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Dr. Awani Bhushan Assistant Professor SMEC, VIT Chennai

The document outlines the content of lectures on machining processes given by Dr. Awani Bhushan. It includes 6 modules covering topics like mechanics of machining, tool wear and tool life, manufacturing processes, metal casting, metal joining, and metal working processes. Key machining processes discussed are turning, milling, and drilling. Advantages of machining include achieving a high surface finish and dimensional accuracy while producing a variety of geometry features. Disadvantages relate to operator dependency and the difficulty of producing complex shapes. A video on piston manufacturing is also included.

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Ayush Agrawal
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49 views21 pages

Dr. Awani Bhushan Assistant Professor SMEC, VIT Chennai

The document outlines the content of lectures on machining processes given by Dr. Awani Bhushan. It includes 6 modules covering topics like mechanics of machining, tool wear and tool life, manufacturing processes, metal casting, metal joining, and metal working processes. Key machining processes discussed are turning, milling, and drilling. Advantages of machining include achieving a high surface finish and dimensional accuracy while producing a variety of geometry features. Disadvantages relate to operator dependency and the difficulty of producing complex shapes. A video on piston manufacturing is also included.

Uploaded by

Ayush Agrawal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Dr.

Awani Bhushan
Assistant Professor
SMEC, VIT Chennai
Sl No. Lecture No. Content
  Module1 Machining process

1 MMP Module1.1 Brief introduction and history of machining - Scope and significance of machining -
2 MMP Module1.2 Plastic deformation - Stress and strain -

3 MMP Module1.3 Mechanism of Plastic Deformation: Slips, defects, plastic deformation on atomic scale
  Module2 Mechanics of Machining Process
4 MMP Module2.1 Mechanics of metal cutting - Orthogonalcutting -
5 MMP Module2.2 Mechanics of metal cutting - Oblique cutting -
6 MMP Module2.3 Types of chips - Merchant’s analysis -

7 MMP Module2.4 Stress, strain, strain rate, shear angle and force relationships – Turning - Drilling – Milling

8 MMP Module2.5 Stress, strain, strain rate, shear angle and force relationships – Griding - Shaping
  Module3 Tool Wear and Tool Life
9 MMP Module3.1 Tool nomenclature – Tool geometry -
10 MMP Module3.2 Progressive tool wear - Flank wear -

11 MMP Module3.3 Crater wear - Tool life : Variables affecting tool life - Cutting conditions -

12 MMP Module3.4 Tool materials - Cutting fluids - Determination of tool life equation - Machinability
  Module4 Manufacturing Processes

13 MMP Module4.1 Fundamental approaches of manufacturing - specific advantages and limitations - Classification of manufacturing processes –

14 MMP Module4.2 Selection and applications - Effect on mechanical properties,


15 MMP Module4.3 Introduction to advanced manufacturing processes.
  Module5 Metal Casting Processes
16 MMP Module5.1 Introduction - Steps of casting processes – Terminologies –
17 MMP Module5.2 Patterns - Types of patterns
18 MMP Module5.3 Allowances - Sand moulding -
19 MMP Module5.4 Casting defects and their preventions -
20 MMP Module5.5 Shell mould - Investment casting -
21 MMP Module5.6 Permanent mould casting - Melting furnace
  Module6 Metal Joining Processes

22 MMP Module6.1 Principle of welding, soldering, Brazing and adhesive bonding -


23 MMP Module6.2 Classification of welding - Gas welding -
24 MMP Module6.3 Arc welding - Resistance welding -
25 MMP Module6.4 Plasma and laser beam welding - Electron beam welding -

26 MMP Module6.5 TIG, MIG - Friction stir welding – Disimilar metal joining process
  Module7 Metal Working Processe

27 MMP Module7.1 Metal working - Concept of strain hardening - Hot and cold working –
28 MMP Module7.2 Rolling and forging operations – Extrusion -
29 MMP Module7.3 Wire and tube drawing processes - Shearing –
30 MMP Module7.4 Blanking – Piercing - Coining and embossing
Contents
• What is Machining?
• Why Machining is important?
• Tools required for Machining
• Advantages and Disadvantages
• Types of Machining Processes/operations
• What is Machining?

Metal removal process to get the desired shape


Why Machining is important?

Primary Shaping
Processes
(Casting, Metal
forming, Powder
metallurgy)
Machine Tools and Cutting Tools

Lathe Milling machine Drilling machine


Lathe Machine – Turning operation
Lathe Machine - Facing operation
Lathe Machine – Grooving operation
Milling
Machine
Drilling
Machine
Advantages

• A high surface finish can be obtained.


• Machining is not only performed on the metal but it also
performs on wood, plastic, composites, and ceramics.
• A variety of geometry features are possible, such a Screw
threads, Very straight edges, Accurate round holes, etc. 
• Good dimensional accuracy.

Disadvantages

• The accuracy of the components produce is dependent on the


efficiency of the operator.
• Consistency in manufacturing is not present. Hence 100%
inspection of the component is required.
• The personal needs of the operator are reducing the production
rates.
• Because of the large amount of Manpower involved, the labor
problem will also be high.
• The complex shapes like parabolic Curvature components, Cubicle
Curvature components are difficult to manufacture.
• Frequent design changes in the component cannot be incorporated
into the existing layout.
Piston Manufacturing

https://www.youtube.com/watch?v=oteRREC
MeSo
History of Machining Process

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