MACHINING SCIENCE & METROLOGY
Course Code BME402
CIE Marks 50
Teaching Hours/Week (L:T:P: S) 3:0:2:0
SEE Marks 50
Total Hours of Pedagogy 40 hours Theory + 8-10 Lab slots
Total Marks 100
Credits 04
Exam Hours 03
Examination nature (SEE) Theory
MODULE-1
Introduction to Metal cutting: Orthogonal and oblique cutting. Classification of cutting tools: single,
and multipoint; tool signature for single point cutting tool. Mechanics of orthogonal cutting; chip
formation, shear angle and its significance, Merchant circle diagram. Numerical problems. Cutting tool
materials and applications.
Introduction to basic metal cutting machine tools: Lathe- Parts of lathe machine,
accessories of lathe Machine and various operations carried out on lathe. Kinematics of lathe. Turret and
Capstan lathe.
MODULE-2
Milling Machines: up milling & down milling, classification of milling machines, constructional features
(Column and Knee and vertical milling machine), milling cutter nomenclature, various milling
operations, calculation of machining time.
Indexing: Need of indexing Simple, compound and differential indexing calculations. Simple numerical
on indexing.
Shaping, Slotting and Planning Machines Tools: Driving mechanisms of Shaper, Slotter and Planer.
Operations done on Shaper, Planer & Slotter Difference between shaping and planning operations.
Drilling Machines: Constructional features (Radial & Bench drilling Machines), operations, types of
drill & drill bit nomenclature. Calculation of machining time.
Grinding: Grinding operation, classification of grinding processes: cylindrical, surface
¢erless grinding
MODULE-3
Thermal aspects, Tool wear, and Machinability
Temperature in Metal Cutting: Heat generation in metal cutting; temperature distribution in metal
cutting, effect of cutting speed on temperatures, measurement of cutting temperatures Tool life and tool
Wear: progressive tool wear;
forms of wear in metal cutting: crater wear, flank wear, tool-life criteria, cutting tool materials: basic
requirements of tool materials, major classes of tool materials: high-speed steel, cemented carbide,
ceramics, CBN and diamond, tool coatings; the work material and its machinability
Cutting fluids: Action of coolants and application of cutting fluids.
MODULE-4
Introduction: Introduction to metrology & measurements, definition, objectives and
classification of metrology, standards of length- wave length standard, sub division of
standards, numerical problems on length calibration.
Line & End Standards: Line and end standard, slip gauges, wringing phenomena, numerical
problems on slip gauges.
Systems of Limits, Fits & Tolerance: Definition of tolerance, tolerance specification in
assembly, principle of interchangeability and selective assembly, limits of size, Indian
standards, concepts of limits of size and tolerances, cost v/s tolerances, compound tolerances,
accumulation of tolerances, definition of fits, types of fits and their designation.
MODULE-5
Gauges: Classification of gauges, Taylor’s principle, design of GO, NO GO gauges, wear
allowance on gauges, types of gauges- plain plug gauges, ring gauges, snap gauge, limit gauge,
simple problems.
Comparators: Introduction to comparators, classification, characteristics, systems of
displacement amplification in mechanical comparators, Reed type, Sigma comparator, Zeiss
ultra-optimeter, Solex air gauge, ultrasonic gauges, LVDT.
Angular Measurements: Bevel protractor, sine bar, angular gauges, numerical on building of
angles.
PRACTICAL COMPONENT OF IPCC (May cover all / major modules)
Experiments
1 Preparation of one model on lathe involving - Plain turning, Facing, Knurling, Drilling, Boring,
Internal Thread cuts and Eccentric turning.
2 Preparation of One model on lathe involving - Plain turning, Facing , Taper turning, Step turning,
Thread cutting, Facing, Knurling, Drilling, Boring, Internal Thread cutting and Eccentric turning.
3 One Job, Cutting of V Groove/ dovetail / Rectangular groove using a shaper.
4 Cutting of Gear Teeth using Milling Machine.
5Simple operations and One Job on the drilling and grinding machine.
6 Cutting force measurement with dynamometers (Demonstration) for turning, drilling, grinding
operations.
7 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.
8Experiment on anyone advanced machining process
9 Study & Demonstration of power tools like power drill, power hacksaw, portable hand grinding,
cordless screw drivers, production air tools, wood cutter, etc., used in Mechanical Engineering.
10 Demonstration/Experimentation of simple programming of CNC machine operations.
11 Demonstration / Experiment on tool wears and tool life on anyone conventional machining
process.
12 To study the tool geometry of a single point turning tool (SPTT) in the American Standards
Association (ASA) system.
Suggested Learning Resources:
Books
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.
7. Mechanical Measurements Beckwith Marangoni and Lienhard Pearson Education 6thEd.,
8. Instrumentation, Measurement and Analysis B C Nakra, K K Chaudhry McGraw–Hill 4th Edition
9. Engineering Metrology R.K. Jain Khanna Publishers 2009
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/
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