Lovely Professional University, Punjab

Course Code Course Title Course Planner Lectures Tutorials Practicals Credits

MEC405 THEORY OF METAL CUTTING 15750::Manoj Kumar R 3.0 0.0 0.0 3.0

Course Category Courses with numerical and conceptual focus

TextBooks

Sr No Title Author Edition Year Publisher Name

T-1 Principles of Metal Cutting Shaw,M.C 3rd Oxford and IBH Publishing Co. Pvt. Ltd New Delhi

Reference Books

Sr No Title Author Edition Year Publisher Name

R-1 Principles of Machine Tools Sen & Bhattacharya 2nd New Central Book Agency (P) Ltd, India.

R-2 Fundamentals of Tool Engineering Design

Basu, Mukhopadhyay & Mishra

2nd Oxford and IBH Publishing Co. Pvt. Ltd New Delhi

R-3 Metal cutting principle Dr.B.J.Ranganath 1st Vikas Publication

Other Reading

Sr No Journals articles as Compulsary reading (specific articles, complete reference)

OR-1 METAL CUTTING THEORY - MISSED CHANCES OR ASCIENCE WITHOUT HISTORY: Part 2 by Viktor P. Astakhov ,

OR-2 Tribology of Metal Cutting by Viktor P. Astakhov ,

OR-3 Metal Cutting Theory and Cutting Tool Design, Arshinov & Acherken, MTR Publishers ,

Relevant Websites

Sr No (Web address) (only if relevant to the course) Salient Features

RW-1 www.iscar.com cutting tool manufacturer site

RW-2 www.ehow.com/metal-cutting-tools metal cutting tools

RW-3 http://www.americanmachinist.com Metal cutting related site

Detailed Plan For Lectures

LTP week distribution: (LTP Weeks)

Weeks before MTE 7

Weeks After MTE 6

Spill Over 2

Week Number

Lecture Number

Broad Topic(Sub Topic) Chapters/Sections of Text/reference books

Other Readings,Relevant Websites, Audio Visual Aids, software and Virtual Labs

Lecture Description Learning Outcomes Pedagogical ToolDemonstration/ Case Study / Images / animation / ppt etc. Planned

Week 1 Lecture 1 Introduction(Importance of Material Removal)

T-1:Reference 1Chapter 1

R-3:reference 1 chapter 1.1

OR-3 it covers the importance of material removal

understand the concept of process

Slide Show

Introduction(Classification of Metal Removal Operation)

T-1:Reference 1Chapter 1

R-3:reference1 chapter 1.3

OR-1 covers the classification understand the classification

Slide Show

Introduction(Overview of Cutting Processes and Types of Chips)

T-1:Reference 1Chapter 1

R-3:reference 1.3

RW-1 it covers the overview of cutting process

understand the cutting process

Slide Show

Lecture 2 Introduction(Chip formation Analysis.)

T-1:Reference 1Chapter 1

R-3:reference 1.5

OR-2 it covers the chip analysis

clearly understanding the concept behind the topic

Slide Show

Cutting 0perations(Principle Cutting Operations.)

T-1:Reference 1Chapter 2

R-3:reference 2.2

RW-1 clearly it covers cutting operation

clearly understanding the concept behind the topic

Slide Show

Cutting 0perations(Other Cutting Operations)

T-1:Reference 1Chapter 2

R-3:reference 2.4

RW-1 clearly it covers cutting operation

clearly understanding the concept behind the topic

Slide Show

Lecture 3 Mechanics of Orthogonal Steady State Cutting(Card Model)

T-1:Reference 1Chapter 3

R-3:Reference 2.6

OR-3RW-2

clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Forces)

T-1:Reference 1Chapter 3

R-3:Reference 2.7

RW-1 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Stresses)

T-1:Reference 1Chapter 3

R-3:Reference 2.7

RW-1 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Week 2 Lecture 4 Mechanics of Orthogonal Steady State Cutting(Shear Angle)

T-1:Reference 1Chapter 3

R-3:Reference 2.8

RW-2 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Week 2 Lecture 4 Mechanics of Orthogonal Steady State Cutting(Shear Strain)

