Manufacturing Processes II.pdf

Great course material/ebook from IIT Kharagpur, contains great deal of informations about manufacturing processes that I believe every mechanical and industrial engineers should know. You can learn (or at least read) about abrasive process, EDM, Abrasive Jet Machining and more aside of conventional manufacturing processes such as grinding, turning, etc!
You might also want to browse all of our industrial engineering books* (pdf).

This ebook is available FREE at National Programme on Technology Enhanced Learning Indian Institute of Technology Madras, India website, we merely collect the information, we are neither affiliated with the author(s), the website and any brand nor responsible for its content and change of content. (Read our disclaimer here or here before you download the document from the website written above by clicking the below link).

Table of Contents ALONG WITH DOWNLOAD LINKS:

• Module 1 Classification of Metal Removal Processes and Machine tools
  • Lesson 1 Introduction to Manufacturing and Machining, objectives: Identify the necessity of “manufacturing”; Define with examples the concept of “manufacturing”; List the main classifications of the manufacturing processes with examples; State the main purposes of “machining”; Define with examples the concept of “machining”; State with example the principles of “machining”; State with examples the main requirements for “machining”; State with examples the main functions of “Machine tools”; Define the concept of “machine tools”, contents: [ Manufacturing - Need and concept ~ Broad classification of Engineering Manufacturing Processes. ~ Machining - Purpose, Principle and Definition ~ Machining requirements ~ Basic functions of Machine Tools ~ Machine Tool - definition ]
  • Lesson 2 Basic working principle, configuration, specification and classification of machine tools, objectives: Describe the basic functional principles of machine tools: Illustrate the concept of Generatrix and Directrix; Demonstrate Tool - work motions; Give idea about machine tool drives; Show configuration of basic machine tools and state their uses; Give examples of machine tools - specification; Classify machine tools broadly., contents: [ Basic functional principles of machine tool operations ~ Configuration of Basic Machine Tools and their use ~ Specification of Machine Tools. ~ Broad classification of Machine Tools ]
• Module 2 Mechanics of Machining
  • Lesson 3 Geometry of single point cutting tools, objectives: conceive rake angle and clearance angle of cutting tools; classify systems of description of tool geometry; demonstrate tool geometry and define tool angles in : Machine Reference System; Orthogonal Rake System and Normal Rake System; designate cutting tool geometry in ASA, ORS and NRS , contents: [ Geometry of single point turning tools ]
  • Lesson 4 Conversion of tool angles from one system to another , objectives: State the purposes of conversion of tool angles; Identify the four different methods of conversion of tool angles; Employ the graphical method for conversion of Rake angles; clearance angles; Cutting angles; From ASA to ORS and ORS to ASA systems; Convert rake angle and clearance angle from ORS to NRS; Demonstrate tool angle’s relationship in some critical conditions., contents: [ Purposes of conversion of tool angles from one system to another ~ Methods of conversion of tool angles from one system to another ~ Conversion of tool angles by Graphical method - Master Line principle. ~ Conversion of tool angles from ORS to NRS ~ Tool geometry under some critical conditions ]
  • Lesson 5 Mechanism of chip formation, objectives: describe with illustration the mechanism of chip formation in machining ductile materials and brittle materials; illustrate and assess geometrical characteristics of ductile chips : chip reduction coefficient & cutting ratio ; shear angle and cutting strain; Identify and state the causes, characteristics and effects of built - up - edge (BUE) formation.; Classify chips and identify the condition for different chip forms, contents: [ Mechanism of chip formation in machining ~ Geometry and characteristics of chip forms ~ Built-up-Edge (BUE) formation ~ Types of chips and conditions for formation of those chips ]
  • Lesson 6 Orthogonal and oblique cutting, objectives: define and distinguish, with illustrations, between orthogonal cutting and oblique cutting; identify the causes of oblique cutting and chip flow deviation; determine angle of chip flow deviation.; illustrate and deduce effective rake angle; state the effects of oblique cutting, contents: [ Orthogonal and oblique cutting ~ Causes and amount of chip flow deviation ~ Effective Rake, ~ Effects of oblique cutting ]
