The document discusses material removal processes and metal cutting. It describes the nature of relative motion between the tool and workpiece in different operations like turning, boring, drilling, etc. It discusses factors that influence the cutting process like cutting speed, depth of cut, and tool angles. It explains the mechanics of chip formation through shear plane theory and describes different types of chips like continuous, discontinuous, and those with built-up edges. It also discusses tool wear patterns like flank and crater wear.
This document provides information on various metal cutting processes and fundamentals of cutting. It begins with acknowledging photographs from a textbook on the subject. It then discusses the nature of relative motion between the tool and workpiece for different operations like turning, boring, drilling, etc. It covers topics like types of cutting, factors influencing the cutting process, types of chips, chip breakers, tool nomenclature, forces in cutting, temperature distribution, tool wear, mechanics of chip formation, and surfaces produced by cutting. It also provides three example problems calculating cutting speed and material removal rate for turning, milling and drilling operations.
The document provides information on fundamental concepts of cutting processes used in manufacturing. It discusses the mechanics of chip formation where plastic deformation occurs along a shear plane as the tool cuts into the workpiece. Continuous and discontinuous chips are described along with factors that influence each type. Tool geometry including rake and inclination angles are defined. Temperature distribution in the cutting zone is discussed along with wear patterns on the flank and crater of cutting tools.
- Cutting involves removing material from a workpiece through chip formation using a cutting tool. There are different types of cutting processes like turning, cutting-off, milling.
- Factors like cutting speed, depth of cut, tool geometry influence chip formation and cutting forces. Continuous, built-up edge, discontinuous chips can form depending on materials and conditions.
- Chip formation involves shear along a shear plane determined by tool geometry. Temperature rises significantly in the cutting zone and influences tool wear.
- Tool wear modes include flank wear and crater wear. Tool life is determined by maximum acceptable wear or catastrophic failure like chipping. Cutting forces are measured to analyze effects of parameters.
This document discusses various rotary machining operations and tools. It describes operations like drilling, boring, reaming, tapping and milling that use rotating tools. It also discusses rotary cutting tools for turning operations and their benefits like increased tool life and surface finish. Rotary tool geometry and principles of rotary cutting are explained. Factors affecting rotary tool life and problems associated with rotary tools are also summarized.
This document provides an overview of sheet metal forming processes. It discusses that sheet metal forming is used to produce parts with versatile shapes and is lightweight. Common materials used are low-carbon steel, aluminum, and titanium. The main forming processes discussed are shearing, punching, bending, deep drawing, and stamping. It covers the characteristics of sheet metal that influence formability like elongation, anisotropy, and springback. Forming parameters that affect processes like deep drawing are also summarized such as blankholder pressure, draw ratio, and clearance.
The document discusses the theory of metal cutting, including the process of chip formation and different types of chips. It describes orthogonal and oblique cutting, factors that influence the cutting process, and chip formation mechanisms. It also covers cutting tool materials like high-speed steel, cemented carbides, ceramics, and coatings. Tool geometries such as rake angle, nose radius, and flank are defined. Different tool bit angles and tool signatures are also introduced.
This document provides an overview of sheet metal forming processes. It begins by describing common applications of sheet metal forming such as metal desks, appliances, and car bodies. It then discusses various sheet metal forming operations like punching, blanking, bending, and deep drawing. The document discusses important sheet metal characteristics like formability, anisotropy, and springback that influence formability. It also summarizes various techniques for cutting, bending, and shaping sheet metal, as well as methods for minimizing scrap.
This document provides information on various metal cutting processes and fundamentals of cutting. It begins with acknowledging photographs from a textbook on the subject. It then discusses the nature of relative motion between the tool and workpiece for different operations like turning, boring, drilling, etc. It covers topics like types of cutting, factors influencing the cutting process, types of chips, chip breakers, tool nomenclature, forces in cutting, temperature distribution, tool wear, mechanics of chip formation, and surfaces produced by cutting. It also provides three example problems calculating cutting speed and material removal rate for turning, milling and drilling operations.
The document provides information on fundamental concepts of cutting processes used in manufacturing. It discusses the mechanics of chip formation where plastic deformation occurs along a shear plane as the tool cuts into the workpiece. Continuous and discontinuous chips are described along with factors that influence each type. Tool geometry including rake and inclination angles are defined. Temperature distribution in the cutting zone is discussed along with wear patterns on the flank and crater of cutting tools.
- Cutting involves removing material from a workpiece through chip formation using a cutting tool. There are different types of cutting processes like turning, cutting-off, milling.
- Factors like cutting speed, depth of cut, tool geometry influence chip formation and cutting forces. Continuous, built-up edge, discontinuous chips can form depending on materials and conditions.
- Chip formation involves shear along a shear plane determined by tool geometry. Temperature rises significantly in the cutting zone and influences tool wear.
- Tool wear modes include flank wear and crater wear. Tool life is determined by maximum acceptable wear or catastrophic failure like chipping. Cutting forces are measured to analyze effects of parameters.
This document discusses various rotary machining operations and tools. It describes operations like drilling, boring, reaming, tapping and milling that use rotating tools. It also discusses rotary cutting tools for turning operations and their benefits like increased tool life and surface finish. Rotary tool geometry and principles of rotary cutting are explained. Factors affecting rotary tool life and problems associated with rotary tools are also summarized.
This document provides an overview of sheet metal forming processes. It discusses that sheet metal forming is used to produce parts with versatile shapes and is lightweight. Common materials used are low-carbon steel, aluminum, and titanium. The main forming processes discussed are shearing, punching, bending, deep drawing, and stamping. It covers the characteristics of sheet metal that influence formability like elongation, anisotropy, and springback. Forming parameters that affect processes like deep drawing are also summarized such as blankholder pressure, draw ratio, and clearance.
