Industrial Engineering ONLINE Course
Machining productivity science is being developed by Prof. K.V.S.S. Narayana Rao to support the productivity science principle of Principles of Industrial Engineering presented in the 2017 Annual Conference of IISE at Pittsburgh.
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Principles of Industrial Engineering presented in the 2017 Annual Conference of IISE at Pittsburgh.
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1. Metal Cutting Processes - Industrial Engineering and Productivity Aspects
2. Machine Tools - Industrial Engineering and Productivity Aspects
3. Machining Cutting Tools - Industrial Engineering and Productivity Aspects
4. Machine Tool Toolholders - Industrial Engineering and Productivity Aspects
5. Metal Cutting Temperatures - Industrial Engineering and Productivity Aspects
6. Machining Process Simulation - Industrial Engineering and Productivity Analysis
7. Cutting Tool Wear and Tool Life Analysis - Industrial Engineering and Productivity Aspects
8. Surface Finish - Industrial Engineering and Productivity Aspects
9. Work Material - Machinability - Industrial Engineering and Productivity Aspects
10. Machine Rigidity - Industrial Engineering and Productivity Aspects
11. Machining Time Reduction - Machining Cost Reduction - Industrial Engineering of Machining Operations
12. Machine Tool Cutting Fluids - Industrial Engineering and Productivity Aspects
13. High Speed Machining - Industrial Engineering and Productivity Aspects
14. Design for Machining - Industrial Engineering and Productivity Aspects
Butterworth-Heinemann, 22-Oct-2013 - Technology & Engineering - 408 pages
Of interest to all mechanical, manufacturing and materials engineers.
Theoretical and practical problems addressed
https://books.google.co.in/books?id=p2LJOOfhaIIC
Machining Science - Swayam Course
https://swayam.gov.in/nd1_noc20_me45/preview
Machining Science
By Prof. Sounak Kumar Choudhury | IIT Kanpur
1. Introduction : Machining; Plastic Deformation, Tensile Test, Stress and Strain; Mechanism of Plastic Deformation: Slips, defects, plastic deformation on
atomic scale.
2. Machining Process : Types of machining processes; Chip formation; Orthogonal and Oblique Cutting; Types of Chips; Built-up edge formation.
3. Tool Geometry : Reference planes; Tool specification: American System (ASA), continental or Orthogonal System (ORS), International or Normal Rake system (NRS); Tool angle relationships in ORS, ASA and NRS; Selection of Tool Angles; Multiple-point cutting tools: twist drill, helical milling cutter.
4 . Mechanics of Metal Cutting : Merchant's Circle Diagram; Co-efficient of Friction: Determination of stress, strain and strain rate; Measurement of shear angle; Thin Zone model: Lee and Shaffer's Relationship; Thick Zone model: Okushima and Hitomi Analysis
5. Friction in Metal Cutting : Nature of sliding friction; Friction in Metal Cutting: Sticking and Sliding Zones, Analysis of Stress Distribution on the tool face: Zorev’s model; Determination of mean angle of friction.
6. Mechanism of Oblique cutting : Rake angles in oblique cutting: Analytical determination of Normal Rake angle, velocity rake angle and effective rake angle; their relationship; shear angles in oblique cutting; velocity relationship; Force relationships in oblique cutting.
7. Practical Machining Operations : Turning, shaping and planning, Slab milling, Drilling: Machining Parameters, force magnitudes, power consumption, material removal rate, time per pass.
8. Measurement of cutting Forces : Basic methods of measurement: Axially Loaded members, Cantilever Beam, Rings and Octagon, dynamometer requirements; machine tool
dynamometers.
9. Tool Material, Tool Wear and Tool Life : Types of tool wear; Mechanisms of wear: Abrasion, Adhesion and Diffusion. Progressive tool wear: flank and crater wear. Tool Life: variables affecting tool life - cutting conditions, tool geometry, Types of tool materials, fabrication of cutting inserts, coatings, work material and cutting fluid; Machinability and their criteria.
10. Abrasive Machining Processes: Processes and analyses
11. Economics of Machining: determination of optimal cutting conditions for minimum cost, maximum production rate and maximum profit rate
12. Thermal Aspects of Machining: analytical determination of temperature in the shear zone and the chip-tool contact area
13. Surface finish: comparison and analytical determination of surface finish in turning, milling and grinding
INTENDED AUDIENCE : Mechanical Engineering, Metallurgy, Aerospace Engineering, Production Engineering
PREREQUISITES : Basic Manufacturing Engineering Courses
INDUSTRY SUPPORT : All Manufacturing industries, Machine tool manufacturing industries, Automobile Industries and aeronautical industries
COURSE LAYOUT
Week 1 : Machining; Plastic Deformation, Tensile Test, Stress and Strain; Mechanism of Plastic Deformation: Slips, defects,
plastic deformation on atomic scale; Types of machining processes; Chip formation; Orthogonal and Oblique Cutting;
Types of Chips; Built-up edge formation; Tool specification; Tool angle relationships in ORS and ASA and NRS;
Selection of Tool Angles; Multiple-pointcutting tools: twist drill, helical milling cutter.