  • Lesson 7 Use of chip breaker in machining, objectives: identify the need and purposes of chip breaking; illustrate the various principles of chip breaking; design simple chip breakers; demonstrate configuration and working principle of some common type chip breakers; state the overall effects of chip breaking, contents: [ Need and purpose of chip-breaking ~ Principles of chip-breaking ~ Design principle of simple step type chip breaker. ~ Configuration and working principle of some chip breakers in practice ~ Overall effects of chip breaking ]
  • Lesson 8 Machining forces and Merchant’s Circle Diagram (MCD), objectives: Ascertain the benefits and state the purposes of determining cutting forces; Identify the cutting force components and conceive their significance and role; Develop Merchant’s Circle Diagram and show the forces and their relations; Illustrate advantageous use of Merchant’s Circle Diagram, contents: [ Benefit of knowing and purpose of determining cutting forces. ~ Cutting force components and their significances ~ Merchant's Circle Diagram and its use ~ Advantageous use of Merchant's Circle Diagram (MCD) ]
  • Lesson 9 Analytical and Experimental determination of cutting forces, objectives: Develop and use equations for estimation of major cutting force components in turning under Orthogonal cutting & Oblique cutting; Evaluate analytically the major cutting forces in Drilling & Plain milling; Identify the needs and purposes of measurement of cutting forces; State the possible methods of measurement of cutting forces, contents: [ Development of equations for estimation of cutting forces ~ Analytical Estimation of cutting forces in drilling and milling. ~ Needs and Purposes of Measurement of Cutting Forces ~ General methods of measurement of cutting forces ]
  • Lesson 10 Dynamometers for measuring cutting forces, objectives: show the general principle of measurement; classify and apply different transducers for converting cutting forces into suitable signals; state the design requirements of tool-force dynamometers; develop and use strain gauge type dynamometer for turning, drilling, milling, grinding, contents: [ General principle of measurement. ~ Different types of transducers used in dynamometers for measuring machining forces. ~ Design requirements for Tool - force Dynamometers ~ Construction and working principle of some common tool - force dynamometers. ]
  • Lesson 11 Cutting temperature - causes, effects, assessment and control, objectives: Identify the causes of development of heat and temperature in machining; State the effects of cutting temperature on cutting tool and job; Determine the value of cutting temperature; Analytical methods; Experimental methods; Evaluate the roles of variation of the different machining parameters on cutting temperature.; Point out the general methods of controlling cutting temperature, contents: [ Sources Determination of cutting temperature and causes of heat generation and development of temperature in machining ~ Determination of cutting temperature ~ Role of variation of the various machining parameters on cutting temperature ~ Control of cutting temperature ]
  • Lesson 12 Control of cutting temperature and cutting fluid application, objectives: State the possible ways of controlling cutting temperature; Identify the purposes of application of cutting fluid in machining; Ascertain the essential properties of cutting fluids; Illustrate the principle of cutting fluid action; Classify the types of cutting fluids and state their application; Demonstrate the methods of application of cutting fluid in machining and grinding, contents: [ Basic methods of controlling cutting temperature ~ Purposes of application of cutting fluid in machining and grinding. ~ Essential properties of cutting fluids ~ Principles of cutting fluid action ~ Types of cutting fluids and their application ~ Methods of application of cutting fluid ]
• Module 3 Machinability
  • Lesson 13 Concept of Machinability and its Improvement, objectives: Conceptualise machinability and state its ; Definition; Criteria of judgement; Illustrate how machinability is governed or influenced by several factors, Chemical and physical properties of work material; Processing parameters; Cutting tool parameters; Environmental factors; Suggest various methods of improvement of machinability, contents: [ Concept, Definition And Criteria Of Judgement Of Machinability ~ Role Of Variation Of The Different Machining Parameters Or Factors On Machinability Of Work Materials. ~ Possible Ways Of Improving Machinability Of Work Materials ]
