call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
This document presents a study on modeling and analyzing a surface milling cutter using finite element analysis. The study involves designing a face milling cutter using CATIA V5 software. A single tooth of the cutter is then modeled and analyzed in ANSYS for different spindle speeds ranging from 50 to 2000 rpm. The stresses acting on the tooth are calculated and compared with theoretical values. The stress values obtained from finite element analysis match well with theoretical calculations. The study demonstrates an integrated approach for computer-aided design and analysis of milling cutters.
EXPERIMENTAL INVESTIGATION AND DESIGN OPTIMIZATION OF END MILLING PROCESS PAR...IAEME Publication
Monel 400 is a precipitation hard enable, Nickel copper alloy with corrosion resistance. Typical applications for Monel 400 include fasteners, springs, chain, pump, impeller and Valve components due their excellent Mechanical properties. The continuous development of carbide milling cutter and its coating technology are great concern with manufacturing Environment. CBN coating play an important role in milling cutter to produce better surface finish and tool life with minimum cost. In this paper deals investigation of End Milling operation of Monel 400 plates with different process parameters like spindle speed, feed rate and depth of cut and to find optimal machining conditions of minimum surface roughness(Ra), Material removal designed and conducted based on design of Experiments using L9 orthogonal array and Optimized by Taguchi Method.
This document contains lecture notes on manufacturing processes and metal cutting theory. It begins with definitions of manufacturing and an overview of various manufacturing processes. It then describes machine tools and their functions in metal cutting. Key sections cover classifications of manufacturing processes, cutting parameters like speed, feed and depth of cut, and characteristics and types of cutting tools materials. In summary, the document provides a comprehensive introduction to manufacturing processes, metal cutting theory, and machine tools.
This document summarizes key concepts in traditional machining processes. It discusses chip formation, types of chips, tool geometry including rake angle, tool wear, cutting parameters such as depth of cut and step over distance, recommended feeds and speeds, factors that affect machinability, and power and force calculations. Examples are provided to demonstrate how to estimate cutting speeds, feeds, and power requirements for different machining operations and materials.
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
MULTI OBJECTIVE OPTIMIZATION OF CUTTING PARAMETERS IN TURNING OPERATION OF ST...IAEME Publication
Turning is a machining operation in which the cutting tool moves linearly while the work piece rotates to remove material. Turning is one the most important machining operation in
industries. The process of turning is influenced by many factors such as the cutting velocity, feed rate, depth of cut, geometry of cutting tool cutting conditions etc.
This document provides information about the ME 210 "Machine Tools and Machining" course taught by Vikrant Sharma at MITS University. The course objectives are to understand basic machining parameters, tool wear, machine tools, and methods for generating surfaces. Recommended textbooks are listed. Manufacturing is defined as the process of converting raw materials into products through value-adding processes. Machining involves gradually removing excess material from a workpiece in the form of chips using cutting tools. Machine tools are powered devices that facilitate machining processes. Chip formation and types of chips formed are also discussed.
Classification of metal removal process and machines: Concept of generatrix and directrix Geometry of single point cutting tool and tool angles, tool nomenclature in ASA, ORS, NRS. Concept of orthogonal and oblique cutting, Mechanism of Chip Formation: Type of chips. Mechanics of metal cutting, interrelationships between cutting force, shear angle, strain and strain rate. Various theories of metal cutting, Thermal aspects of machining and measurement of chip tool interface temperature, Friction in metal cutting
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
This document presents a study on modeling and analyzing a surface milling cutter using finite element analysis. The study involves designing a face milling cutter using CATIA V5 software. A single tooth of the cutter is then modeled and analyzed in ANSYS for different spindle speeds ranging from 50 to 2000 rpm. The stresses acting on the tooth are calculated and compared with theoretical values. The stress values obtained from finite element analysis match well with theoretical calculations. The study demonstrates an integrated approach for computer-aided design and analysis of milling cutters.
