MACHINING SCIENCE AND JIGS & FIXTURES (IPCC) (21ME42)

MACHINING SCIENCE AND JIGS & FIXTURES (IPCC)

Course Code 21ME42 
CIE Marks 50
Teaching Hours/Week (L:T:P: S) 3:0:2*:0 
SEE Marks 50
Total Hours of Pedagogy 40 hours Theory + 12 Lab slots 
Total Marks 100
Credits 04 
Exam Hours 03

* Additional one hour may be considered as per requirement

MODULE-1

Introduction to Machining Processes and Machine Tools: Subtractive manufacturing processes and classifications. Construction, specification operations of machine tools:– Lathe, Shaping, Milling, Drilling, Grinding Machine. Introduction to CNC machines: CNC Lathe, Milling, Drilling, Machine Center.

Click here to download Module-1

MODULE-2 

Mechanics of Metal Cutting: Single point turning tool geometry (SPTT) influences the chip formation mechanisms of the Orthogonal and Oblique cutting process. Cutting Force Analysis (Orthogonal Cutting):Analysis of machining forces and power requirement, ‘Merchant’s model of Orthogonal Cutting and Theory of Lee & Shaffer’ Chip Velocity, Velocity relationships (simple numerical); the influence of cutting temperature on machinability. CuttingFluids: Characteristics of Cutting fluids, Selections, and applying methods of cutting fluids.

Click here to download Module-2

MODULE-3 

Machinability and Tool Life Process of cutting tool failure wears and time relationship, tool wear index, feed marks, the effect of tool wear on the machined surface, surface finish, machinability, machinability index/rating, tool life & variables affecting tool life, tool materials. Finishing Process: Importance of surface finishing processes, Grinding, Abrasive Flow Machining, Honing. Sanding, Abrasive blasting, Polishing, Lapping. Surface Finishing and Protection: Powder Coating, Liquid Coating, Electroplating, Galvanizing, Anodizing.

Click here to download Module-3

MODULE-4 

Advanced Machining Process; Importance and classification of advanced machining process; Process principal, process parameters, and application of: - Abrasive Jet Machining (AJW), Water Jet Machining (WJM), Abrasive Water Jet Machining (AWJM); Ultrasonic Machining (USM);Electrical Discharge Machining (EDM); Wire Electrical Discharge Machining (WEDM); Electro Chemical Machining (ECM). Laser Beam Machining (LBM), Electron Beam Machining (EBM), and Plasma Arc Machining (PAM). Hybrid Machining Process: Importance of hybrid machining process; Process principal, process parameters, and application of: - Electrochemical Discharge Machining (ECDM), Ultrasonic Assisted Electric Discharge Machining (UAEDM), Electrochemical Discharge Grinding (EDG), Powder Assisted Electric Discharge Machining (PAEDM).

Click here to download Module-4

MODULE 5 

Jigs and Fixtures: Importance of jigs and fixtures; the difference between jigs and fixtures; types of jigs and fixtures; essential features of jigs and fixtures, Materials used. Factors to be considered for the design of Jigs and Fixtures; Jigs: Template, Plate, Channel, Diameter, Leaf, Rung, Box, Fixtures: Turning, Milling, Broaching, Grinding, Boring, Indexing, Tapping, Duplex, Welding, and Assembly fixtures.

Click here to download Module-5

PRACTICAL COMPONENT OF IPCC

Sl.NO Experiments

1 One Job on Lathe machine with simple operations (turning, facing, Thread cutting and tapering) on low carbon steel and/or heat-treated low carbon steel, and Demonstration of tungsten carbide cutting tool inserts.

2 Operations and One Job each on shaping/milling machine

3 Simple operations and One Job on the drilling and grinding machine.

4 Demonstration/Experimentation of simple programming of CNC machine operations.

5 To study the tool geometry of a single point turning tool (SPTT) in the American Standards Association (ASA) system.

6 Cutting force measurement with dynamometers (Demonstration) for turning, drilling, grinding operations.

7 Application of cutting fluids in turning operations and case study on optimizing process parameters onturning operation.

8 Analysis of chip formation and chip reduction coefficient in turning of mild steel by HSS tool with different depth of cut, speed, and feed rate.

9 Experiment on tool wears and tool life on anyone conventional machining process.

10 Experiment on anyone advanced machining process

11 Design of Jigs and Fixture for any one application using any software tool.

12 Experiment using Drill/template Jig and Demonstration on turning and grinding fixtures.

13 Experiment using milling Indexing fixtures.

Suggested Learning Resources:

Textbook:

1. Shaw, M C, (2014), Metal Cutting Principles, Oxford University Press.

2. McGeough, J A, (1988), Advanced Methods of Machining, Springer.

3. Boothroyd, G., and Knight, W. A., Fundamentals of Machining and Machine Tools, CRC Press.

4. Chattopadhyay, A B, (2013), Machining and Machine Tools, Wiley India.

5. Mikell P. Groover, (2019), Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Wiley Publications.

6. Rao P. N., Manufacturing Technology II, Tata McGraw Hill.

Web links and Video Lectures (e-Resources):

1. V. K. Jain, Advanced Machining Processes, NPTEL Course Department of Mechanical Engineering, IIT Kanpur, Link: http://nptel.ac.in/courses/112104028/.

2. U. S. Dixit, Mechanics of Machining, NPTEL Course Department of Mechanical Engineering Guwahati, Link: http://nptel.ac.in/courses/112103248/.

3. A. B. Chattopadhyay, Manufacturing Processes II, NPTEL Course of Department of Mechanical Engineering, IIT Kharagpur, https://nptel.ac.in/courses/112/105/112105126/

Activity Based Learning (Suggested Activities in Class)/ Practical Based learning 

Visit any one machining center or machining industry and/or Case study on process parameter influence on anyone advanced machining process and hybrid machining process.