Machining Processes and

Metrology
MEE2006

School of Mechanical Engineering

Vellore Institute of Technology-632014
Module Topics
1 Metal Cutting - Mechanics of metal cutting - cutting tool materials, temperature, wear, and tool life
considerations, geometry and chip formation, surface finish and machinability, optimization.

2 Basic Machine Tools - Lathe and its types - Constructional details including accessories and
attachments, operations, types of lathe, Constructional and operational details of Shaping - Planing -
Slotting – Drilling - Boring – Reaming – Tapping – Broaching.
3 Milling machine - Cutters - Milling operations - Indexing – Gear Generation: Gear generating
principles - Gear Hobber - Gear finishing methods - Bevel gear generator.

4 Grinding machine- Operations and applications of surface, cylindrical and centreless grinding
processes, dressing, truing and balancing of grinding wheels, grading and selection of grinding
wheels, micro-finishing (honing, lapping, super-finishing).
5 Unconventional methods - Electro-chemical, electro-discharge, ultrasonic, LASER, electron beam,
water jet machining.

6 Introduction to Metrology - Linear and angular measurements – taper measurement, threads,

surface finish, inspection of straightness, flatness and alignment-– Comparators - Gear testing.

7 Advances in Metrology - Precision Instrumentation based on Laser Principals, Coordinate measuring

machines, Optical Measuring Techniques: Tool Maker’s Microscope, Profile Projector. Nano-
measurements: Scanning Electron Microscope-.Atomic Force Microscopy-Transmission Electron
Microscopy.
8 Contemporary Discussion

2
 Manufacturing Processes

• Subtractive (Material Removal)

• Additive (Material Build-up)

• Formative (Material distribution)

Mechanics of metal cutting 3

 Manufacturing Process Selection

1. Material

2. Tolerances

3. Geometry, strength and endurance

4. Surface finish

5. Production volume

Mechanics of metal cutting 4

 Machining
Removing material in the form of chips

Very accurate
• highest of all manufacturing processes
• small amounts of materials removed
• precise tools, dies, moulds can be made

Highly Flexible
• shape is programmed
• many different parts can be made on one machine
• any arbitrary shape can be machined

Low cost tooling

• contour is generated by path of tool, rather than its shape, in most cases
• cutting tools are mass-produced in
• standardized shapes
5
 Basic requirements for metal cutting

• There should be a relative motion between the cutting tool and the
workpiece.

• The cutting tool should be harder than the workpiece

• There should be sufficient power available to overcome the cutting

forces
 Solid state physics
 Physical metallurgy
 Engineering mechanics
 Thermodynamics
 Theories of wear and lubrication

Mechanics of metal cutting 6

 What is required?

1. Rapid removal of metal

2. Satisfactory surface finish

3. Low-cost tools, maintenance

4. Minimum down time of the machines

Mechanics of metal cutting 7

 Machining Operation

1. Workpiece
2. Tool
3. Chip
4. Cutting fluid

Mechanics of metal cutting 8

Ref: www.mecholic.com
Mechanics of metal cutting 9
 Shear Zone

The region between the

lower surface, where
elongation of the grain
structure begins and in
the upper section where
it ends

Mechanics of metal cutting 10

 Stress – Force – Material removal
P
Ps

𝑃𝑛 = 𝑃 𝑐𝑜𝑠𝜃
P
ϴ n
𝑃𝑠 = 𝑃 𝑠𝑖𝑛𝜃
Pn
ϴ
𝑃
n 𝑆𝑛 = 𝑐𝑜𝑠 2 𝜃
𝐴
𝑃 𝑃 m
𝑆𝑠 = 𝑠𝑖𝑛𝜃 𝑐𝑜𝑠𝜃 = 𝑠𝑖𝑛2𝜃
𝐴 2𝐴
m
Maximum shear stress 2ϴ = 90 °
ϴ = 45 °

P
Mechanics of metal cutting 11