CONTENTS 1 THEORYOFMETALCUTTING 1-54 1.1. General 1 12. The Mechanics of Chip formation 1 1.3. Single Point Cutting Tool 1 1.4. Methods of Machining 9 1.5. Types of Chips 9 1.6. Principal Elements of Metal Machining 15 1.7. Determination of Shear Angle 15 1.8. Determination of Undeformed Chip Thickness 17 1.9. Force Relations 18 1.10. Energy considerations in Metal Cutting 23 1.11. Tool Wear and Tool Life 24 1.12. Surface Roughness 30 1.13. Solved Examples 33 PROBLEMS 47 2. CUTTINGTOOL MATERIALS AND CUTTING FLUIDS 55-73 2.1. General 55 2.2. Cutting Tool Materials 56 2.3. Cutting Fluids 66 PROBLEMS 71 3 MACHINE TOOLS 74-203 3.0. General 74 3.1. Lathe Machines 78 PROBLEMS 102 3.2. Shapers, Planers and Slotters 103 PROBLEMS 117 3.3. Drilling Machines, Reamers and Tap Tools 134 PROBLEMS 135 3.4. Boring Machines 140 PROBLEMS 141 3.5. Milling 162 PROBLEMS . 164 3.6. Grinding Operation 191 PROBLEMS o 191 3.7. Broaching Machines 196 PROBLEMS 196 3.8. Sawing Machines 196 PROBLEMS 4. MACHINING VARIABLES AND RELATED RELATIONS 204-220 4.1. General 204 4.2. Solved Examples 210 PROBLEMS 219 5 TOOL LAYOUT FOR CAPSTANS AND TURRETS 221-239 5.1. General 221 5 .2 Types of Turret Lathes 222 5.3. Main Parts 223 5.4 Work Holding Equipment 226 5.5. Standard Equipment and Tools 228 5.6. Machine Operations 230 5.7. Advantages of Turret Lathes 231 5.8. Tool Layout 231 5.9. Bar Stock Feeding Mechanism 232 5.10. Solved Examples 234 PROBLEMS 238 6. TOOL LAYOUT FOR AUTOMATICS 240-258 6.1 Automatic Lathes 240 6.2 Classification of Automatic Machines240 6.3 Classification of Semi-automatics 248 6.4. Setting up of Automatics and Semi-automatics 248 6.5 Tooling Layout and Operation Sheet 248 6.6. Cam Design250 6.7 Tool Layout for Automatic Screw Machine 251 6.8. Programmed Automatic Lathes 256 6.9 Bar Stock Feeding 256 PROBLEMS257 7. GEARMANUFACIUREVG 259-278 7.1. Introduction 259 7.2. Materials 259 7.3. Methods of Manufacture 260 7.4. Gear Cutting by Milling 261 7.5. Gear Cutting with Single Point formed Tool on Shaper/Planer 263 7.6. Broaching 263 7.7 Gear Speed Process 263 7.8. Gear Planing 263 7.9. GearShapers265 7.10 GearHobbing 266 7.11. Bevel Gear Generating 268 7.12. Miscellaneous Gear Manufacturing Methods 270 7.13. Practical Aspects of Gear Manufacturing 270 7.14. Gear Finishing Operations 277 PROBLEMS 277 8. NUMERICALLY CONTROLLED MACHINE TOOLS 279-291 8.1. General 279 8.2. Working of NC Machine Tool 280 8.3. Classification of NC Machines 282 8.4. Programming for NC Machines 284 8.5. Methods of listing the co-ordinates of points in NC System 286 8.6. Applications of NC Machines 286 8.7 Advantages and Disadvantages of NC Machines 286 8.8. Computer Numerical Control (CNC) and Direct Numerical Control (DNC) 287 8.9. Machining Centre 289 8.10. Adaptive Control 290 PROBLEMS 291 APPENDIX Problems from Competitive Examinations 292-313 INDEX 314