EXPERIMENTAL INVESTIGATION AND DESIGN OPTIMIZATION OF END MILLING PROCESS PAR...IAEME Publication
Monel 400 is a precipitation hard enable, Nickel copper alloy with corrosion resistance. Typical applications for Monel 400 include fasteners, springs, chain, pump, impeller and Valve components due their excellent Mechanical properties. The continuous development of carbide milling cutter and its coating technology are great concern with manufacturing Environment. CBN coating play an important role in milling cutter to produce better surface finish and tool life with minimum cost. In this paper deals investigation of End Milling operation of Monel 400 plates with different process parameters like spindle speed, feed rate and depth of cut and to find optimal machining conditions of minimum surface roughness(Ra), Material removal designed and conducted based on design of Experiments using L9 orthogonal array and Optimized by Taguchi Method.
This document contains lecture notes on manufacturing processes and metal cutting theory. It begins with definitions of manufacturing and an overview of various manufacturing processes. It then describes machine tools and their functions in metal cutting. Key sections cover classifications of manufacturing processes, cutting parameters like speed, feed and depth of cut, and characteristics and types of cutting tools materials. In summary, the document provides a comprehensive introduction to manufacturing processes, metal cutting theory, and machine tools.
This document summarizes key concepts in traditional machining processes. It discusses chip formation, types of chips, tool geometry including rake angle, tool wear, cutting parameters such as depth of cut and step over distance, recommended feeds and speeds, factors that affect machinability, and power and force calculations. Examples are provided to demonstrate how to estimate cutting speeds, feeds, and power requirements for different machining operations and materials.
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
MULTI OBJECTIVE OPTIMIZATION OF CUTTING PARAMETERS IN TURNING OPERATION OF ST...IAEME Publication
Turning is a machining operation in which the cutting tool moves linearly while the work piece rotates to remove material. Turning is one the most important machining operation in
industries. The process of turning is influenced by many factors such as the cutting velocity, feed rate, depth of cut, geometry of cutting tool cutting conditions etc.
This document provides information about the ME 210 "Machine Tools and Machining" course taught by Vikrant Sharma at MITS University. The course objectives are to understand basic machining parameters, tool wear, machine tools, and methods for generating surfaces. Recommended textbooks are listed. Manufacturing is defined as the process of converting raw materials into products through value-adding processes. Machining involves gradually removing excess material from a workpiece in the form of chips using cutting tools. Machine tools are powered devices that facilitate machining processes. Chip formation and types of chips formed are also discussed.
Classification of metal removal process and machines: Concept of generatrix and directrix Geometry of single point cutting tool and tool angles, tool nomenclature in ASA, ORS, NRS. Concept of orthogonal and oblique cutting, Mechanism of Chip Formation: Type of chips. Mechanics of metal cutting, interrelationships between cutting force, shear angle, strain and strain rate. Various theories of metal cutting, Thermal aspects of machining and measurement of chip tool interface temperature, Friction in metal cutting
This document provides an overview of fundamental machining processes including turning, milling, drilling, broaching, and shaping. It discusses key concepts such as chip formation, cutting forces, tool angles, friction at tool-chip interfaces, and sources of chatter vibration. Examples are provided to calculate speeds, feeds, cutting times, and metal removal rates for different machining setups and operations.
metal cutting,manufacturing processes,Production TechnologyProf.Mayur Modi
The document discusses principles of metal cutting, classification of metal cutting processes, types of chips formed, chip thickness, velocity relationships, forces acting on the chip during orthogonal cutting according to Merchant's analysis, tool force dynamometers, cutting tool materials, tool coatings, and types of tool wear like crater wear. It provides information on the mechanics and physics involved in different metal cutting processes.
International Journal of Engineering Research and Applications (IJERA) aims to cover the latest outstanding developments in the field of all Engineering Technologies & science.