Week 2 : Merchant's Circle Diagram; Co-efficient of Friction: Determination of stress, strain and strain rate; Measurement of
shear angle; Thin Zone model: Lee and Shaffer's Relationship; Thick Zone model: Okushima and Hitomi
Analysis; Nature of sliding friction; Friction in Metal Cutting: Sticking and Sliding Zones, Determination of mean angle of friction
Week 3 : Mechanism of Oblique Cutting: Normal Rake angle, velocity rake angle and effective rake angle;
shear angles; velocity relationship; Force relationships in oblique cutting; Practical Marching Processes:
Turning, shaping and planning, Slab milling, Drilling: Machining Parameters, force magnitudes, power consumption,
material removal rate, time per pass.
Week 4 : Measurement of Cutting Forces: Basic methods of measurement: Axially Loaded members, Cantilever Beam,
Rings and Octagon, dynamometer requirements; machine tool dynamometers; Types of tool wear;
Mechanisms of wear: Abrasion, Adhesion and Diffusion.Progressive tool wear: flank and crater wear. Tool Life:
variables affecting tool life - cutting conditions, tool geometry, Types of tool materials, fabrication of cutting
inserts, coatings, work material and cutting fluid; Machinability and their criteria. Abrasive Machining Processes;
Oblique Cutting; Economics of Machining; Thermal Aspects of Machining; Surface Finish.
BOOKS AND REFERENCES
1. E.J.A. Armarego and R.H.Brown-The Machining of Metals
2. G Boothroyd-Fundamentals of Metal Machining and Machine tools
3. A.Ghosh and Asok Mallik- Machining Science
4. G.K.Lal and S.K.Choudhury-Fundamental of Manufacturing Processes
5. M.C.Shaw-Metal Cuttting Principles
The Playlist on YouTube
https://www.youtube.com/watch?v=JpQHtQm-wBo&list=PLFW6lRTa1g811vIFgNhj-NLhUONoxvpnp
________________
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Machining productivity science is being developed by Prof. K.V.S.S. Narayana Rao to support the productivity science principle of Principles of Industrial Engineering presented in the 2017 Annual Conference of IISE at Pittsburgh.
_______________
Principles of Industrial Engineering presented in the 2017 Annual Conference of IISE at Pittsburgh.
_______________
1. Metal Cutting Processes - Industrial Engineering and Productivity Aspects
2. Machine Tools - Industrial Engineering and Productivity Aspects
3. Machining Cutting Tools - Industrial Engineering and Productivity Aspects
4. Machine Tool Toolholders - Industrial Engineering and Productivity Aspects
5. Metal Cutting Temperatures - Industrial Engineering and Productivity Aspects
6. Machining Process Simulation - Industrial Engineering and Productivity Analysis
7. Cutting Tool Wear and Tool Life Analysis - Industrial Engineering and Productivity Aspects
8. Surface Finish - Industrial Engineering and Productivity Aspects
9. Work Material - Machinability - Industrial Engineering and Productivity Aspects
10. Machine Rigidity - Industrial Engineering and Productivity Aspects
11. Machining Time Reduction - Machining Cost Reduction - Industrial Engineering of Machining Operations
12. Machine Tool Cutting Fluids - Industrial Engineering and Productivity Aspects
13. High Speed Machining - Industrial Engineering and Productivity Aspects
14. Design for Machining - Industrial Engineering and Productivity Aspects
Metal Machining: Theory and Applications
T.H.C. ChildsButterworth-Heinemann, 22-Oct-2013 - Technology & Engineering - 408 pages
Metal machining is the most widespread metal-shaping process in the mechanical manufacturing industry. World-wide investment in metal machining tools increases year on year - and the wealth of nations can be judged by it. This text - the most up-to-date in the field - provides in-depth discussion of the theory and application of metal machining at an advanced level. It begins with an overview of the development of metal machining and its role in the current industrial environment and continues with a discussion of the theory and practice of machining. The underlying mechanics are analysed in detail and there are extensive chapters examining applications through a discussion of simulation and process control.
"Metal Machining: Theory and Applications" is essential reading for senior undergraduates and postgraduates specialising in cutting technology. It is also an invaluable reference tool for professional engineers. Professors Childs, Maekawa, Obikawa and Yamane are four of the leading authorities on metal machining and have worked together for many years.
Of interest to all mechanical, manufacturing and materials engineers.
Theoretical and practical problems addressed
https://books.google.co.in/books?id=p2LJOOfhaIIC
Machining Science - Swayam Course
https://swayam.gov.in/nd1_noc20_me45/preview
Machining Science
By Prof. Sounak Kumar Choudhury | IIT Kanpur
1. Introduction : Machining; Plastic Deformation, Tensile Test, Stress and Strain; Mechanism of Plastic Deformation: Slips, defects, plastic deformation on
atomic scale.
