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Sr. No.

Particulars

Page Number

1 Scheme 3

2 Syllabus 4

3 Lecture Plan 6

4 List of Books 8

5 Tutorial Sheets -

6 Assignments 9

7 Question Papers 16

3

Course of Study and Scheme of Examination for Batch

starting from DEC-MAY 2018-19

B.E 6TH Semester (Mechanical)

Teaching Scheme Credits Examination Marks

Total Marks L T P C

Theory Marks Practical Marks

ESE

(E)

PA (M) PA (V) PA

(I) PA ALA ESE OEP

3 0 2 5 70 20 10 20 10 20 150

4

SSYYLLLLAABBUUSS

UNIT-I

Metal Cutting:

Principles of metal cutting, classification of Metal cutting/machining processes: Orthogonal and oblique

cutting, Effect of tool geometry and other cutting parameters, Mechanisms of formation of chips, types of

chips formed, chip Breakers, concept of specific cutting pressure, The forces acting on the cutting tool and

their measurement, Merchant’s circle diagram, force dynamometer, force and velocity relationship, Tool

wear, Factors causing wear, tool life, variables affecting tool life, economical cutting speed, mach inability

of metals

.UNIT-II

Thermal Aspects in Machining:

Sources of heat generation in machining and its effects, Temperature Measurement techniques in machining,

types of cutting fluids, Functions of cutting fluid, Characteristics of cutting fluid, Application of cutting

fluids, Economics of Metal Cutting Operations.

UNIT-III

Gear and Thread Manufacturing:

Different types of Threads manufacturing methods, and tools involved, Different gear forming and

generating methods with their special features, Gears finishing processes.

UNIT-IV

Jigs and Fixtures:

Definition, Differences between Jigs and Fixtures, Its usefulness in mass production, design principles, 3-2-

1 location principle and its application to short and long cylinders, types of locators, concept of work piece

control, geo metric control, dimensional control and mechanical control, Clamps, jig bushes, Jigs and

fixtures for various machining operations.

Semester Course Title Course Code Theory Paper

L T P

MECHANICAL COMPUTER AIDED

DESIGN 2161903 3 0 2

Max.Marks:70

Min. Marks:23

Duration :2:30 hours

5

UNIT – V

Press Tool:

Classification of presses, Classification of dies, cutting actions in dies, clearance, cutting forces, Methods of reducing

cutting forces, Minimum Diameter of Piercing Center of Pressure, Blanking, Piercing, Drawing, Bending and

Progressive Die design, scrap reduction, strip layout.

.

UNIT-VI Non-conventional Machining:

EDM, IBM, ECM, ECG, CM, AJM, Wire cut EDM, USM, LBM process principle, process parameters and their

applications. Process capabilities and their applications.

