathes: semi automatic – single spindle: Swiss type, automatic screw type –
multi spindle:

UNIT-III SHAPER, MILLING AND GEAR CUTTING MACHINES 9

Shaper - Types of Operations. Drilling, Reaming, Boring, Tapping, Milling Operations - Types of
Milling Cutter. Gear Cutting – Forming And Generation Principle and Construction of Gear Milling,
Hobbing and Gear Shaping Processes – Finishing of Gears.

UNIT-IV ABRASIVE PROCESS AND BROACHING 9

Abrasive processes: grinding wheel – specifications and selection, types of grinding process –
cylindrical grinding, surface grinding, centreless grinding and internal grinding - typical applications –
concepts of surface integrity, broaching machines: broach construction – push, pull, surface and
continuous broaching machines.

UNIT-V CNC MACHINING 9

Numerical Control (NC) machine tools – CNC types, constructional details, special features, machining
centre, part programming fundamentals CNC – manual part programming – micro
machining – wafer machining.
Name of the Content Developer: S.ARUN KUMAR Affiliation: ANNA UNIVERSITY
Medium of Instruction: ENGLISH Department: MECHANICAL ENGG.
Course: B.E. (MECH) Semester: IV
Subject: ME 8451 Manufacturing Technology - II

UNIT-I THEORY OF METAL CUTTING 9

Mechanics of Chip Formation, Single Point Cutting Tool, Forces in Machining, Types of Chip, Cutting
Tools– Nomenclature, Orthogonal Metal Cutting, Thermal Aspects, Cutting Tool Materials, Tool
Wear, Tool Life, Surface Finish, Cutting Fluids and machinability.
Learning objectrives:
 To understand about the mechanisms of Chip formation
 To understand about the types of cutting tools and various aspects of cutting tools
Session 1:
In any engineering industry, components are made into various shapes and sizes by using metals.
These shapes and sizes are formed either by using non-cutting or chipless operations such as forging,
blanking, shaping etc., or by using metal cutting or chip forming operations such as turning, milling, drilling,
shaping etc., During machining, the excess metal is gradually removed from the parent metal by using the
suitable tools in the form of chips. Depending on the type of operations, suitable tools are used to cut the
metal. The following are the basic objectives of the economical and efficient machining practice:
 Quick metal removal
 High-class surface finish
 Economy in tool cost
1.1 Mechanics of chip formation:
Name of the Content Developer: S.ARUN KUMAR Affiliation: ANNA UNIVERSITY
Medium of Instruction: ENGLISH Department: MECHANICAL ENGG.
Course: B.E. (MECH) Semester: IV
Subject: ME 8451 Manufacturing Technology - II

1.1.1 Geometry of chip formation

Generally, the chip thickness after cutting is larger than the chip thickness before cutting the work
piece. Also, the metal prior to being cut is much longer than the chip which is removed.
Let t1, b1, l1 – Thickness, width & length of chip before cutting.
t2, b2, l2 – Thickness, width & length of chip after cutting.
The ratio of chip thickness before cutting to the chip formation after cutting is called chip thickness
ratio. It is denoted by r.
Chip thickness ratio, r = t1/t2
The chip thickness ratio is always less than one. A ratio 1:2 yields good results.
The reciprocal of chip thickness ratio is called chip reduction coefficient. It is denoted by the letter k.
k = 1/r
There is no change in volume when the metal is cut.
Volume of metal to be removed = Volume of chip.
t1 × b1 × l1 = t2 × b2 × l2
Since, b1 = b2
t1 × l1 = t2 × l2
𝑡1 𝑙1
= =𝑟
𝑡2 𝑙2
Name of the Content Developer: S.ARUN KUMAR Affiliation: ANNA UNIVERSITY
Medium of Instruction: ENGLISH Department: MECHANICAL ENGG.
Course: B.E. (MECH) Semester: IV
Subject: ME 8451 Manufacturing Technology - II

The chip thickness ratio is used to measure shear angle (β) as follows.
𝑡1
𝐴𝐵 =
sin 𝛽