2. Machining Process : Types of machining processes; Chip formation; Orthogonal and Oblique Cutting; Types of Chips; Built-up edge formation.
3. Tool Geometry : Reference planes; Tool specification: American System (ASA), continental or Orthogonal System (ORS), International or Normal Rake system (NRS); Tool angle relationships in ORS, ASA and NRS; Selection of Tool Angles; Multiple-point cutting tools: twist drill, helical milling cutter.
4 . Mechanics of Metal Cutting : Merchant's Circle Diagram; Co-efficient of Friction: Determination of stress, strain and strain rate; Measurement of shear angle; Thin Zone model: Lee and Shaffer's Relationship; Thick Zone model: Okushima and Hitomi Analysis
5. Friction in Metal Cutting : Nature of sliding friction; Friction in Metal Cutting: Sticking and Sliding Zones, Analysis of Stress Distribution on the tool face: Zorev’s model; Determination of mean angle of friction.
6. Mechanism of Oblique cutting : Rake angles in oblique cutting: Analytical determination of Normal Rake angle, velocity rake angle and effective rake angle; their relationship; shear angles in oblique cutting; velocity relationship; Force relationships in oblique cutting.
7. Practical Machining Operations : Turning, shaping and planning, Slab milling, Drilling: Machining Parameters, force magnitudes, power consumption, material removal rate, time per pass.
8. Measurement of cutting Forces : Basic methods of measurement: Axially Loaded members, Cantilever Beam, Rings and Octagon, dynamometer requirements; machine tool
dynamometers.
9. Tool Material, Tool Wear and Tool Life : Types of tool wear; Mechanisms of wear: Abrasion, Adhesion and Diffusion. Progressive tool wear: flank and crater wear. Tool Life: variables affecting tool life - cutting conditions, tool geometry, Types of tool materials, fabrication of cutting inserts, coatings, work material and cutting fluid; Machinability and their criteria.
10. Abrasive Machining Processes: Processes and analyses
11. Economics of Machining: determination of optimal cutting conditions for minimum cost, maximum production rate and maximum profit rate
12. Thermal Aspects of Machining: analytical determination of temperature in the shear zone and the chip-tool contact area
13. Surface finish: comparison and analytical determination of surface finish in turning, milling and grinding
INTENDED AUDIENCE : Mechanical Engineering, Metallurgy, Aerospace Engineering, Production Engineering
PREREQUISITES : Basic Manufacturing Engineering Courses
INDUSTRY SUPPORT : All Manufacturing industries, Machine tool manufacturing industries, Automobile Industries and aeronautical industries
COURSE LAYOUT
Week 1 : Machining; Plastic Deformation, Tensile Test, Stress and Strain; Mechanism of Plastic Deformation: Slips, defects,
plastic deformation on atomic scale; Types of machining processes; Chip formation; Orthogonal and Oblique Cutting;
Types of Chips; Built-up edge formation; Tool specification; Tool angle relationships in ORS and ASA and NRS;
Selection of Tool Angles; Multiple-pointcutting tools: twist drill, helical milling cutter.
Week 2 : Merchant's Circle Diagram; Co-efficient of Friction: Determination of stress, strain and strain rate; Measurement of
shear angle; Thin Zone model: Lee and Shaffer's Relationship; Thick Zone model: Okushima and Hitomi
Analysis; Nature of sliding friction; Friction in Metal Cutting: Sticking and Sliding Zones, Determination of mean angle of friction
Week 3 : Mechanism of Oblique Cutting: Normal Rake angle, velocity rake angle and effective rake angle;
shear angles; velocity relationship; Force relationships in oblique cutting; Practical Marching Processes:
Turning, shaping and planning, Slab milling, Drilling: Machining Parameters, force magnitudes, power consumption,
material removal rate, time per pass.
Week 4 : Measurement of Cutting Forces: Basic methods of measurement: Axially Loaded members, Cantilever Beam,
Rings and Octagon, dynamometer requirements; machine tool dynamometers; Types of tool wear;
Mechanisms of wear: Abrasion, Adhesion and Diffusion.Progressive tool wear: flank and crater wear. Tool Life:
variables affecting tool life - cutting conditions, tool geometry, Types of tool materials, fabrication of cutting
inserts, coatings, work material and cutting fluid; Machinability and their criteria. Abrasive Machining Processes;
Oblique Cutting; Economics of Machining; Thermal Aspects of Machining; Surface Finish.
BOOKS AND REFERENCES
1. E.J.A. Armarego and R.H.Brown-The Machining of Metals
2. G Boothroyd-Fundamentals of Metal Machining and Machine tools
3. A.Ghosh and Asok Mallik- Machining Science
4. G.K.Lal and S.K.Choudhury-Fundamental of Manufacturing Processes
5. M.C.Shaw-Metal Cuttting Principles
The Playlist on YouTube
https://www.youtube.com/watch?v=JpQHtQm-wBo&list=PLFW6lRTa1g811vIFgNhj-NLhUONoxvpnp
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