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
This document is a project report submitted by five students at the National Institute of Technology Raipur for their Bachelor of Technology degree. The report details a project to develop an association of a data acquisition system in a CNC machine for micro milling processes. The report includes an introduction on micro milling, copper machining, and data acquisition. It then reviews relevant literature, identifies problems with current micro milling processes like poor surface finish and lack of accuracy. It describes the experimental setup used and the process, with the goal of overcoming issues by integrating a data acquisition system to provide additional feedback parameters like cutting forces.
The document discusses cutting tool materials and Merchant's Circle Diagram (MCD) for calculating forces in machining. It provides information on 7 common cutting tool materials: high carbon steel, high speed steel, cast alloys, cemented carbides, coated carbides, ceramics, and diamonds. It also explains what MCD is and how it can be used graphically to calculate cutting, tangential, friction, normal, shear and normal shear forces from measured cutting forces. An example calculation using MCD is provided.
The document provides information about tool wear and tool life in machining processes. It discusses how tool wear occurs due to forces, temperature, and sliding action during cutting. The three main types of tool wear are flank wear, crater wear, and chipping. Flank wear is caused by abrasion from hard particles in the workpiece while crater wear results from high temperatures and diffusion at the tool-chip interface. Maintaining optimal cutting conditions and tool geometry can increase tool life. The document also covers tool materials, machinability factors, cutting fluids, machining forces, and lathe operations such as turning, facing, and threading.
This document provides an overview of the contents of a book on metal cutting, metal forming, and metrology. It lists the sections and chapters of the book, along with the page numbers for each chapter. The sections include theory of metal cutting, metal forming, and metrology. The chapters within these sections cover topics such as basics of metal cutting, tool life/wear, cold working, rolling, forging, extrusion, sheet metal operations, limits and fits, and measurement of lines and surfaces. The document also provides sample questions from past IES, GATE, and other exams related to these topics.
This document provides an overview of machining processes and metal cutting theory. It defines machining as a material removal process using sharp cutting tools. Key topics covered include the orthogonal cutting model, forces acting on the chip and tool, shear plane angle and strain, chip types, cutting forces and temperatures, and power and energy relationships in machining. Equations for forces, stress, power, and temperature are presented.
this is 2nd presentation of manufacturing processes in this presentation we discuss in detail about the theory of metal cutting, machiening processes,cutters etc
The document provides an overview of metal cutting principles and processes. It discusses:
- The fundamentals of metal cutting including chip formation and common cutting processes like turning, milling, and cutting-off.
- Key variables that influence the cutting process like cutting speed, feed, depth of cut, tool material, and workpiece material.
- Different tool geometries including single-point and multi-point tools as well as tool nomenclature systems.
- The mechanics of chip formation involving shear deformation along the shear plane as material is removed.
- The two main methods of metal cutting - orthogonal and oblique cutting.
This document discusses machine tools and machining processes. It covers topics such as cutting tools, tool selection factors, tool design and terminology, forces in metal cutting, tool life, cutting speeds and feeds, tool failure modes, machinability, cutting inserts, and cutting fluids. The document is presented by Vikrant Sharma of the Mechanical Engineering department and contains diagrams to illustrate machining concepts.
Turning is one of the most basic machining processes where a part is rotated while being machined. Lathes are versatile machines capable of producing a variety of shapes through processes like turning, facing, cutting, boring, drilling, parting, threading, and knurling. The material removal rate in turning depends on factors like the cutting speed, depth of cut, and feed rate. Forces on the cutting tool include the cutting force, thrust force, and radial force. Tool geometry, workpiece material, and cutting conditions must be selected appropriately for different operations.
Machining by broaching removes material in one stroke using a broach tool with gradually increasing cutting teeth. Broaching is used to make holes, slots, gears, and other precision components. Broaching machines come in horizontal and vertical configurations and can be single-station or multi-station. Broaching provides high productivity and precision compared to other machining methods for suitable applications.