The document discusses the theory of metal cutting, including the process of chip formation and different types of chips. It describes orthogonal and oblique cutting, factors that influence the cutting process, and chip formation mechanisms. It also covers cutting tool materials like high-speed steel, cemented carbides, ceramics, and coatings. Tool geometries such as rake angle, nose radius, and flank are defined. Different tool bit angles and tool signatures are also introduced.
This document provides an overview of sheet metal forming processes. It begins by describing common applications of sheet metal forming such as metal desks, appliances, and car bodies. It then discusses various sheet metal forming operations like punching, blanking, bending, and deep drawing. The document discusses important sheet metal characteristics like formability, anisotropy, and springback that influence formability. It also summarizes various techniques for cutting, bending, and shaping sheet metal, as well as methods for minimizing scrap.
This document provides an overview of various machining processes and related topics. It discusses cutting action in machining and classifies common machining processes like turning, drilling, and milling. It also describes operations related to turning on a lathe like facing and threading. The document outlines workholding methods in lathes and different types of milling operations. Additionally, it covers tool materials, tool geometry, and use of chip breakers to control chip formation during machining.
Mechanics of Chip Formation - Unit of MFThodmech61
The document discusses material removal processes and machining. It covers various machining operations like turning, drilling, boring, and milling. It describes the fundamental process of orthogonal cutting and factors that influence the cutting process like cutting speed, depth of cut, feed, cutting fluids, tool angles, chip types, and tool wear. Continuous chips result in good surface finish and tool life while discontinuous chips are easier to dispose but can cause vibration. Proper selection of factors like material, cutting speed, and rake angle can produce different chip types.
This document contains the answer key for a unit test on Manufacturing Technology-II. It discusses various topics related to cutting tools and machining processes, including:
1. Types of cutting tools such as single point and multipoint tools.
2. Factors that affect tool life such as rake angle, tool wear, and cutting fluids.
3. Different types of chips produced during machining such as continuous, discontinuous, and chips with built-up edge.
4. Tool materials used for different temperature ranges such as carbon steel, high-speed steel, cemented carbides, and ceramics.
5. Merchant's circle diagram which models the forces during chip formation.
This document discusses oblique machining processes. It begins by defining orthogonal and oblique cutting, with oblique cutting having the cutting edge at an angle other than 90 degrees to the cutting velocity. It describes how in oblique cutting the chip forms in a helical pattern at an inclination angle. The document outlines different methods for determining the chip flow angle in oblique cutting, including observing tool scratches or photographing the process. It also discusses the various rake angles involved in oblique cutting, such as the normal, velocity, and effective rake angles.
Sheet metal forming is a versatile manufacturing process used to produce lightweight parts with complex shapes. Common forming operations include punching, blanking, bending, deep drawing, and stamping. Key considerations in sheet metal forming include the material properties, forming limits, stresses induced during forming, and techniques to reduce waste and improve dimensional accuracy. Proper tool and die design is critical for successful forming of sheet metal parts.
This document discusses fundamentals of machining processes. It introduces common machining operations like turning, cutting off, and milling. It then focuses on turning operations and the orthogonal cutting process. Key concepts covered include tool geometry, chip formation through shearing, different types of chips, factors that influence machining, and forces involved in cutting. Continuous, built-up edge, serrated, and discontinuous chips are described along with how tool geometry and machining parameters impact chip type.
The document discusses metal machining processes. It defines turning, milling and drilling as the three main machining operations. It describes the geometry of single point cutting tools and multiple edge tools. Key terms related to tool geometry like rake angle and relief angle are explained. The orthogonal cutting model and variables that define cutting conditions like cutting speed, feed and depth of cut are introduced. Different types of chips formed during machining and factors affecting tool life are also summarized.
This document provides information on metal cutting processes and machining technology. It discusses:
- The purpose, principles, and definition of machining as a process to produce parts to desired dimensions and surface finish through chip removal.
- Classification of metal cutting processes as orthogonal or oblique cutting. It also discusses cutting tool angles like back rake angle and relief angles.
- Factors that affect cutting forces like rake angle, feed rate, and depth of cut.
- Tool designation systems like ASA and common tool materials like high-speed steel and cemented carbide.
- The mechanism of chip formation and different chip types like continuous, discontinuous, and chips with built-up edge
This document discusses various sheet metal forming processes. It describes cutting processes like shearing, blanking, and punching. It also describes bending, drawing, embossing, stretch forming, roll forming, and spinning. Sheet metal is commonly used to make parts for vehicles, appliances, furniture and more. Cutting is done using punches and dies in presses or shears. Proper clearance and tool sizes are important. Bending involves straining metal around an axis. Drawing forms complex curved shapes using punches and dies.
This document summarizes various traditional manufacturing processes including casting, forming, cutting, joining, and surface treatment. It provides details on specific cutting processes like sawing, shaping, broaching, drilling, tapping, grinding, turning, and milling. For each process, it discusses the process characteristics, tools used, mechanics of material removal, effects of process parameters, tool wear modeling, and empirical results from experimentation. The document emphasizes the importance of process planning, modeling, and analysis for process optimization, control and improving machining economics.
This document provides an overview of machining technology and machine tools. It discusses various machining processes including subtractive processes where material is removed from a workpiece using tools. Lathes, mills, drills and other machine tools are described as examples of machines that perform subtractive machining. The document also covers topics such as tool geometry, chip formation, cutting forces, tool life and wear. Different types of chips, tool materials, tool angles and variables that influence machinability are defined.