T-1:Reference 1Chapter 3

R-3:Reference 2.9

RW-2 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Velocity Relation)

T-1:Reference 1Chapter 3

R-3:reference 2.5

OR-3 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Lecture 5 Mechanics of Orthogonal Steady State Cutting(Merchant Circle Diagram and Analysis)

T-1:Reference 1Chapter 3

R-3:Reference 2.10

OR-3 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Lecture 6 Mechanics of Orthogonal Steady State Cutting(Power and Energy Relationship)

T-1:Reference 1Chapter 3

R-3:Reference 2.13

OR-1 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Flow Lines in a Chip)

T-1:Reference 1Chapter 3

R-3:Reference 2.14

RW-3 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Rate of Strain)

T-1:Reference 1Chapter 3

R-3:Reference 2.9

OR-3 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Week 3 Lecture 7 Mechanics of Orthogonal Steady State Cutting(Other chip types)

T-1:Reference 1Chapter 3

R-3:Reference 2.14

RW-3 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Mechanics of Orthogonal Steady State Cutting(Estimation of Cutting Force)

T-1:Reference 1Chapter 3

R-3:Reference 2.15

RW-3 clearly it covers the cutting mechanism

clearly understanding the concept behind the topic

Slide Show

Lecture 8 Plastic Behavior(Dislocation Theory)

T-1:Reference 1Chapter 5

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Plastic Behavior(Theoretical Shear Strength)

T-1:Reference 1Chapter 5

OR-3RW-1

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 9 Plastic Behavior(Metal Whisker's) T-1:Reference 1Chapter 5

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Plastic Behavior(Constancy of Volume and Possion s Ratio)

T-1:Reference 1Chapter 5

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 4 Lecture 10 Plastic Behavior(Von Mises Flow Criterion)

T-1:Reference 1Chapter 5

RW-2RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 4 Lecture 11 Fracture(Fracture Mechanics) T-1:Reference 1Chapter 6

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Fracture(Griffith Theory) T-1:Reference 1Chapter 6

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 12 Homework,Test 1

Week 5 Lecture 13 Fracture(Crack Initiation in Compression)

T-1:Reference 1Chapter 6

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Fracture(Theory Assuming Spherical Voids)

T-1:Reference 1Chapter 6

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 14 Fracture(Disc Test) T-1:Reference 1Chapter 6

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 15 Fracture(Fracture of Cemented Tungsten Carbide)

T-1:Reference 1Chapter 6

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 6 Lecture 16 Dynamometry(Dynamometer Requirement Force Measurement)

T-1:Reference 1Chapter 7

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 17 Dynamometry(Electric Transducer)

T-1:Reference 1Chapter 7

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 18 Dynamometry(Whetstone Bridge) T-1:Reference 1Chapter 7

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 7 Lecture 19 Dynamometry(Design Consideration)

T-1:Reference 1Chapter 7

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 20 Dynamometry(Strain Gage Lathe Dynamometer)

T-1:Reference 1Chapter 7

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 21 Dynamometry(Strain Rings) T-1:Reference 1Chapter 7

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Dynamometry(Bonded Strain Gages)

T-1:Reference 1Chapter 7

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

MID-TERMWeek 8 Lecture 22 Geometry of Cutting Tools(Single

Point and Multi Point Cutting Tools)

R-3:Reference 1Chapter 3

RW-2RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Geometry of Cutting Tools(Tool Nomenclature)

R-3:Reference 1Chapter 3

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 8 Lecture 23 Geometry of Cutting Tools(Effect of Cutting Parameters on Tool Geometry)

R-3:Reference 1Chapter 3

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 24 Wear and Tool Life(Types of Cutting Tool Wear)

T-1:Reference 1Chapter 11

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Wear-Land Wear)

T-1:Reference 1Chapter 11

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Crater Wear) T-1:Reference 1Chapter 11

OR-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 9 Lecture 25 Wear and Tool Life(Tool Life Testing)

T-1:Reference 1Chapter 11

OR-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Groove Formation)