Theory of metal cutting MG University(S8 Production Notes)Denny John
Theory of metal cutting MG University(S8 Production Notes)
Scenario of manufacturing process – Deformation of metals,
Schmid’s law (review only) – Performance and process parameters – single point cutting
tool nomenclature - attributes of each tool nomenclature - attributes of feed and tool
signature on surface roughness obtainable, role of surface roughness on crack initiation -
Oblique and orthogonal cutting – Mechanism of metal removal - Primary and secondary
deformation shear zones - Mechanism of chip formation, card model, types of chip,
curling of chips, flow lines in a chip, BUE, chip breakers, chip thickness ratio –
Mechanism of orthogonal cutting: Thin zone and thick zone, Merchant’s analysis – shear
angle relationship, Lee and Shaffer`s relationship, simple problems – Friction process in
metal cutting: nature of sliding friction, columb`s law, adhesion theory, ploughing, sublayer
flow – Empirical determination of force component.
To introduce machining process
To understand mechanics of chip formation
To study important parameters of metal machining
To understand methods of machining
This document contains the syllabus for the manufacturing technology course ME1252 being offered in the 4th semester of the mechanical engineering program at N.P.R. College of Engineering and Technology. The syllabus is divided into 5 units that will cover topics such as the theory of metal cutting, lathe operations, other machine tools like milling and drilling machines, abrasive processes and gear cutting, and CNC machine tools and part programming. The course will be taught by Mr. S. Paul Singarayar and aims to provide students with knowledge of various manufacturing processes and machine tools.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
Machining processes involve cutting a workpiece into a desired shape and size through controlled material removal. The three main machining processes are turning, drilling, and milling. Turning involves rotating the workpiece and feeding a single-point cutting tool parallel to the axis of rotation to cut external or internal features. Drilling produces round holes using a rotating drill bit. Milling uses a multi-toothed cutting tool to cut flat and complex shapes by rotating the tool perpendicular to the workpiece feed direction. Other machining processes include grinding, broaching, and advanced processes like water jet machining or electrical discharge machining.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals
This document provides information about shaping, planning, and slotting operations. It discusses the differences between these processes and the machines used. Shaping and slotting involve reciprocating the tool while feeding the workpiece, while planning involves reciprocating the workpiece and feeding the tool. Examples of shaping machines include horizontal and vertical shapers. Key parameters that affect machining include cutting speed, feed, depth of cut, and material removal rate. Example calculations are provided to determine machining time and cost for specific shaping operations.
This document provides an overview of fundamental machining processes including turning, milling, drilling, broaching, and shaping. It discusses key concepts such as chip formation, cutting forces, tool angles, friction at tool-chip interfaces, and sources of chatter vibration. Examples are provided to calculate speeds, feeds, cutting times, and metal removal rates for different machining setups and operations.
metal cutting,manufacturing processes,Production TechnologyProf.Mayur Modi
The document discusses principles of metal cutting, classification of metal cutting processes, types of chips formed, chip thickness, velocity relationships, forces acting on the chip during orthogonal cutting according to Merchant's analysis, tool force dynamometers, cutting tool materials, tool coatings, and types of tool wear like crater wear. It provides information on the mechanics and physics involved in different metal cutting processes.
International Journal of Engineering Research and Applications (IJERA) aims to cover the latest outstanding developments in the field of all Engineering Technologies & science.
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
This document is a project report submitted by five students at the National Institute of Technology Raipur for their Bachelor of Technology degree. The report details a project to develop an association of a data acquisition system in a CNC machine for micro milling processes. The report includes an introduction on micro milling, copper machining, and data acquisition. It then reviews relevant literature, identifies problems with current micro milling processes like poor surface finish and lack of accuracy. It describes the experimental setup used and the process, with the goal of overcoming issues by integrating a data acquisition system to provide additional feedback parameters like cutting forces.
