Lecture 18

Water Jet Machining1. Introduction.2. The machining system3. Process parameters4. Factors affecting WJM performance.5. Applications6. Advantages and disadvantages of WJM7. Abrasive Jet Machining(AJM)8. Machining system9. Material removal rate10.Applications11.Advantages and limitations of AJM12.Abrasive Water Jet Machining(AWJM)13.Ice Jet Machining( IJM)

Lecture No 2.

Main Topics:

Classification of cutting tools. Cutting tool Nomenclature/Designation. Cutting tool planes. Single point Cutting tools Geometry. ASA System – American standards Association system or

American National standards Institute (ANSI).

Tool Signature: (for various systems):

Significance of Various Tool Angles: Rake Angle (back & side). Relief angle(back & side). Approach angles. Nose Radius Inclination angle

Lecture No.6

Chip formation process

Main topics.

1. Basic Principles

2. Theories that explained chip formation process.

3. Analytic theory.

4. Mechanistic theory.

5. Numerical Method.

6. Friction in metal cutting.

7. Cutting types: orthogonal and oblique cutting.

Lectuare NO 10

Machine tool Dynamometer

1. Introduction.2. Applications of dynamometers.3. Main requirements of a good Dynamometer.4. Design of dynamometers.5. Dynamometer classification.6. Active type.7. Passive type.8. Mechanical deflection dynamometers.9. Hydraulic and pneumatic dynamometers.10.Inductive type dynamometers.11.Capacitive type dynamometers.12.Strain gauge dynamometers

Lecture No 11

Power required for metal cutting

1. Introduction.2. The total power required for cutting in (KW).3. The total power required for cutting in vol. of chip removed.4. Power at the shear zone.5. Power at tool chip interface region.6. Mathematical relations and derivations.7. Solved problems.

Lecture No 12

Heat generated in metal cutting

1. Introduction.2. Heat sources in metal cutting.3. At primary deformation zone4. At secondary deformation zone.5. At tertiary deformation zone.6. Calculations of cutting temperature in metal cutting.7. Mathematical relations.8. Solved problems.

Lecture No 14

Wear of Cutting Tools

1. Introduction

2. Tool Wear classifications

3. Typical wear zones.

4. Wear mechanisms

1. Abrasion wear.

2. Diffusion wear.

3. Oxidation wear.

4. Fatigue wear.

5. Adhesion wear

5. Basic wear mechanism in metal cutting.

6. Wear types.

7. Flank wear.

8. Crater wear.

9. Typical tool wear curve.

10.Effect of cutting speed on tool wear curve.

11.Effect of cutting temperature on tool wear curve.

Lecture No1

Main topics

1. Basic metal cutting definition.

2. Relation between metal cutting and metal forming and other

manufacturing technology.

3. Basic machining principles and Aspects.

Cutting speed.

Feed Rate.

Depth of cut.

Chip cross sectional area.

Metal removal rate in machining processes.

Specific cutting pressure.

Power required for cutting.

Specific power consumption.

Total power required for machining.

Cutting efficiency coefficient.

4. Solved Problems.

Lecture No.3,4 5

Cutting Tool Materials

Main Topics:

Introduction.

General Specifications for cutting tool Materials.

Development of cutting tool materials relative to mr r.

Chronolgical Development of cutting tool materials.

Cutting Tool Materials Types.

Common Cutting tool Materials

1.Carbon and Medium alloy steels.

2. High Speed Steel.

3. Cemented Carbides ( Sintered Carbides).

4. Stellite.

5. Plain Ceramics.

Advanced Cutting Tool Materials.

6. Coated Tools (Coated cemented carbides).

7.Cermets.

8. Coronite.

9. High Performance Ceramics (HPC.

10. Cubic Boron Nitride (CBN).

11. Diamond Tools.

Lecture No.8

Basic theoretical relations in chip formation.

1. Chip contraction coefficient.2. The relation between chip contraction coefficient, shear angle

and rake angle.3. Relation between chip contraction coefficient, cutting speed and

chip flow speed.4. Graphical method.5. Analytical method.6. Strain in metal cutting due to change in dimensions.7. Strain in metal cutting due to change in velocities.8. Strain rate in metal cutting.9. Solved problems.

Lecture No.9

Cutting Forces in metal cutting

1. Cutting forces analysis.2. Cutting forces due to Merchant theory.3. Cutting forces group.4. Shear forces group.5. Friction forces group.6. Merchant theory principles.7. Advantages of Merchant Circle.8. Mathematical relations from Merchant circle.9. Solved problems.

Lecture No.15

Tool Life

1. Introduction.2. Taylor’s Tool Life Mode.

3. The practical values of n for some cutting tool materials.

4. The Extended Taylor’s Model :

5. Extended solved problems.

Lectur e No16

Quality of machined surfaces

1. Introduction.2. Effect of surface quality on performance of machined parts.3. Surface roughness definition and classification.4. The ideal surface roughness.5. The real surface finish.6. Basic mathematical relations and derivations.7. The ISO table of surface roughness.8. The vibration types in metal cutting.9. Self excited vibrations10. Forced vibrations.

Lecture No.17

Nontraditional Machining

1. Introduction.

2. Single-action nontraditional machining

3. Mechanical Machining :

4. Thermal Machining.

5. Chemical and Electrochemical Machining:

6. Hybrid Machining

7. Hybrid Chemical and Electro-chemical processes:

8. Hybrid Thermal Machining.

9. Mechanical Processes. Ultrasonic Machining The machining

system

10. The magnetostrictor, mechanical amplifier tools. Abrasive

slurry.

11. Material removal process

12. Factors affecting material removal rate

13. Dimensional accuracy and surface quality

14. Applications

Lecture No. 7

Main Topics

1. Built up Edge.2. Chip types.3. Continuous chip with BUE.4. Continuous chip without BUE.5. Discontinuous chip.6. Ground chip.7. Comparison between chip types.8. The methods used to break continuous chips.9. Step type chip breaker.10.Groove type chip breaker.11.The use of external or internal cutting fluid.

Lecture No13

Experimental methods of determination of cutting temperature.

1. Introduction.

2. Photo-cell technique.

3. Infra-red photographic technique.4. Limitations of :infrared thermography.5. Thermo electric technique.6. Tool work thermo couple.7. Embedded thermo couple .8. Metallurgical techniques.9. Change in micro structure10.Change in micro hardness.