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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