The document discusses cutting tool materials and Merchant's Circle Diagram (MCD) for calculating forces in machining. It provides information on 7 common cutting tool materials: high carbon steel, high speed steel, cast alloys, cemented carbides, coated carbides, ceramics, and diamonds. It also explains what MCD is and how it can be used graphically to calculate cutting, tangential, friction, normal, shear and normal shear forces from measured cutting forces. An example calculation using MCD is provided.
The document provides information about tool wear and tool life in machining processes. It discusses how tool wear occurs due to forces, temperature, and sliding action during cutting. The three main types of tool wear are flank wear, crater wear, and chipping. Flank wear is caused by abrasion from hard particles in the workpiece while crater wear results from high temperatures and diffusion at the tool-chip interface. Maintaining optimal cutting conditions and tool geometry can increase tool life. The document also covers tool materials, machinability factors, cutting fluids, machining forces, and lathe operations such as turning, facing, and threading.
This document provides an overview of the contents of a book on metal cutting, metal forming, and metrology. It lists the sections and chapters of the book, along with the page numbers for each chapter. The sections include theory of metal cutting, metal forming, and metrology. The chapters within these sections cover topics such as basics of metal cutting, tool life/wear, cold working, rolling, forging, extrusion, sheet metal operations, limits and fits, and measurement of lines and surfaces. The document also provides sample questions from past IES, GATE, and other exams related to these topics.
This document provides an overview of machining processes and metal cutting theory. It defines machining as a material removal process using sharp cutting tools. Key topics covered include the orthogonal cutting model, forces acting on the chip and tool, shear plane angle and strain, chip types, cutting forces and temperatures, and power and energy relationships in machining. Equations for forces, stress, power, and temperature are presented.
this is 2nd presentation of manufacturing processes in this presentation we discuss in detail about the theory of metal cutting, machiening processes,cutters etc
The document provides an overview of metal cutting principles and processes. It discusses:
- The fundamentals of metal cutting including chip formation and common cutting processes like turning, milling, and cutting-off.
- Key variables that influence the cutting process like cutting speed, feed, depth of cut, tool material, and workpiece material.
- Different tool geometries including single-point and multi-point tools as well as tool nomenclature systems.
- The mechanics of chip formation involving shear deformation along the shear plane as material is removed.
- The two main methods of metal cutting - orthogonal and oblique cutting.
This document discusses machine tools and machining processes. It covers topics such as cutting tools, tool selection factors, tool design and terminology, forces in metal cutting, tool life, cutting speeds and feeds, tool failure modes, machinability, cutting inserts, and cutting fluids. The document is presented by Vikrant Sharma of the Mechanical Engineering department and contains diagrams to illustrate machining concepts.
Turning is one of the most basic machining processes where a part is rotated while being machined. Lathes are versatile machines capable of producing a variety of shapes through processes like turning, facing, cutting, boring, drilling, parting, threading, and knurling. The material removal rate in turning depends on factors like the cutting speed, depth of cut, and feed rate. Forces on the cutting tool include the cutting force, thrust force, and radial force. Tool geometry, workpiece material, and cutting conditions must be selected appropriately for different operations.
Machining by broaching removes material in one stroke using a broach tool with gradually increasing cutting teeth. Broaching is used to make holes, slots, gears, and other precision components. Broaching machines come in horizontal and vertical configurations and can be single-station or multi-station. Broaching provides high productivity and precision compared to other machining methods for suitable applications.