The document discusses metal cutting and machining processes. It defines material removal processes as shaping operations that remove material from a work part to achieve a desired geometry. The two main types are machining, using a sharp cutting tool, and abrasive processes, using abrasive particles. Machining is important because it can cut a variety of materials and produce complex part shapes and features like threads and holes. However, it wastes material in chips and can be time consuming. The document then discusses chip formation mechanisms and types of chips produced from different materials and cutting conditions. It also defines tool elements, angles, and different types of single-point and multi-point cutting tools.
Cutting tools are used to remove metal from workpieces through shear deformation. There are two basic types: single-point and multiple-point tools. Single-point tools have a single dominant cutting edge and are used for turning, while multiple-point tools have more than one cutting edge and are used for drilling and milling. Cutting tools must be made of materials harder than the workpiece material and able to withstand the heat generated during machining. Common tool materials include high-speed steel, cemented carbides, ceramics, and polycrystalline diamond. Cutting tools must have properties like hardness, hot hardness, toughness, wear resistance, and ability to dissipate heat.
Machining is used to modify parts after casting or forming to achieve desired surface finishes, dimensions, and tolerances. It involves removing material through cutting processes like turning, milling, and drilling. Parts often require machining to produce features like smooth bearing surfaces, small deep holes, sharp edges, threads, and close tolerances that cannot be achieved through casting or forming alone. Machining also imparts special surface textures and finishes.
This document summarizes several traditional manufacturing processes including casting, forming, sheet metal processing, cutting, joining, powder processing, plastics processing, and surface treatment. It then provides more detailed descriptions and diagrams of specific cutting processes like sawing, shaping, broaching, drilling, tapping, grinding, turning, milling, and the important concept of process planning which involves fixturing, operations sequencing, setup planning, and operations planning. Key characteristics of each process like material removal rate, surface finish, precision and cost are also discussed.
This document discusses traditional manufacturing processes including casting, forming, sheet metal processing, cutting, joining, powder processing, plastics processing, and surface treatment. It provides details on specific cutting processes like sawing, shaping, broaching, drilling, grinding, turning, and milling. It also covers topics like fixturing, tool wear analysis, modeling of cutting mechanics and parameters, and optimizing processes for factors like production rate and cost.
Manufacturing Processes(Sheet Metal Forming.ppt)sadanand50
This document discusses various sheet metal forming processes including shearing, bending, deep drawing, and spinning. It provides examples of common sheet metal parts and describes key operations like punching, blanking, and fine blanking. Important considerations for sheet metal formability are outlined, such as material properties and tests. The document also covers design factors for efficient sheet metal forming and examples of equipment used.
The document discusses milling processes and provides details about various milling techniques. It defines milling, describes up and down milling methods, and covers topics such as milling machines, cutters, operations, and factors that influence tool life. Examples of peripheral and face milling are illustrated.
The document discusses tool specification and chip formation mechanisms. It begins by outlining the American System for specifying tool angles such as rake, relief, and cutting edge angles. It then explains how each angle impacts cutting forces and tool strength. The document also describes the mechanics of chip formation, defining shear angle and relating it to tool rake angle. It outlines factors that influence chip type and discusses tool surfaces and reference planes. Finally, it covers tool wear mechanisms, tool life definitions, and factors that tool life depends on such as cutting speed, depth of cut, and feed rate.
Sheet metal processing involves cutting, forming, and joining operations to shape raw sheet metal into parts. Common sheet metal processes include shearing, punching, bending, and deep drawing. Shearing uses large scissors to cut sheet metal to size. Punching and blanking cut out shapes from sheet metal using round or rectangular punches and dies. Bending forms sheet metal into angles and curves. Deep drawing stretches sheet metal over forming dies to create containers and pots. Sheet metal parts often involve combinations of these operations to create complex shapes.
A review on techniques and modelling methodologies used for checking electrom...nooriasukmaningtyas
The proper function of the integrated circuit (IC) in an inhibiting electromagnetic environment has always been a serious concern throughout the decades of revolution in the world of electronics, from disjunct devices to today’s integrated circuit technology, where billions of transistors are combined on a single chip. The automotive industry and smart vehicles in particular, are confronting design issues such as being prone to electromagnetic interference (EMI). Electronic control devices calculate incorrect outputs because of EMI and sensors give misleading values which can prove fatal in case of automotives. In this paper, the authors have non exhaustively tried to review research work concerned with the investigation of EMI in ICs and prediction of this EMI using various modelling methodologies and measurement setups.
This document provides an overview of various machining processes and related topics. It discusses cutting action in machining and classifies common machining processes like turning, drilling, and milling. It also describes operations related to turning on a lathe like facing and threading. The document outlines workholding methods in lathes and different types of milling operations. Additionally, it covers tool materials, tool geometry, and use of chip breakers to control chip formation during machining.
Mechanics of Chip Formation - Unit of MFThodmech61
The document discusses material removal processes and machining. It covers various machining operations like turning, drilling, boring, and milling. It describes the fundamental process of orthogonal cutting and factors that influence the cutting process like cutting speed, depth of cut, feed, cutting fluids, tool angles, chip types, and tool wear. Continuous chips result in good surface finish and tool life while discontinuous chips are easier to dispose but can cause vibration. Proper selection of factors like material, cutting speed, and rake angle can produce different chip types.
This document contains the answer key for a unit test on Manufacturing Technology-II. It discusses various topics related to cutting tools and machining processes, including:
1. Types of cutting tools such as single point and multipoint tools.
2. Factors that affect tool life such as rake angle, tool wear, and cutting fluids.
3. Different types of chips produced during machining such as continuous, discontinuous, and chips with built-up edge.
4. Tool materials used for different temperature ranges such as carbon steel, high-speed steel, cemented carbides, and ceramics.
