HD1 : METAL CUTTING AND TOOL DESIGN

1    METAL MACHINING

Introduction 

2    MECHANICS OF METAL CUTTING

Chip formation. Shear Zone. Shear Plane angle: Different Theories. Friction in Metal Cutting. Chip Flow Velocity. Shear Strain.

3    MEASUREMENT OF CUTTING FORCES

Dynamometer Requirements. Classification of Cutting Force Dynamometers. Mechanical Type Hydraulic and Pneumatic Type. Optical Type. Inductance Type. Piezoelectric Type. Strain, Gauge Dynamometers. Lathe Tool Dynamo-­meter. Drill Dynamometer, Milling Dynamo­meter. Grinding Dynamometer.

4    HEAT IN METAL CUTTING   

Heat Sources in Metal Cutting. Temperature in Chip Formation. Temperature Distribution. Factors Effecting the Temperature-Work Material, Cutting Variables, Tool Geometry, Cutting Fluid.

5    FAILURE OF CUTTING TOOLS

Tool Wear and Tool Life; Premature failure. Gradual Wear. Crater Wear. Flank Wear, Grooving Wear, Chip notching, Wear Mecha­nisms in Metal Cutting, Abrasive Wear, Diffusion Wear. Adhesion, Oxidation Wear. Tool Life, Taylor's Tool Life Equation. Woxen's Equation. Cutting Conditions for Limiting Tool Life Conditions. T-V-he Tool Life Plots. Cutting Rate- Tool Life Characteristics Curve.

6    TOOL WEAR MEASUREMENT

Optical Methods; Flank Wear, Crater Wear Measurement. Radioactive Methods. Electron Probe Micro Analyser-EPMA. Energy_ Dispersive X-ray Analysis-EDXA. Augur Electron SpectroScopy -AES.

7    TOOL MATERIALS

Requirements of Tool Material. Classification. Tool Steels. H.S.S. Coated H.S.S. Powder Metallurgy H.S.S. Cast Cobalt Alloys-Stellite, Cemented Carbides; Tungsten Carbide Manufacture of Powder, Blending, Briquetting, Sintering, Hot Isostatic Pressing, Properties. Multi Carbide Tools; Properties. Coated Carbide tools; Coating Techniques; PVD Process, CVD Process. Performance of coated Tools. Oxi­coated Tools. TiN coated Tools. ALON coated Tools.

8    CEMENTED TITANIUM CARBIDE TOOL

Properties, Microstructure Performance, Crater Wear Propagation. Diffusion Wear in CTC tools. Mechanisms of Wear in CTC tools. Ledge Formation, TiC coated CTC Tools. Micro­structure. Performance.

9    CERAMIC CUTTING TOOLS

Manufacture; Powder Preparation, Sintering. Additives, Properties. Performance. SIALON tools. Cubic Boron Nitride (CBN) tools; Properties, Applications. Synthetic Diamond tools; Properties; Performance.

10  TOOL GEOMETRY

Tool Nomenclature. Basic Tool Angles, Effect of Basic Angles. Tool Nomenclature Systems; British System, American Standard Association System, German System, ISO System. Geometrical Relationship of True Rake Angle, Angle of Inclination.

11  CUTTING FLUIDS

Functions of Cutting Fluid, Lubrication in Metal Cutting; Cooling Properties of Cutting Fluids. Types of Cutting Fluids; Petroleum Based, Emulsified, Synthetic Type. Additives, Selection and Application of Cutting Fluids.

12  ECONOMICS OF MACHINING

Production Cost. Economic Tool Life. Optimum Cutting Speed for Maximum Production. Tool Life for Maximum Profit.

13  CUTTING TOOL DESIGN

General Considerations.

14  DESIGN OF SINGLE POINT TOOL

Tool Strength and Rigidity. Design of Form Tools. Types of Form Tools. Circular Form Tool. Profile Design; Geometrical Method. Analytical Method. Flat Form Tool Design. Grinding the Form Tool. Profile for a Tapered Surface. Tangential Type of Form Tool.

15  DESIGN OF DRILL

Twist Drill Construction. Drill Diameter. Flute Angle. Web Thickness and Chisel Edge. Land

Width Margin. Shape of Flute Section. Flute Length, Shank. Geometry of the Cutting Edge, Rake Angle, Relief Angle, Angle of Inclination.

16  DESIGN OF MILLING CUTTER

Types of Milling Cutters, Profile Sharpened, Form Relieved Milling Cutters. Design of Profile Sharpened Milling Cutters. Design of Form Relieved Milling Cutters.

17  DESIGN OF BROACH

Design Elements of Broach. Number of Teeth, Tooth, Pitch and Chipspace. Rear Pilot Length of Broach, Strength of Broach.

18  CUTTING TOOL MANUFACTURING

Single Point Tool Production. Twist Drill Production, Manufacture of Broach. Manufacture of Milling Cutter.

19  GEAR CUTTING TOOLS

Gear Form Cutting Tools. Gear Generation Cutting Tools. Design of a Gear Cutting Hob. Profile in the Normal Section. Diameter of the Hob. Hob Length. Relief Angle. Cam Relief. Pitch Cylinder Diameter. Gear Shaper Tools.

20  THREAD CUTTING TOOLS

Thread Cutting Dies. Thread Rolling Tools. Design of Thread Cutting Taps.

21  DESIGN OF REAMER

Reamer Design. Length. Flutes. Rake Angle and Relief Angle. Grinding of Reamer.