  • Lesson 14 Failure of cutting tools and tool life, objectives: State how the cutting tools fail; Illustrate the mechanisms and pattern of tool wear ~ Ascertain the essential properties of cutting tool materials ~ Define and assess tool life ~ Develop and use tool life equation, contents: [ Failure of cutting tools ~ Mechanisms and pattern (geometry) of cutting tool wear ~ Essential properties for cutting tool materials ~ Tool Life ~ Taylor's tool life equation. ]
  • Lesson 15 Cutting Tool Materials of common use, objectives: Identify the needs and cite the chronological development of cutting tool materials.; Describe the characteristics and state the applications of the commonly used cutting tool materials;High speed steel; Stellite; Sintered carbides; Plain ceramics, contents: [ Needs And Chronological Development Of Cutting Tool Materials ~ Characteristics And Applications Of The Primary Cutting Tool Materials ]
  • Lesson 16 Advanced Cutting Tool Materials, objectives: Classify, illustrate the properties and suggest the applications of the advanced cutting tool materials: Coated carbides; Cermets; Coronite; High Performance Ceramics (HPC); Cubic Boron Nitride (cBN); Diamond, contents: [ Development And Application Of Advanced Tool Materials ]
• Module 4 General purpose machine tools
  • Lesson 17 Kinematic systems and operations of lathes, objectives: Name the general purpose machine tools of common use; Classify the different types of lathes; Illustrate the kinematic system of centre lathe and explain its method of working; State the different machining operations that are usually done in centre lathes, contents: [ General Purpose Machine Tools Of Common Use ~ Classification Of Lathes ~ Kinematic System And Working Principle Of Lathes ~ Machining Operations Usually Done In Centre Lathes ]
  • Lesson 18 Kinematic system and operations of drilling machines, objectives: State the basic purposes of use of drilling machines; Classify the types of drilling machines; Illustrate the general kinematic system of drilling machine and explain its working principle; State and visualise the various common and other possible applications of drilling machines, contents: [ Basic purposes of use of drilling machines ~ Classification of drilling machines. ~ Kinematic System of general purpose drilling machine and their principle of working ~ Application of drilling machines ]
  • Lesson 19 Kinematic system and operations of milling machines., objectives: State the basic functions and purposes of using milling machines; Classify milling machines and illustrate their configurations; Visualise kinematic system of commonly used milling machines and explain its working principle.; Show and briefly describe the various applications of milling machines using different types of milling cutters, contents: [ Basic functions and purposes of using milling machines ~ Classification of milling machines ~ Kinematic system of milling machine ~ Various applications of milling machines using different types of milling cutters. ]
  • Lesson 20 Construction, working principle and applications of shaping, planing and slotting machines., objectives: Demonstrate the configurations and functions of shaping machine, planing machine and slotting machine; Illustrate the kinematic systems and explain the working principles of shaping machine, planing machine and slotting machine; Show and describe the various machining applications of shaping, planing and slotting machines, contents: [ Kinematic system and working principles of Shaping machine; Planing machine; Slotting machine ~ Various applications of Shaping machine; Planing machines; Slotting machines ]
  • Lesson 21 Methods of mounting of jobs and cutting tools in machine tools., objectives: State the principles and conditional requirements of mounting jobs and tools in machine tools; Illustrate how the jobs (blanks) and cutting tools are mounted in; Lathes; Drilling machines; Shaping, Planing and slotting machines; Milling machine; Grinding machines; Point out the special requirements and methods on mounting job and cutting tools in CNC machine tools, contents: [ Principles And Conditional Requirements Of Mounting Job And Cutting Tool In Machine Tools ~ Methods Of Mounting Job And Cutting Tool In General Purpose Machine Tools. ~ Mounting of job and tool in CNC machine tools ]