5. Merchant's circle diagram which models the forces during chip formation.
This document discusses oblique machining processes. It begins by defining orthogonal and oblique cutting, with oblique cutting having the cutting edge at an angle other than 90 degrees to the cutting velocity. It describes how in oblique cutting the chip forms in a helical pattern at an inclination angle. The document outlines different methods for determining the chip flow angle in oblique cutting, including observing tool scratches or photographing the process. It also discusses the various rake angles involved in oblique cutting, such as the normal, velocity, and effective rake angles.
Sheet metal forming is a versatile manufacturing process used to produce lightweight parts with complex shapes. Common forming operations include punching, blanking, bending, deep drawing, and stamping. Key considerations in sheet metal forming include the material properties, forming limits, stresses induced during forming, and techniques to reduce waste and improve dimensional accuracy. Proper tool and die design is critical for successful forming of sheet metal parts.
This document discusses fundamentals of machining processes. It introduces common machining operations like turning, cutting off, and milling. It then focuses on turning operations and the orthogonal cutting process. Key concepts covered include tool geometry, chip formation through shearing, different types of chips, factors that influence machining, and forces involved in cutting. Continuous, built-up edge, serrated, and discontinuous chips are described along with how tool geometry and machining parameters impact chip type.
The document discusses metal machining processes. It defines turning, milling and drilling as the three main machining operations. It describes the geometry of single point cutting tools and multiple edge tools. Key terms related to tool geometry like rake angle and relief angle are explained. The orthogonal cutting model and variables that define cutting conditions like cutting speed, feed and depth of cut are introduced. Different types of chips formed during machining and factors affecting tool life are also summarized.
This document provides information on metal cutting processes and machining technology. It discusses:
- The purpose, principles, and definition of machining as a process to produce parts to desired dimensions and surface finish through chip removal.
- Classification of metal cutting processes as orthogonal or oblique cutting. It also discusses cutting tool angles like back rake angle and relief angles.
- Factors that affect cutting forces like rake angle, feed rate, and depth of cut.
- Tool designation systems like ASA and common tool materials like high-speed steel and cemented carbide.
- The mechanism of chip formation and different chip types like continuous, discontinuous, and chips with built-up edge
This document discusses various sheet metal forming processes. It describes cutting processes like shearing, blanking, and punching. It also describes bending, drawing, embossing, stretch forming, roll forming, and spinning. Sheet metal is commonly used to make parts for vehicles, appliances, furniture and more. Cutting is done using punches and dies in presses or shears. Proper clearance and tool sizes are important. Bending involves straining metal around an axis. Drawing forms complex curved shapes using punches and dies.
This document summarizes various traditional manufacturing processes including casting, forming, cutting, joining, and surface treatment. It provides details on specific cutting processes like sawing, shaping, broaching, drilling, tapping, grinding, turning, and milling. For each process, it discusses the process characteristics, tools used, mechanics of material removal, effects of process parameters, tool wear modeling, and empirical results from experimentation. The document emphasizes the importance of process planning, modeling, and analysis for process optimization, control and improving machining economics.
This document provides an overview of machining technology and machine tools. It discusses various machining processes including subtractive processes where material is removed from a workpiece using tools. Lathes, mills, drills and other machine tools are described as examples of machines that perform subtractive machining. The document also covers topics such as tool geometry, chip formation, cutting forces, tool life and wear. Different types of chips, tool materials, tool angles and variables that influence machinability are defined.
The document discusses metal cutting and machining processes. It defines material removal processes as shaping operations that remove material from a work part to achieve a desired geometry. The two main types are machining, using a sharp cutting tool, and abrasive processes, using abrasive particles. Machining is important because it can cut a variety of materials and produce complex part shapes and features like threads and holes. However, it wastes material in chips and can be time consuming. The document then discusses chip formation mechanisms and types of chips produced from different materials and cutting conditions. It also defines tool elements, angles, and different types of single-point and multi-point cutting tools.
Cutting tools are used to remove metal from workpieces through shear deformation. There are two basic types: single-point and multiple-point tools. Single-point tools have a single dominant cutting edge and are used for turning, while multiple-point tools have more than one cutting edge and are used for drilling and milling. Cutting tools must be made of materials harder than the workpiece material and able to withstand the heat generated during machining. Common tool materials include high-speed steel, cemented carbides, ceramics, and polycrystalline diamond. Cutting tools must have properties like hardness, hot hardness, toughness, wear resistance, and ability to dissipate heat.
Machining is used to modify parts after casting or forming to achieve desired surface finishes, dimensions, and tolerances. It involves removing material through cutting processes like turning, milling, and drilling. Parts often require machining to produce features like smooth bearing surfaces, small deep holes, sharp edges, threads, and close tolerances that cannot be achieved through casting or forming alone. Machining also imparts special surface textures and finishes.
This document summarizes several traditional manufacturing processes including casting, forming, sheet metal processing, cutting, joining, powder processing, plastics processing, and surface treatment. It then provides more detailed descriptions and diagrams of specific cutting processes like sawing, shaping, broaching, drilling, tapping, grinding, turning, milling, and the important concept of process planning which involves fixturing, operations sequencing, setup planning, and operations planning. Key characteristics of each process like material removal rate, surface finish, precision and cost are also discussed.
This document discusses traditional manufacturing processes including casting, forming, sheet metal processing, cutting, joining, powder processing, plastics processing, and surface treatment. It provides details on specific cutting processes like sawing, shaping, broaching, drilling, grinding, turning, and milling. It also covers topics like fixturing, tool wear analysis, modeling of cutting mechanics and parameters, and optimizing processes for factors like production rate and cost.
Manufacturing Processes(Sheet Metal Forming.ppt)sadanand50
This document discusses various sheet metal forming processes including shearing, bending, deep drawing, and spinning. It provides examples of common sheet metal parts and describes key operations like punching, blanking, and fine blanking. Important considerations for sheet metal formability are outlined, such as material properties and tests. The document also covers design factors for efficient sheet metal forming and examples of equipment used.