T-1:Reference 1Chapter 11

OR-3RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Gross Tool Fracture)

T-1:Reference 1Chapter 11

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 26 Wear and Tool Life(Simplified Griffith Theory for Circular Voids)

T-1:Reference 1Chapter 11

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Stress Intensification for a Spherical Void)

T-1:Reference 1Chapter 11

RW-2RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 27 Wear and Tool Life(Tool Fracture at Entrance and Exit)

T-1:Reference 1Chapter 11

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Wear and Tool Life(Thermal Contraction)

T-1:Reference 1Chapter 11

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 10 Lecture 28 Cutting Temperature(Experimental Techniques.)

T-1:Reference 1Chapter 12

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Cutting Temperature(Thermal Energy in Cutting)

T-1:Reference 1Chapter 12

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 29 Cutting Fluids(Carbon Tetra Chloride)

T-1:Reference 1Chapter 13

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Cutting Fluids(Low Speed Cutting Fluid Action)

T-1:Reference 1Chapter 13

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 30 Tool Material(Tool Material Requirement)

T-1:Reference 1Chapter 14

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 10 Lecture 30 Cutting Fluids(Practical Consideration)

T-1:Reference 1Chapter 13

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Tool Material(Machining System) T-1:Reference 1Chapter 14

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 11 Lecture 31 Tool Material(Major Tool Material Types)

T-1:Reference 1Chapter 14

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Tool Material(Physical Vapor Deposition)

T-1:Reference 1Chapter 14

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Tool Material(Design and Performance)

T-1:Reference 1Chapter 14

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 32 Homework,Test 2

Lecture 33 Work Material Consideration(Machining High Strength Materials)

T-1:Reference 1Chapter 15

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Work Material Consideration(Fracture During Chip Formation)

T-1:Reference 1Chapter 15

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 12 Lecture 34 Work Material Consideration(hot Hardness of Work Piece)

T-1:Reference 1Chapter 15

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 35 Chip Control(Chip Flow Direction and Chip Types)

T-1:Reference 1Chapter 18

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Chip Control(Chip Barker Performance)

T-1:Reference 1Chapter 18

RW-3 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 36 Chip Control(Rational Approach Control)

T-1:Reference 1Chapter 18

RW-1RW-2

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Chip Control(Chip Breaking Grooves)

T-1:Reference 1Chapter 18

RW-2 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 13 Lecture 37 Chip Control(Chip Curling/Breaking Analysis)

T-1:Reference 1Chapter 18

RW-1RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Lecture 38 Optimization(Machining Economics)

T-1:Reference 1Chapter 19

RW-2RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Optimization(Levels of Optimization)

T-1:Reference 1Chapter 19

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Week 13 Lecture 39 Optimization(Optimum Productive Rate)

T-1:Reference 1Chapter 19

RW-2RW-3

it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

Optimization(Adaptive Control) T-1:Reference 1Chapter 19

RW-1 it covers the clear concept of topic

clearly understanding the concept behind the topic

Slide Show

SPILL OVERWeek 37 Lecture 109 T-1:refer full book OR-3

RW-1RW-3

Revision to improve the knowledge of metal cutting principles

Animations

Lecture 110 T-1:refer full book OR-3RW-1RW-3

Revision to improve the knowledge of metal cutting principles

slide show

Scheme for CA:Component Frequency Out Of Each Marks Total Marks

Homework,Test 2 3 10 20

Total :- 10 20

Details of Academic Task(s)

AT No. Objective Topic of the Academic Task Nature of Academic Task(group/individuals/field

work

Evaluation Mode Allottment / submission Week

Test 2 To check the basic knowledge of the subject

Wear and tool life,Cutting Temperature,Cutting Fluids Individual test 10 / 10

Homework 1 To check the indepth knowledge of the subject

Fracture Mechanics,Dynamometry, plastic behavior. Individual viva 4 / 6

Test 1 To check the basic knowledge of the subject

Introduction,Typical Cutting Operations,orthogonal cutting,PlasticBehaviour

Individual test 4 / 4