ME- 309 E MANUFACTURING SCIENCE
ME- 309 E MANUFACTURING SCIENCE
Sessional : 50 Marks
Theory : 100 Marks
Unit I Mechanism of Metal Cutting: Deformation of metal during machining, nomenclature of lathe, milling tools, mechanics of chip formation, built-up edges, mechanics of orthogonal and oblique cutting, Merchant cutting force circle and shear angle relationship in orthogonal cutting, factors affecting tool forces. Cutting speed, feed and depth of cut, surface finish. Temperature distribution at tool chip interface. Numericals on cutting forces and Merchant circle.
Unit II Cutting Tool Materials & Cutting Fluids: Characteristics of tool materials, various types of cutting tool materials, coated tools, cutting tool selection, Purpose and types of cutting fluids, basic actions of cutting fluids, effect of cutting fluid on tool life, selections of cutting fluid.
Unit III Tool Wear and Machinability: Types of tool wear, tool life, factors governing tool life, Machinability: Definition and evaluation. Economics of machining. Numericals on tool life.
Unit IV Gear Manufacturing: Introduction, methods of manufacture. Gear generation and forming: Gear cutting by milling, single point form tool, gear hobbing and shaping. Gear finishing operations: Gear shaving, gear burnishing, gear grinding, lapping.
Unit V Unconventional Machining Processes: Abrasive jet machining: Principles, applications, process parameters. Ultrasonic machining: Principles, applications, analysis of process parameters. Electro-chemical machining and grinding: Principles, classifications, choice of electrolytes, applications. Electric discharge machining: Principles, selection of tools materials and dielectric fluid. Electron beam machining: Generation of electron beam, relative merits and demerits. Laser beam machining: Principles and applications.
Unit VI Jigs & Fixtures: Introduction, location and location devices, clamping and clamping devises, Drill Jigs, Milling Fixtures.
Unit VII Manufacturing Accuracy: Product cycle in manufacturing, part print analysis, location principles, tolerance stacking, accuracy of machining, operation selection, tolerance analysis.
Unit VIII Metrology & Machine Tools Testing: Tolerances, limits and fits, methods of linear measurement and angular measurement, Go and No Go gauges. Introduction to Machine tools testing, measuring instruments used for testing, test procedures, acceptance tests of machine tools.
Text Books
Manufacturing Technology – Metal cutting and machine Tools: P.N. Rao, T.M.H, New Delhi
Introduction to Jig and Tool Design: Kempster M.H.A, Hodder & Stoughton, England
Reference Books
Principles of Machine Tools – G.C. Sen & A. Bhattacharya, Tata McGraw Hill, New Delhi
Manufacturing Engg.& Tech, Kalpakian, Serope Addison -Wisly Publishing Co. New York.
Modern Machining Processes: P.C. Pandey & H.S. Shan, T.M.H. Company, New Delhi
Text Book of Production Engineering: P.C. Sharma, S.Chand & Sons.
Note: In the semester examination the examiner will set 8 questions, at least one question from each unit. Students will be required to attempt 5 questions.
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