Sheet metal cutter page 17 of 17 the procedure of cutting the sheet begins by placing delimiter on the required distance from the lower knife. Manufacturing process study notes handwritten free pdf. Manufacturing implies creating value to a raw material by applying useful mental and physical labour. Machining is a process of cutting metal work piece by means of a tool to convert it into desire shape. From p n rao metal cutting and machine tools, tata mcgraw hill, 2000 1.
Pdf modelling of metal cutting by finite element method. Usually, the portion that is fractured away is in small sized pieces, called chips. Metal cutting notes free pdf download faadooengineers. Cutting conditions milling cutters plain milling cutters form milling cutters face milling cutters end milling cutters cutting conditions. Basic working principle, configuration, specification and classification of machine tools.
Within a limited time of 10 hours, this course would elaborate on the theory of metal cutting supplemented with numerical problems. Plastic properties of metals are used during the process of metal forming. Runners and gates are made by cutting the parting surface with a gate cutter. To understand the concept and basic mechanics of metal cutting, working of standard machine tools such as lathe, shaping and allied machines, milling, drilling and allied machines, grinding and allied machines and broaching. Economics of metal cutting 1 free download as powerpoint presentation. Metal beneath the surface undergoes shear deformation. Tool geometry, chip formation, cutting force calculations and measurement, tool wear and other aspects will be given due attention. Machining is a metal removal process, which can be accomplished by applying force on raw material by means of a cutting tool. Multiple cutting edge tools more than one cutting edge motion relative to work usually achieved by rotating drilling and milling use rotating multiple cutting edge tools. A gate cutter is a piece of sheet metal bent to the desired.
Oblique cutting characteristics cutting edge at an angle. Lecture notes design and manufacturing ii mechanical. To investigate the performance of cutting, the measurement of cutting forces is essential. No cutting tool is perfectly sharp, and in the idealized picture as shown in figure 2 the cutting edge is represented by a cylindrical surface joining the tool flank and tool face. After that, the steel sheet is being placed on the left between the knives, until it reach delimiter. Today i will tell you about types of chips in metal cutting form during machining process. Unit 4 metal coating processes metal coating processes. Kim 3 orthogonal cutting in a lathe rake angle shear angle t o. The resultant too force in metal cutting is distributed over the areas of the tool that contact the chip and workpiece.
Before discussing on this topic, first you should know about machining process. Metal cutting complete seminar report ebook free download ppt. Most metal cutting is done by high speed steel tools or carbide tools. Metal cutting cutting processes work by causing fracture of the material that is processed. The analysis of three forces system, which balance each other for cutting to occur. Important casting terms nptel course on manufacturing processes i, pradeep kumar et al. However, the cutting force becomes unstable with the variation coinciding with the fracturing cycle. Paul,department of mechanical engineering, iit kharagpur. Microscopic study of chips frozen by drop tool or quick. Manufacturing technology theory of metal cutting metal cutting or machining is the process of producing a work piece by removing unwanted material from a block of metal, in the form of chips. Deformation of metals mechanism of plastic deformation machining processes. Lecture series on manufacturing processes ii by prof. Thanks to abb sixaxis robots, automation can be implemented throughout the production line from cutting steel plate or tubes, via a range of processing applications, to shipment of the finished part. Metal forming is the main method of making metal products and semifinished products.
In this article we mainly focus on sheet metal cutting operations and. Do you need help with calculating starting values, figure out what causes and solves poor tool life or do you need tips on how to optimize your machining processes. We are here to provides you the best study notes from best coaching like made easy, ace academy etc and lecture notes from best institutions like mit open course, iit nptel, crec tirupati, washington, middle east technical university etc. Find materials for this course in the pages linked along the left. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. Longer term applications metal matrix composites with high specific stiffness and strength could be used in applications in which saving weight is an important factor. The monitoring and control of turning operations in a metalcutting system are examined. More than 90% of smelted metal is processed by different methods of metal forming. Nptel provides elearning through online web and video courses various streams. Single point cutting tool geometry indian institute of. Introduction to metal cutting engineering tutorials. Sheetmetal characteristics elongation the capability of the sheet metal to stretch without necking and failure. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing.
Contentcommon features of machining processes, geometry of single point tool and tool signature, concept of speed, feed and depth of cut applicable to various machining processes. This process is most important since almost all the products get their final shape and size by metal removal, either directly or indirectly. Introduction of machining or metal cutting lecture 17. Mrr, tool wear physics of cutting mechanics force, power tool materials design for manufacturing 2. The machining of material is highly dependable on chips. When you need an experts advice for metal cutting, this is the place to go.
Joyjeet ghose, bit, mesra, lecture notes on pe5005 definition of manufacturing the word manufacturing is derived from latin. Merchant circle diagram is used to analyze the forces acting in metal cutting. Cutting metalworking fluids lubricate the workpiecetool metaltometal contact zone preventing tool galling and seizure, which assures good surface finish. This course would encompass a comprehensive study of metal cutting and machine tools. Actually, the metal is forced off the work piece by being compressed, shearing off, and sliding along the face of the cutting tool. Tool geometry, chip formation, cutting force calculations and measurement, tool wear and other aspects will.
The tool should be having sufficient toughness withstand the shock and vibration. If the tool having sufficient amount of toughness, the fine edge of cutting tool does not break down or chip formation. Sources of heat in metal cutting for example, in a typical study of machining mild steel at 30 mmin at about 750 deg of cutting temperature at toolchip interface, the distribution of total energy developed at the shear zone is as follows energy at chip 60 percent. Tool geometry, chip formation, cutting force calculations and. It is a combination properties of strength and ductility. Mechanical engineering manufacturing processes ii nptel. Metal cutting and machine tools iitkgp 31,285 views. Economics of metal cutting 1 machining mathematical.
Lecture 3 theory of metal cutting linkedin slideshare. Common cutting processes include sawing, shaping or planing, broaching, drilling, grinding, turning and milling. Metal cutting is one of the most widely used manufacturing techniques in the industry and there are lots of studies to investigate this complex process in both academic and industrial world. From the uniaxial tensile test, one can understand material behavior considerably. These manufacturing process som study notes will help you to get conceptual deeply knowledge about it. Lubrication and cooling effects provided by cutting fluids coolants result in the following benefits of metalworking.
Chapter 4 metal matrix composites princeton university. A material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. Nptel project is licensed under creative commons ccbysa. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. Before coating the surface of substrate metal is first cleaned perfectly to ensure adhesion of the sprayed metal and deposition of an even and uniform layer. Singlepoint tools one cutting edge turning uses single point tools point is usually rounded to form a nose radius 2. Lowtomedium cutting speeds toolchip friction causes portions of chip to adhere to rake face bue formation is cyclical. Included in this category are robots, highspeed machinery, and highspeed rotating shafts for ships or land vehicles. The capacity of lathe tool dynamometer is 500kg, sensitivity is 1 kg, cross interference of 2%, natural frequency is 800 cps min. Mainly sheet metal process can be divided into three types. The metal used for deposition may be either in the form of wire or powder. Robot automation solutions for every process cutting robots are ideal.
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