  • Lesson 22 Use of various Attachments in Machine Tools., objectives: Comprehend and state the use of accessories and attachments in machine tools; Realize and Identify why and when Attachments are necessarily used; Describe the basic construction and application principles of different attachments used in; Centre lathes; Drilling machines; Shaping machines; Planing machines; Milling machines, contents: [ Use Of Various Accessories And Attachments In General Purpose Machine Tools. ~ Conditions And Places Suitable For Application Of Attachments In Machine Tools. ~ Working Principles And Application Of Various Attachments In Different Machine Tools. ]
  • Lesson 23 Construction, Operation and Tool layout in Semiautomatic and Automatic lathes., objectives: Illustrate the constructional features and uses of semiautomatic and automatic lathes.; Show the kinematic system and explain the working principles of semiautomatic and automatic lathes of common use.; Plan and visualise tool layout for machining in semiautomatic and automatic lathes, contents: [ Constructional Features And Uses Of General Purpose Semiautomatic And Automatic Lathes. ~ Kinematic Systems And Working Principles Of Semi Automatic And Automatic Lathes ~ Process Planning And Tool Layout For Machining A Product In Semi-Automatic And Automatic Lathes. ]
  • Lesson 24 Forces developing and acting in machine tools, objectives: Identify the sources and pattern of the forces that develop in machine tools during machining.; State the effects of the forces in machine tools and its operations.; Comprehend the purposes of analysis of forces acting in machine tools; Visualise and evaluate the forces originated and distributed in machine tools, contents: [ Sources And The Types Of The Forces That Develop in Machine Tools During Machining. ~ Effects Of The Various Forces On Machining And Machine Tools ~ Purposes Of Analysis And Evaluation Of The Forces Acting In Machine Tools ~ Analysis Of Forces Acting During Machining In : Centre lathes; Drilling machines; Shaping machines; Planing machines; Milling machines. ]
  • Lesson 25 Estimation of machining time, objectives: Realize the necessity of evaluating the machining time requirement; Identify the factors that govern the machining time.; Estimate or evaluate the time required for specific; turning operation; drilling and boring operations; shaping and planing operations; milling operation, contents: [ Necessity Of Estimation Or Determination Of Machining Time Requirement For Particular Operations. ~ Major Factors That Govern Machining Time ~ Estimation Of Machining Time By Calculations ]
  • Lesson 26 Broaching - Principles, Systems and Applications, objectives: State and visualise the basic principle of broaching; Describe constructional features and functioning of broaching tools; Illustrate different broaching tools and their applications; Classify broaching machines w.r.t. configuration and use; Identify the advantages and limitations of broaching, contents: [ BASIC PRINCIPLES OF BROACHINING ~ Construction And Operation Of Broaching ~ Different Types Of Broaches And Their Applications ~ Broaching Machines ]
• Module 5 Abrasive Processes (Grinding)
  • Lesson 27 Basic principle, purpose and application of grinding, objectives: understand basic principle of grinding.; recognize purpose and application of grinding.; understand cause of development of force during grinding.; understand variation of grinding characteristics with grinding conditions.; illustrate various methods of wheel conditioning, contents: [ Grinding ~ Major advantages and applications of grinding ~ Grinding wheel and workpiece interaction ~ Variation of critical grit depth of cut with grinding velocity ~ Various stages of grinding with grit depth of cut ~ Chip accommodation problem in grinding ~ Grit depth of cut and wheel-workpiece contact length ~ Determination of grit spacing and grit protrusion ~ Specific energy consumption in grinding ~ Grinding wheel performance against materials with different hardness ~ Effect of grinding parameters on grinding force and surface roughness of the workpiece ]
