Syllabus

Module I [Hours 9]
Theory of metal Cutting, Systems of tool nomenclature, machine reference system and tool reference system and its conversion, Geometry of single point cutting tool, orthogonal cutting and oblique cutting, Pissipanen’s card analogy model, Dynamic shear strain, Dynamic shear stress, Force relationship, velocity relationship, Merchant’s Force equilibrium diagram. Derivation of MRS system of Tool geometry to ORS and NRS System, Derivation of True Rake angle, Grinding of cutting tool in a cutting tool grinder
Module II [Hours 6 ]
Merchant and Ernst theory, Modified Merchant theory, Lee and Shaffer theory, Introduction to Kudo and Dewhurst theory for machining with chip-curl, Parallel Shear Zone theory, Stress distribution at the chip/tool interface

Module III [Hours 6]
Geometry of drill bit, drilling forces, drilling torque and thrust, Geometry of milling cutter, milling forces, milling torque, feed force and vertical force.
Module IV [Hours 6]
Modes of cutting tool failure, Tool wear, Taylor’s tool life equation, Tool life test, effect of variables on tool life, machinability criteria, theory and application of cutting fluid, Economics of machining, Minimum cost per piece, Maximum production rate, Maximum profit rate
Module V [Hours 9]
Design of single point cutting tool, Design of flat and circular form tool, Design of broach, Design of high production cutting tool with controlled contact, Types of chip-breaker, underbreaking and over-breaking limit, Hot-machining and cryo-machining, Explosive machining, PVD and CVD coated tool, cryo-treated tool

To enhance the fundamental knowledge in metal cutting theory

Able to apply theory to practical problems

Able to apply theory to design of cutting tool

Able to determine economic tool life of cutting tools

CO1: Able to design cutting tool using metal cutting theory
CO2: This will help to design different cutting tools
CO3:This will help to analyse multipoint cutting tools
CO4. This will help to determine economic tool life of cutting tool
CO5. Knwoledge of machinability criteria will be enhanced

A. Bhattacharya, Metal Cutting, Theory and practice, New Central Book Agency,1st Edition, 2022

A. B. Chattopadhyay, Machining and machine tool, Wiley, 2nd Edition, 2021

A Ghosh, Manufacturing Science, Affiliated East-West Press Private limited, 2nd Edition, 2021

M C. Shaw, Metal Cutting Principles, Oxford University Press, 2nd Edition, 2021

International Journal of Mechanical Science, Science Direct

Journal of Material Processing Technology