6

LECTURE PLAN

Lect Topics to be covered Teaching

Hours

1. Principles of metal cutting, 1

2 classification of Metal cutting/machining processes: Orthogonal and

oblique cutting, 1

3 Effect of tool geometry and other cutting parameters, Mechanisms of

formation of chips, 1

4 types of chips formed 1

5 Chip Breakers, concept of specific cutting pressure, The forces acting

on the cutting tool and their measurement, 1

6 Merchant’s circle diagram 1

7 Force dynamometer, force and velocity relationship, 1

8 Tool wear, Factors causing wear, tool life 1

9 Variables affecting tool life, economical cutting speed 1

10 Machinability of metals 1

11 Sources of heat generation in machining and its effects, 1

12 Temperature Measurement techniques in machining, 1

13 types of cutting fluids, Functions of cutting fluid, 1

14 Characteristics of cutting fluid, Application of cutting fluids 1

15 Economics of Metal Cutting Operations. 1

16 Different types of Threads manufacturing methods, 1

17 tools involved, Different gear forming method 1

18 Different gear generating methods 1

19 special features of gear forming method & gear generating methods 1

20 Gear finishing process 1

21 Definition, Differences between Jigs and Fixtures, 1

22 Its usefulness in mass production, design principles 1

23 3-2-1 location principle and its application to short and long

cylinders 1

24 types of locators, concept of work piece control, 1

25 geo metric control, dimensional control and mechanical control 1

7

26 Clamps, jig bushes, Jigs and fixtures for various machining operations 1

27 Classification of presses 1

28 Classification of dies, cutting actions in dies 1

29 Clearance and cutting forces in die, 1

30 Methods of reducing cutting forces 1

31 Minimum Diameter of Piercing Center of Pressure 1

32 Blanking, Piercing, 1

33 Drawing, Bending 1

34 Progressive Die design, 1

35 scrap reduction, strip layout 1

36 Non-conventional machining principal and process parameters. 1

37 Non-conventional machining process capabilities and their application 1

38 EDM & Wire cut EDM 1

39 IBM 1

40 ECM 1

41 ECG 1

42 CM 1

43 AJM 1

44 USM 1

45 LBM 1

8

REFERENCES

S. No. TITLE AUTHOR PUBLISHER / EDITION

1 Metal Cutting principles, M.C. SHAW Oxford University press

2 Fundamentals of machining and

machine tools Boothroyd

CRC publication

3 Production Technology H.M.T H.M.T

4 Tool Design Donaldson Tata McGraw Hill Pub

5 Metal cutting Principles Trent Tata McGraw Hill Pub

6 Workshop Technology Vol. II Raghuvanshi Dhanpat rai Pub

7 Production Technology R.K.Jain Kanna pub

9

ASSIGNMENT TOPICS

S. No. TOPIC

1 Metal cutting

2 Thermal aspects in metal cutting

3 Gear and thread manufacturing

4 Jig and fixtures

5 Press tool

6 Non conventional machining

10

ASSIGNMENT 1

Sr.

No. Name of Question Remarks

1

The following equation for tool life has been obtained for H. S. S. tool.

VT 0.13

f 0.6

d 0.3

= C

A 60 minute tool life was obtained while cutting at V = 40 m/min, f = 0.25 mm/rev

and d= 2 mm.

Calculate the effect on tool life if speed, feed and depth of cut are together increased

by 25% and also if they are increased individually by 25%. Also give your

comments.

2

In orthogonal cutting, if the feed is 1.25 mm/rev and chip thickness after cutting is

2mm, determine the following.

1. Chip thickness ratio

2. Shear angle

The tool bit has a rake angle of 10º, If shear strength = 600 N/mm2, Width of cut =

10 mm, Cutting speed = 30 m/min, Co-efficient of friction = 0.9

Determine,

a. Shear force

b. Friction angle

c. Cutting force

d. Horse power at the cutting tool

3 Draw a neat sketch of a single point cutting tool indicating its complete geometry on

it.

4 What do you understand by orthogonal and oblique cutting? How do they differ from

each other?

5

Draw a merchant circle diagram and derive expressions to show relationship among

the different forces acting on the cutting tool and different parameter involved in

metal cutting.

11

ASSIGNMENT 2

Sr.

No. Name of Question Remarks

1 What is tool signature? Explain various system of tool angle designation

2 Explain design of single point Turing tool.

3 How cutting force measured? explain types of dynamometers used in metal cutting

4 Write the function of cutting fluids in metal cutting.

5 Write short note on economic of metal machining.

12

ASIGNMENT 3

Sr.

No. Name of Question Remarks

1 Classify the generating process for gear cutting? Explain “Gear Hobbing” in detail.

2

Enlist different types of gears and draw gear tooth terminology. With appropriate

example discuss plain indexing and compound indexing methods of manufacturing a

gear on milling machine.

3 Explain with the help of sketch, principle, types, and applications of gear hobbing.

4 Write short note on Gear finishing process.

5 What are the different types of thread manufacturing processes? Explain in details.

13

ASSIGNMENT 4

Sr.

No. Name of Question Remarks

1 Distinguish between jig and fixture. State advantages of jigs and fixtures

2 Describe the degrees of freedom for workpiece located in space. Draw a simple

sketch to show the 3-2-1 locating principle and explain.

3 List various clamping devices used in jigs and fixtures and explain its working also

give their features and application.

4 Sketch different drill bushes useful in drill jigs.

5 List the various types of locating devices used for both Jigs and Fixture and Explain

of them with neat sketch.

14

ASSIGNMENT 5

Sr.

No. Name of Question Remarks

1 Write in detail the methods of reducing the cutting forces in press working.

2 Discuss the various types of pilots used in progressive die.

3

Sketch and design a progressive die to make a steel washer 30 mm outside diameter

with 15 mm hole. From 1.6 mm thick steel sheet. The ultimate shear strength of the

material is 320 N/mm2. Calculate, a. Maximum punch force necessary to blank and

punch the washer if both punches operate at the same time, b. Punch and die size for

piercing and blanking operation

4

Draw neat schematic diagram of a sectioned view of a blanking die and punch

assembly and label on it. Explain the function of (i) Die Block (ii) Punch (iii) Knock

out.

5

Draw and discuss following clamping devices

(i) Hinged Clamp

(ii) Quick Action Nut

(iii) Hydraulic Clamp

15

ASSIGNMENT 6

Sr.

No. Name of Question Remarks

1 Define Non-conventional machining? Why do we need these processes? Give

classification of the Non conventional processes?

2 What is LASER? Explain LBM.

3 Write important functions of dielectric fluid and electrolyte. Also write various types

of commonly used dielectric fluid and electrolyte.

4

Describe Ultrasonic Machining (USM) process with neat sketch. Discuss how the

following factors effects the material removal rate of USM. (i) Grain Size (iv) Feed

force (ii) Frequency (v) Hardness ratio (iii) Amplitude (vi) Abrasive concentration

5 Describe principle of Electrical Discharge Machining (EDM) with figure and state its

advantages, limitation and application.

16

GTU PAPERS

17

18

19

20

21

Mid paper