  • Lesson 28 Selection of wheels and their conditioning, objectives: identify need and purpose of grinding wheel specification; state the role of various compositional parameters of the grinding wheel; state the logical steps in selecting a grinding wheel; recognize need and purpose of grinding wheel conditioning; illustrate various methods of wheel conditioning, contents: [ Grinding wheels ~ Specification of grinding wheel ~ Selection of grinding wheels ~ Truing and dressing of grinding wheel ]
  • Lesson 29 Classification of grinding machines and their uses, objectives: recognise various types of basic grinding machines; illustrate techniques of grinding in these machines; state various applications of grinding machines, contents: [ Grinding Machines ~ Surface grinding machine: ~ Cylindrical grinding machine ~ Internal grinding machine ~ Tool and cutter grinder machine ]
• Module 6 Superfinishing processes
  • Lesson 30 Superfinishing processes, Honing, Lapping and Superfinishing, objectives: understand the significance of superfinishing process; state various applications of the superfinishing process; illustrate various techniques of superfinishing process, contents: [ Lapping ~ Honing ~ Superfinishing ]
• Module 7 Screw threads and Gear Manufacturing Methods
  • Lesson 31 Production of screw threads by Machining, Rolling and Grinding, objectives: Identify the general applications of various objects having screw threads; Classify the different types of screw threads; State the possible methods of producing screw threads and their characteristics.; Visualise and describe various methods of producing screw threads by; Machining; Rolling; Grinding, contents: [ General Applications Of Screw Threads ~ Classification Of Screw Threads ~ Production Of Screw Threads - Possible Methods And Their Characteristics. ~ Processes, Machines And Tools Used For Producing Screw Threads By; Machining; Rolling; Grinding ]
  • Lesson 32 Manufacturing of Gears., objectives: State the basic purposes of use of gears; Cite the general applications of gears; Classify the types of gears of common use; Specify gears; Describe the different methods of manufacturing various types of gears; Preforming; Producing gear teeth by machining; Finishing gear teeth, contents: [ Basic Purpose Of Use Of Gears ~ General Applications Of Gears ~ Types Of Gears And Their Characteristics ~ Specification Of Gears ~ Manufacture Of Gears ]
• Module 8 Jigs and Fixtures for Machine shops
  • Lesson 33 Purposes of jigs and fixtures and their Design principles, objectives: Define Fixture and Jig that aid machining; Conceive the purposes of use of jigs and fixtures; State the design considerations for jigs and fixtures; Illustrate the methods of ; locating ; supporting and ; clamping of blanks ; guidance of cutting tools in fixtures and jigs to facilitate machining, contents: [ Definition Of Fixture And Jig ~ Purpose Of Using Fixtures And Jigs ~ Design Considerations For Jigs And Fixtures ~ Principles And Methods Of Locating, Supporting And ~ Clamping Blanks And Tool Guidance In Jigs And Fixtures ]
  • Lesson 34 Design and Application of typical jigs and fixtures, objectives: Analyze economic viability and judge necessity of jig - fixture for specific production by machining; Plan for designing a fixture or jig; Design fixture or jig (configuration and working) for specific jobs and their machining requirements, contents: [ Economic Viability Analysis And Judging Necessity Of Jig - Fixture. ~ Planning Prior To Design And Construction Of A Fixture Or Jig ~ Design Of Fixtures And Jigs For Some Specific Jobs ]
• Module 9 Non-conventional machining
  • Lesson 35 Introduction and Abrasive Jet Machining, objectives: Identify the characteristics of conventional machining; Identify the characteristics of non traditional machining; Differentiate between conventional and non traditional machining; Classify different non traditional machining processes; Identify the need for non traditional machining processes; Describe the basic mechanism of material removal in AJM; Identify major components of AJM equipment; State the working principle of AJM equipment; Draw schematically the AJM equipment; Identify the process parameters of AJM; Identify the machining characteristics of AJM; Analyse the effect of process parameters on material removal rate (MRR); Draw variation in MRR with different process parameters; Develop mathematical model relating MRR with abrasive jet machining parameters; List three applications of AJM; List three limitations of AJM, contents: [ Classification of Non Traditional Machining Processes ~ Need for Non Traditional Machining ~ Abrasive Jet Machining ~ Process Parameters and Machining Characteristics. ~ Modelling of material removal ~ Applications ~ Limitations ]
