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Machining Science And Jigs & Fixtures (21ME42)

Subject code

Module - 1

Introduction to Machining Processes and Machine Tools: Subtractive manufacturing processes and classifications. Construction, specification operations of machine tools:– Lathe, Shaping, Milling, Drilling, Grinding Machine. Introduction to CNC machines: CNC Lathe, Milling, Drilling, Machine Center.

Module - 2

Mechanics of Metal Cutting: Single point turning tool geometry (SPTT) influences the chip formation mechanisms of the Orthogonal and Oblique cutting process. Cutting Force Analysis (Orthogonal Cutting):Analysis of machining forces and power requirement, ‘Merchant’s model of Orthogonal Cutting and Theory of Lee & Shaffer’ Chip Velocity, Velocity relationships (simple numerical); the influence of cutting temperature on machinability. CuttingFluids: Characteristics of Cutting fluids, Selections, and applying methods of cutting fluids.

Module - 3

Machinability and Tool Life Process of cutting tool failure wears and time relationship, tool wear index, feed marks, the effect of tool wear on the machined surface, surface finish, machinability, machinability index/rating, tool life & variables affecting tool life, tool materials. Finishing Process: Importance of surface finishing processes, Grinding, Abrasive Flow Machining, Honing. Sanding, Abrasive blasting, Polishing, Lapping. Surface Finishing and Protection: Powder Coating, Liquid Coating, Electroplating, Galvanizing, Anodizing.

Module - 4

Advanced Machining Process; Importance and classification of advanced machining process; Process principal, process parameters, and application of: – Abrasive Jet Machining (AJW), Water Jet Machining (WJM), Abrasive Water Jet Machining (AWJM); Ultrasonic Machining (USM);Electrical Discharge Machining (EDM); Wire Electrical Discharge Machining (WEDM); Electro Chemical Machining (ECM). Laser Beam Machining (LBM), Electron Beam Machining (EBM), and Plasma Arc Machining (PAM). Hybrid Machining Process: Importance of hybrid machining process; Process principal, process parameters, and application of: – Electrochemical Discharge Machining (ECDM), Ultrasonic Assisted Electric Discharge Machining (UAEDM), Electrochemical Discharge Grinding (EDG), Powder Assisted Electric Discharge Machining (PAEDM).

Module - 5

Jigs and Fixtures: Importance of jigs and fixtures; the difference between jigs and fixtures; types of jigs and fixtures; essential features of jigs and fixtures, Materials used. Factors to be considered for the design of Jigs and Fixtures; Jigs: Template, Plate, Channel, Diameter, Leaf, Rung, Box, Fixtures: Turning, Milling, Broaching, Grinding, Boring, Indexing, Tapping, Duplex, Welding, and Assembly fixtures.