Theory of metal cutting MG University(S8 Production Notes)Denny John
Theory of metal cutting MG University(S8 Production Notes)
Scenario of manufacturing process – Deformation of metals,
Schmid’s law (review only) – Performance and process parameters – single point cutting
tool nomenclature - attributes of each tool nomenclature - attributes of feed and tool
signature on surface roughness obtainable, role of surface roughness on crack initiation -
Oblique and orthogonal cutting – Mechanism of metal removal - Primary and secondary
deformation shear zones - Mechanism of chip formation, card model, types of chip,
curling of chips, flow lines in a chip, BUE, chip breakers, chip thickness ratio –
Mechanism of orthogonal cutting: Thin zone and thick zone, Merchant’s analysis – shear
angle relationship, Lee and Shaffer`s relationship, simple problems – Friction process in
metal cutting: nature of sliding friction, columb`s law, adhesion theory, ploughing, sublayer
flow – Empirical determination of force component.
To introduce machining process
To understand mechanics of chip formation
To study important parameters of metal machining
To understand methods of machining
This document contains the syllabus for the manufacturing technology course ME1252 being offered in the 4th semester of the mechanical engineering program at N.P.R. College of Engineering and Technology. The syllabus is divided into 5 units that will cover topics such as the theory of metal cutting, lathe operations, other machine tools like milling and drilling machines, abrasive processes and gear cutting, and CNC machine tools and part programming. The course will be taught by Mr. S. Paul Singarayar and aims to provide students with knowledge of various manufacturing processes and machine tools.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
Machining processes involve cutting a workpiece into a desired shape and size through controlled material removal. The three main machining processes are turning, drilling, and milling. Turning involves rotating the workpiece and feeding a single-point cutting tool parallel to the axis of rotation to cut external or internal features. Drilling produces round holes using a rotating drill bit. Milling uses a multi-toothed cutting tool to cut flat and complex shapes by rotating the tool perpendicular to the workpiece feed direction. Other machining processes include grinding, broaching, and advanced processes like water jet machining or electrical discharge machining.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals
This document provides information about shaping, planning, and slotting operations. It discusses the differences between these processes and the machines used. Shaping and slotting involve reciprocating the tool while feeding the workpiece, while planning involves reciprocating the workpiece and feeding the tool. Examples of shaping machines include horizontal and vertical shapers. Key parameters that affect machining include cutting speed, feed, depth of cut, and material removal rate. Example calculations are provided to determine machining time and cost for specific shaping operations.
Review of influence of different cutting angles of single point cutting tool ...IRJET Journal
This document reviews the influence of different cutting angles of single point cutting tools on turning operations. It discusses tool geometry including back rake angle, side rake angle, end relief angle, side relief angle, end cutting edge angle, side cutting edge angle, and nose radius. The aim is to determine the optimum cutting angles for improved surface finish by minimizing tool wear. Experiments will be conducted on mild steel workpieces using single point cutting tools made of HSS M7 material. Different tool signatures will be tested by varying the cutting angles and measuring the resulting surface roughness to analyze the impact of tool geometry on surface quality.
India aims to grow its manufacturing sector to further develop its economy. Manufacturing provides employment and supports agriculture and services. However, India's growth has relied on services while manufacturing and agriculture have faced challenges. Manufacturing processes can be classified into shaping, joining, removal, and regenerative methods. Mechanical properties like elasticity and plasticity determine how metals deform under forces. Dislocations allow plastic deformation at the atomic level. Tool geometry, such as rake and clearance angles, affect tool performance and machining characteristics like surface finish and forces. Maintaining proper tool geometry optimizes the machining process.
This document discusses milling machines and their components and operations. It defines milling as a machining process that uses a rotating multi-tooth cutter to remove material from a workpiece as it travels along different axes relative to the workpiece. It describes the different types of milling machines, milling parameters such as cutting speed and feed, common milling operations including peripheral, face and end milling, and components like the worktable, saddle, knee, and head.
a cutting tool or cutter is any tool that is used to remove material from the work piece by means of shear deformation. Cutting may be accomplished by single-point or multipoint tools. Single-point tools are used in turning, shaping, planing and similar operations, and remove material by means of one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools are also multipoint tools. Each grain of abrasive functions as a microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny chip
Possible Interview Questions/Contents From Manufacturing Technology IIDr. Ramesh B
1. Machining is a process that removes material from a workpiece through cutting or other shear mechanisms in order to change its shape or size. The three fundamental machining parameters are cutting speed, depth of cut, and feed.