  • Lesson 36 Ultrasonic Machining (USM), objectives: Describe the basic mechanism of material removal in USM; Identify the process parameters of USM; Identify the machining characteristics of USM; Analyse the effect of process parameters on material removal rate (MRR); Develop mathematical model relating MRR with USM parameters; Draw variation in MRR with different process parameters; Identify major components of USM equipment; State the working principle of USM equipment; Draw schematically the USM equipment; List three applications of USM; List three limitations of USM, contents: [ Mechanisms of Material Removal in USM and its modelling ~ Process Parameters and their Effects. ~ Applications ~ Limitations ]
  • Lesson 37 Water Jet and Abrasive Water Jet Machining, objectives: List four different non conventional machining processes; Differentiate between water and abrasive water jet machining; List different WJM and AWJM systems; List ten different modules of AWJM systems; List four applications of AWJM; List three advantages of AWJM; List materials that can be processed by AWJM; Mention functions of different elements of AWJM; Identify mechanism of material removal; Develop models for mechanism of material removal; Identify parameters related to product quality; Identify five limitations of AWJM; Identify environmental issues in the area of AWJM, contents: [ Machine ~ Mixing ~ Suspension Jet ~ Catcher ~ Mechanism of material removal ~ Environmental issues and future ]
  • Lesson 38 Electro Chemical Machining, objectives: Identify electro-chemical machining (ECM) as a particular type of non-tradition processes; Describe the basic working principle of ECM process; Draw schematically the basics of ECM; Draw the tool potential drop; Describe material removal mechanism in ECM; Identify the process parameters in ECM; Develop models for material removal rate in ECM; Analyse the dynamics of ECM process; Identify different modules of ECM equipment; List four application of ECM; Draw schematics of four such ECM applications, contents: [ Process ~ Equipment ~ Modelling of material removal rate ~ Dynamics of Electrochemical Machining ~ Process Parameters ]
  • Lesson 39 Electro Discharge Machining, objectives: Identify electro-discharge machining (EDM) as a particular type of non-tradition processes; Describe the basic working principle of EDM process; Draw schematically the basics of EDM; Describe spark initiation in EDM; Describe material removal mechanism in EDM; Draw the basic electrical waveform used in EDM; Identify the process parameters in EDM; Describe the characteristics of EDM; Identify the purpose of dielectric fluid in EDM; List two common dielectric fluid; Analyse the required properties of EDM tool; List four common tool material for EDM; Develop models for material removal rate in EDM; Identify the machining characteristics in EDM; Analyse the effect of process variables on surface roughness; Analyse taper cut and over cut in EDM; Identify different modules of EDM system; Draw schematic representation of different electrical generators used in EDM; Analyse working principle of RC type EDM generator, contents: [ Characteristics of EDM ~ Dielectric ~ Electrode Material ~ Modelling of Material Removal and Product Quality ~ Power generator ~ Analysis of RC type Relaxation EDM Generator ]
  • Lesson 40 Electron Beam and Laser Beam Machining, objectives: Describe the basic mechanism of material removal in EBM & LBM; Identify major components of EBM & LBM equipment; State the working principle of EBM & LBM equipment; Draw schematically the EBM & LBM equipment; Identify the process parameters of EBM & LBM; Identify the machining characteristics of EBM & LBM; List three applications of EBM & LBM; List three limitations of EBM & LBM, contents: [ Electron Beam Machining - Process ~ Electron Beam Machining - Equipment ~ Electron Beam Process - Parameters ~ Electron Beam Process Capability ~ Electron Beam Machining - Advantages and Limitations ~ Laser Beam Machining - Introduction ~ Laser Beam Machining - The LAsing Process ~ Lasing Medium ~ Laser Construction ~ Laser Beam Machining - Application ~ Laser Beam Machining - Advantages - Limitations]

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manufacturing processes, manufacturing, lathe, manufacturing process, Jigs and fixtures, Manufacturing Processes II, machine tools, CNC, milling fixture, Merchant circle analysis for lathe machine

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