The document discusses milling processes and provides details about various milling techniques. It defines milling, describes up and down milling methods, and covers topics such as milling machines, cutters, operations, and factors that influence tool life. Examples of peripheral and face milling are illustrated.
The document discusses tool specification and chip formation mechanisms. It begins by outlining the American System for specifying tool angles such as rake, relief, and cutting edge angles. It then explains how each angle impacts cutting forces and tool strength. The document also describes the mechanics of chip formation, defining shear angle and relating it to tool rake angle. It outlines factors that influence chip type and discusses tool surfaces and reference planes. Finally, it covers tool wear mechanisms, tool life definitions, and factors that tool life depends on such as cutting speed, depth of cut, and feed rate.
Sheet metal processing involves cutting, forming, and joining operations to shape raw sheet metal into parts. Common sheet metal processes include shearing, punching, bending, and deep drawing. Shearing uses large scissors to cut sheet metal to size. Punching and blanking cut out shapes from sheet metal using round or rectangular punches and dies. Bending forms sheet metal into angles and curves. Deep drawing stretches sheet metal over forming dies to create containers and pots. Sheet metal parts often involve combinations of these operations to create complex shapes.
A review on techniques and modelling methodologies used for checking electrom...nooriasukmaningtyas
The proper function of the integrated circuit (IC) in an inhibiting electromagnetic environment has always been a serious concern throughout the decades of revolution in the world of electronics, from disjunct devices to today’s integrated circuit technology, where billions of transistors are combined on a single chip. The automotive industry and smart vehicles in particular, are confronting design issues such as being prone to electromagnetic interference (EMI). Electronic control devices calculate incorrect outputs because of EMI and sensors give misleading values which can prove fatal in case of automotives. In this paper, the authors have non exhaustively tried to review research work concerned with the investigation of EMI in ICs and prediction of this EMI using various modelling methodologies and measurement setups.
Understanding Inductive Bias in Machine LearningSUTEJAS
This presentation explores the concept of inductive bias in machine learning. It explains how algorithms come with built-in assumptions and preferences that guide the learning process. You'll learn about the different types of inductive bias and how they can impact the performance and generalizability of machine learning models.
The presentation also covers the positive and negative aspects of inductive bias, along with strategies for mitigating potential drawbacks. We'll explore examples of how bias manifests in algorithms like neural networks and decision trees.
By understanding inductive bias, you can gain valuable insights into how machine learning models work and make informed decisions when building and deploying them.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
CHINA’S GEO-ECONOMIC OUTREACH IN CENTRAL ASIAN COUNTRIES AND FUTURE PROSPECTjpsjournal1
The rivalry between prominent international actors for dominance over Central Asia's hydrocarbon
reserves and the ancient silk trade route, along with China's diplomatic endeavours in the area, has been
referred to as the "New Great Game." This research centres on the power struggle, considering
geopolitical, geostrategic, and geoeconomic variables. Topics including trade, political hegemony, oil
politics, and conventional and nontraditional security are all explored and explained by the researcher.
Using Mackinder's Heartland, Spykman Rimland, and Hegemonic Stability theories, examines China's role
in Central Asia. This study adheres to the empirical epistemological method and has taken care of
objectivity. This study analyze primary and secondary research documents critically to elaborate role of
china’s geo economic outreach in central Asian countries and its future prospect. China is thriving in trade,
pipeline politics, and winning states, according to this study, thanks to important instruments like the
Shanghai Cooperation Organisation and the Belt and Road Economic Initiative. According to this study,
China is seeing significant success in commerce, pipeline politics, and gaining influence on other
governments. This success may be attributed to the effective utilisation of key tools such as the Shanghai
Cooperation Organisation and the Belt and Road Economic Initiative.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
Traditionally, dealing with real-time data pipelines has involved significant overhead, even for straightforward tasks like data transformation or masking. However, in this talk, we’ll venture into the dynamic realm of WebAssembly (WASM) and discover how it can revolutionize the creation of stateless streaming pipelines within a Kafka (Redpanda) broker. These pipelines are adept at managing low-latency, high-data-volume scenarios.
Comparative analysis between traditional aquaponics and reconstructed aquapon...bijceesjournal
The aquaponic system of planting is a method that does not require soil usage. It is a method that only needs water, fish, lava rocks (a substitute for soil), and plants. Aquaponic systems are sustainable and environmentally friendly. Its use not only helps to plant in small spaces but also helps reduce artificial chemical use and minimizes excess water use, as aquaponics consumes 90% less water than soil-based gardening. The study applied a descriptive and experimental design to assess and compare conventional and reconstructed aquaponic methods for reproducing tomatoes. The researchers created an observation checklist to determine the significant factors of the study. The study aims to determine the significant difference between traditional aquaponics and reconstructed aquaponics systems propagating tomatoes in terms of height, weight, girth, and number of fruits. The reconstructed aquaponics system’s higher growth yield results in a much more nourished crop than the traditional aquaponics system. It is superior in its number of fruits, height, weight, and girth measurement. Moreover, the reconstructed aquaponics system is proven to eliminate all the hindrances present in the traditional aquaponics system, which are overcrowding of fish, algae growth, pest problems, contaminated water, and dead fish.
Batteries -Introduction – Types of Batteries – discharging and charging of battery - characteristics of battery –battery rating- various tests on battery- – Primary battery: silver button cell- Secondary battery :Ni-Cd battery-modern battery: lithium ion battery-maintenance of batteries-choices of batteries for electric vehicle applications.
Fuel Cells: Introduction- importance and classification of fuel cells - description, principle, components, applications of fuel cells: H2-O2 fuel cell, alkaline fuel cell, molten carbonate fuel cell and direct methanol fuel cells.
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Sinan from the Delivery Hero mobile infrastructure engineering team shares a deep dive into performance acceleration with Gradle build cache optimizations. Sinan shares their journey into solving complex build-cache problems that affect Gradle builds. By understanding the challenges and solutions found in our journey, we aim to demonstrate the possibilities for faster builds. The case study reveals how overlapping outputs and cache misconfigurations led to significant increases in build times, especially as the project scaled up with numerous modules using Paparazzi tests. The journey from diagnosing to defeating cache issues offers invaluable lessons on maintaining cache integrity without sacrificing functionality.
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Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
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Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
Recycled Concrete Aggregate in Construction Part II
9.Metalcutting.pdf
1. ORGANIZATION
ACKNOWLEDGEMENT: A GOOD NO. OF PHOTOGRAPHS ARE FROM THE BOOK BY KALPAKJIAN
NATURE OF RELATIVE MOTION BETWEEN THE TOOL AND WORKPIECE
FUNDAMENTALS OF CUTTING
FACTORS INFLUENCING CUTTING PROCESS
TYPES OF CHIPS
CHIP BREAKERS
CUTTING TOOL
TYPES OF CUTTING
TEMPERATURE DISTRIBUTION
TOOL WEAR
MECHANICS OF CHIP FORMATION
2. INEFFICIENT BUT MOST IMPORTANT MANUFACTURING
PROCESS
MACHIING
CONDITIONS
M/C TOOL PRODUCT
WORK MATERAIL
CUTTING TOOL
Metal Cutting Plastic Deformation/Flow Process
Orthogonal Cutting
Oblique Cutting
Classification of Cutting
3. MATERIAL REMOVAL PROCESSES
MRPs
Traditional Advanced
Cutting Finishing
Circular
Shape
Other/Prismatic
Shape
Bonded
Abrasive
Loose
Abrasive
• Turning
• Drilling
• Boring
• Milling
• Planning
• Shaping
• Gear Cutting
• Broaching
• Grinding
• Honing
• Coated
Abrasive
• Lapping
• Polishing
Metal Cutting: Relative Motion between workpiece & cutting edge of tool
Cutting Tools: 1. Single Point tool
2. Multiple Point tool
5. OPERATION MOTION OF
JOB
MOTION OF
CUTTING
TOOL
FIGURE OF
OPEARTION
TURNING ROTARY TRANSLATORY
(FORWARD)
BORING ROTATION TRANSLATION
(FORWARD)
DRILLING FIXED (NO
MOTION)
ROTATION AS
WELL AS
TRANSLATOR
Y FEED
6. PLANING TRANSLATORY INTERMITTENT
TRANSLATION
MILLING TRANSLATORY ROTATION
GTRINDING ROTARY /
TRANSLATORY
ROTARY
WHAT IS THE BASIC DIFFERENCE BETWEEN ?
TURNING
BORING
PLANING
DRILLING
MILLING
GRINDING
• SINGLE VS MULTI POINT
• CONTINUOUS AND
INTERMITTENT
AND
7. Fundamentals of Cutting
Examples of cutting processes.
Figure: Basic principle of the
turning operations.
Figure: Two-dimensional cutting
process, also called orthogonal
cutting. Note that the tool shape
and its angles, depth of cut, to, and
the cutting speed, V, are all
independent variables.
8. Types of Cutting
o Orthogonal Cutting (2-D Cutting):
Cutting edge is (1) straight, (2)parallel to the original plane surface on the
work piece and (3)perpendicular to the direction of cutting. For example:
Operations: Lathe cut-off operation, Straight milling, etc.
o Oblique Cutting (3-D Cutting):
Cutting edge of the tool is inclined to the line normal to the cutting
direction. In actual machining, Turning, Milling etc. / cutting operations are
oblique cutting(3-D)
ORTHOGONAL CUTTING
OBLIQUE CUTTING
9. Factors Influencing Cutting Process
PARAMETER INFLUENCE AND INTERRELATIONSHIP
CUTTING SPEED,
DEPTH OF CUT, FEED,
CUTTING FLUIDS
FORCES, POWER, TEMPERATURE RISE, TOOL LIFE,
TYPE OF CHIP, SURFACE FINISH.
TOOL ANGLES AS ABOVE, INFLUENCE ON CHIP FLOW DIRECTION,
RESISTANCE TO TOOL CHIPPING.
CONTINUOUS CHIP GOOD SURFACE FINISH; STEADY CUTTING FORCES;
UNDESIRABLE IN AUTOMATED MACHINERY.
BUILT-UP EDGE CHIP POOR SURFACE FINISH, THIN STABLE EDGE CAN
PROTECT TOOL SURFACES.
DISCONTINUOUS
CHIP
DESIRABLE FOR EASE OF CHIP DISPOSAL;
FLUCTUATING CUTTING FORCES; CAN AFFECT
SURFACE FINISH AND CAUSE VIBRATION AND
CHATTER.
TEMPERATURE RISE INFLUENCES TOOL LIFE, PARTICULARLY CRATER
WEAR, AND DIMENSIONAL ACCURACY OF
WORKPIECE; MAY CAUSE THERMAL DAMAGE TO
WORKPIECE SURFACE.
TOOL WEAR INFLUENCES SURFACE FINISH, DIMENSIONAL
ACCURACY, TEMPERATURE RISE, FORCES AND
POWER.
TOOL WEAR
MACHINABILITY
RELATED TO TOOL LIFE, SURFACE FINISH, FORCES
AND POWER
10. Mechanics of Chip Formation
(a) Basic mechanism of chip formation in metal cutting. (b)
Velocity diagram in the cutting zone.
V=> Cutting velocity, Vs= Shear velocity, Vc=Chip velocity
Φ= Shear angle, α=Rake angle
11. MECHANICS OF CHIP FORMATION
Plastic deformation along shear plane
(Merchant)
The fig. where the work piece remains
stationary and the tool advances in to the work
piece towards left.
Thus the metal gets compressed very severely,
causing shear stress.
This stress is maximum along the plane is
called shear plane.
If the material of the workpiece is ductile, the
material flows plastically along the shear plane,
forming chip, which flows upwards along the
face of the tool.
The tool will cut or shear off the metal, provided
by;
•The tool is harder than the work metal
•The tool is properly shaped so that its
edge can be effective in cutting the
metal.
•Provided there is movement of tool
relative to the material or vice versa, so
as to make cutting action possible.
Fig: Shear Plane
Primary shear
zone (PSDZ)
Secondary shear
deformation zone
(SSDZ)
Fig: Shear deformation
zones
Fig: Shaping
operation
Fig: Shear deformation
zones
12. Types of Chips
Continues Chips
Discontinues Chips
Continuous Chips
with Built up Edge (BUE)
Conditions for Continuous
Chips:
• Sharp cutting edges
• Low feed rate (f)
• Large rake angle ()
• Ductile work material
• High cutting speed (v=)
• Low friction at Chip-Tool interface
CHIP FORMATION
Fig; Schematic of chip
formation
Fig; Schematic of different types of chip
13. Types of Chips
(a) Continuous chip
with narrow,
straight primary
shear zone;
(b) Secondary shear
zone at the chip-
tool interface;
(c) Continuous chip
with built-up edge
(d) Continuous chip
with large primary
shear zone
(e) Segmented or
nonhomogeneous
chip and
(f) Discontinuous
chip.
(f)
(b)
(a) (c)
(d) (e)
Source: After M. C. Shaw, P. K. Wright, and S. Kalpakjian.
14. Built-Up Edge Chips
(b)
(c)
(a)
(a) Hardness distribution in the cutting zone for 3115 steel. Note that some
regions in the built-up edge are as much as three times harder than the bulk
metal.
(b) (b) Surface finish in turning 5130 steel with a built-up edge. (c) surface finish
on 1018 steel in face milling. Magnifications: 15X. Source: Courtesy of
Metcut Research Associates, Inc.
TURNING LAY
MILLING LAY
15. Continuous chip Results in:
• Good surface finish
• High tool life
• Low power consumptions
Discontinuous Chip:
Chip in the form of discontinuous segments:
Easy disposal
Good surface finish
Conditions for discontinuous chips:
• Brittle Material
• Low cutting speed
• Small rake angle
Built up Edge:
Conditions for discontinuous chips:
High friction between Tool & chip
Ductile material
Particles of chip adhere to the rake face of the tool near cutting edge
16. Chip- Breaking
• The chip breaker break the produced chips into small pieces.
• The work hardening of the chip makes the work of the chip breakers
easy.
• When a strict chip control is desired, some sort of chip breaker has to be
employed.
• The following types of chip breakers are commonly used:
a) Groove type
b) Step type
c) Secondary Rake type
d) Clamp type
Fig: Schematics of different types of chip barkers
17. Chip Breakers
(a) Schematic illustration of the action of a chip breaker. Note that the chip
breaker decreases the radius of curvature of the chip. (b) Chip breaker
clamped on the rake face of a cutting tool. (c) Grooves in cutting tools
acting as chip breakers.
21. Right-Hand Cutting Tool
Figure 20.10 (a) Schematic illustration of a right-hand cutting tool.
Although these tools have traditionally been produced from solid
tool-steel bars, they have been largely replaced by carbide or other
inserts of various shapes and sizes, as shown in (b). The various
angles on these tools and their effects on machining are described in
Section 22.3.1.
22. Types of Cutting
o Orthogonal Cutting (2-D Cutting):
Cutting edge is straight, parallel to the original plane surface at
the work piece and perpendicular to the direction of cutting.
E.g. Operations:
• Lathe cut-off tools
• Straight milling cutters etc.
o Oblique Cutting:
Cutting edge of the tool is inclined to the line normal to the
cutting direction. In actual machining, Turning, Milling etc/ cutting
operations are oblique cutting(3-D
23. Forces in Two-Dimensional Cutting
/ Orthogonal Cutting
Forces acting on a cutting tool in two-dimensional cutting.
Note that the resultant force, R, must be collinear to balance the forces.
24. Cutting With an Oblique Tool
(a)Schematic illustration of cutting with an oblique tool.
(b)Top view showing the inclination angle, i.
(c)Types of chips produced with different inclination.
25. Approximate Energy Requirements in Cutting Operations
Approximate Energy Requirements in Cutting Operations (at
drive motor, corrected for 80% efficiency; multiply
by 1.25 for dull tools).
Specific energy
Material W-s/mm
3
hp-min/in.
3
Aluminum alloys
Cast irons
Copper alloys
High-temperature alloys
Nickel alloys
Refractory alloys
Stainless steels
Steels
Titanium alloys
0.4–1.1
1.6–5.5
1.4–3.3
3.3–8.5
0.4–0.6
4.9–6.8
3.8–9.6
3.0–5.2
2.7–9.3
3.0–4.1
0.15–0.4
0.6–2.0
0.5–1.2
1.2–3.1
0.15–0.2
1.8–2.5
1.1–3.5
1.1–1.9
1.0–3.4
1.1–1.5
26. Temperature Distribution and Heat Generated
Typical temperature distribution in
the cutting zone. Note the steep
temperature gradients within the
tool and the chip. :
G. Vieregge. Source
Percentage of the heat generated in
cutting going into the workpiece,
tool, and chip, as a function of
cutting speed.
Note:Chip carries away most of the
heat.
27. Temperature Distributions
Temperatures developed in turning 52100 steel:
(a)flank temperature distribution; and
(b)tool-chip interface temperature distribution.
Source: B. T. Chao and K. J. Trigger.
28. Flank and Crater Wear
(e)
(d)
(a) (b) (c)
(a) Flank and crater wear in a cutting tool. Tool moves to the left.
(b) View of the rake face of a turning tool, showing nose radius R and crater wear
pattern on the rake face of the tool.
(c) View of the flank face of a turning tool, showing the average flank wear land VB
and the depth-of-cut line (wear notch).
(d) Crater and (e) flank wear on a carbide tool. Source: J.C. Keefe, Lehigh University.
29. Tool Wear
Allowable Average Wear Land (VB) for Cutting
Tools in Various Operations
Allowable wear land (mm)
Operation High-speed Steels Carbides
Turning
Face milling
End milling
Drilling
Reaming
1.5
1.5
0.3
0.4
0.15
0.4
0.4
0.3
0.4
0.15
Note: 1 mm = 0.040 in.
30. Surfaces Produced by Cutting
Figure 20.21 Surfaces produced on steel by cutting, as observed
with a scanning electron microscope: (a) turned surface and (b)
surface produced by shaping. Source: J. T. Black and S.
Ramalingam.
(b)
(a)
31. Dull Tool in Orthogonal Cutting and Feed Marks
Schematic illustration of a dull tool in
orthogonal cutting (exaggerated). Note that
at small depths of cut, the positive rake angle
can effectively become negative, and the tool
may simply ride over and burnish the
workpiece surface.
Schematic illustration of feed
marks in turning (highly
exaggerated).
32. ( )
( )
1
1
1
1 1 1 1
1 1
3
500
0.15 /
0.3
, .
500 2
25
60
1308.9 / sec
1308.9 0.15 0.3
58.905 / sec
c
c
c
v
v c
v
v
N RPM
f mm rev
d mm
CuttingSpeed V R
V
V mm
MRR D N f d
MRR V f d
MRR
MRR mm
ω
π
π
=
=
=
=
×
= ×
=
= × × ⋅
= ⋅
= × ×
=
D1
L
Depth of cut
Feed
N1
W/P
Tool
Turning operation
Problem-1:
A turning operation has to be performed on an aluminum rod of diameter50 mm and
length 300mm. The Spindle speed of lathe is given to be 500 RPM. The feed and depth of
cut are 0.15mm/rev and 0.3 mm respectively. Draw a neat sketch of the turning
operation described above. Find out the cutting speed in mm/s and the volumetric
material removal rate (MRRv).
Solution:
33. Problem-2
An aluminum block of length 50 mm and width 70 mm is being milled using a slab milling
cutter with 50 mm diameter. The feed of the table is 15 mm/min. The milling cutter
rotates at 60 RPM in clockwise direction and width of cut is equal to the width of the
workpiece. Draw a neat sketch of the milling operation describing above conditions. The
thickness of the workpiece is 20 mm. If depth of cut of 2 mm is used then find out
cutting speed and volumetric material removal rate (MRRv).
Milling operation
N2
W
L
D
2
W
Feed
Milling cutter
W/P
t
2
2
2
2
2 2
3
, 50
, 70
, 2
, 15 / min
, / min
1000
50 60
25
1000
9.424 / min
15
70 2
60
35 / sec
c
c
c
v
v
v
Milling Cutter Diameter D mm
Width of cut WOC mm
Depth of cut d mm
feed f mm
DN
Cutting Speed V m
V
V m
MRR WOC f d
MRR
MRR mm
π
π
=
=
=
=
=
× ×
= ×
=
= ⋅ ⋅
= × ×
=
Solution:
34. Problem-3
Following the milling operation, a through hole is to be drilled on the same workpiece.
Find out the cutting speed and volumetric material removal rate if the drill of diameter 10
mm is being rotated at same RPM as in case of milling cutter with feed rate as 0.5
mm/rev.
W/P
Feed
D
3
N3
Drilling operation
Drill bit
t
3
3
3
3 3
2
3
3 3
2
3 3
, 10
60
, 0.5 /
, / min
1000
60 10
/ min
1000
1.884 / min 31.4 / sec
4
10
0.5 60
4
2356.19 / min 39.27 / sec
c
c
c
v
v
v
Diameter of Drill D mm
N RPM
feed f mm rev
N D
Cutting Speed V m
V m
V m mm
D
MRR f N
MRR
MRR mm mm
π
π
π
π
=
=
=
=
× ×
=
= =
×
= × ×
×
= × ×
= =
Solution:
36. Crater Wear
Figure 20.19 Relationship between crater-
wear rate and average tool-chip interface
temperature: (a) High-speed steel; (b) C-1
carbide; and (c) C-5 carbide. Note how
rapidly crater-wear rate increases as the
temperature increases. Source: B. T. Chao
and K. J. Trigger.
Cutting tool (right) and chip (left) interface in
cutting plain-carbon steel. The discoloration of the
tool indicates the presence of high temperatures.
Source: P. K. Wright.
37. Examples of Wear and Tool Failures
Figure 20.18 (a) Schematic
illustrations of types of wear
observed on various types of cutting
tools. (b) Schematic illustrations of
catastrophic tool failures. A study
of the types and mechanisms of tool
wear and failure is essential to the
development of better tool
materials.
38. Range of n Values for Eq. (20.20) for Various
Tool Materials
High-speed steels
Cast alloys
Carbides
Ceramics
0.08–0.2
0.1–0.15
0.2–0.5
0.5–0.7
39. Tool Life
Tool-life curves for a
variety of cutting-tool
materials. The negative
inverse of the slope of
these curves is the
exponent n in the Taylor
tool-life equations and C
is the cutting speed at T
= 1 min.