2. Material removal rate is the volume of material removed per minute during machining operations like turning, where it is calculated as MRR=Vfd. Chip formation affects surface finish, cutting forces, temperature, tool life, and tolerances.
3. Tool wear occurs due to interactions between the tool and chip like adhesion and abrasion, leading to flank wear, crater wear, chipping, and breakage. Tool wear degrades surface finish and increases tolerances and machining
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.
MILLING MACHINE PPT 1: WORKING PRINCIPLE ,MILLING METHODS AND SPECIFICATIONS ...POLAYYA CHINTADA
Milling machines are used to remove materials from a workpiece via a revolving cutting tool. There are two types of milling: up-milling and down-milling. Up-milling involves cutting against the workpiece movement, resulting in varying cutting forces. Down-milling cuts in the same direction as workpiece movement, generating less heat and allowing for a better surface finish. Milling machines can cut flat, curved, or angled surfaces using multiple tooth cutters mounted on an arbor or spindle. They are suitable for machining surfaces, contours, threads, and other cross-sections.
Traditional machining processes use machine tools like lathes, mills, and drill presses with sharp cutting tools to remove material from a workpiece. Positive rake angles on cutting tools reduce cutting forces but weaken the tool, while negative rake angles strengthen the tool but increase forces. Common machining operations include turning, drilling, milling, grinding, planing, sawing, and stamping/pressing, each using different types of tools and machines to cut or form various geometries in materials. Gear cutting involves using a specialized cutter and dividing head to mill gear teeth according to the involute profile.
The document provides information on various machining operations including turning, boring, shaping, milling, grinding, finishing operations, and design of jigs and fixtures. It discusses the calculations of material removal rate, power required, and cutting time for these operations. It provides examples to calculate cutting speed, feed rate, depth of cut, cutting time, power required, and number of times a cutting tool must be resharpened for specific turning and milling jobs. The document also summarizes the mechanics and calculations for other machining processes like shaper, grinding, and boring.
IRJET- Thermal Analysis of Milling Cutter using Finite Element Analysis ToolIRJET Journal
This document discusses thermal analysis of milling cutters using finite element analysis. It begins with an introduction to milling processes and cutter geometry. Analytical calculations are presented to determine forces and stresses on cutters during milling based on given process parameters like speed and power. These forces are then used to calculate cutting temperatures using analytical thermal models. The goals of the analysis are to understand stress components on cutters and compare materials like HSS and cemented carbide. Finite element analysis software ANSYS is used to further analyze stresses and deformation on the cutters.
Design and stress analysis of broach tool for splinesIJERA Editor
Broaches are used for machining either internal or external surface (i.e. sizing of holds and cutting of serrations,
straight or helical planes, gun rifling and key ways). In this work a broach cutting tool is design to perform
internal splines of synch shuttle transmission for flange coupling. Broaching is a machining process in which a
cutting tool, having multiple transverse cutting edges, is pushed or pulled through a hole or surface to remove
metal by axial method. It is capable of production rates as much as 25 times faster than any traditional metal
removing methods In this work a broach cutting tool is design to perform internal splines on sleeve main shaft.
A sophisticated ANSYS 11 (FEM) package shall be used to analyze the displacements and stresses present in
broach cutting tool. Further the solid model can be used to perform the finite element analysis which would help
in knowing the characteristic of the broach tool under various cutting loads.
Shaping, planing and slotting operationssabry said
This document provides information about shaping, planning and slotting operations. It discusses the key differences between these processes, describes the machines used such as shapers and planers, and covers operating conditions like cutting speed, feed, depth of cut, and material removal rate. It also includes examples of problems calculating machining time and cost for specific shaping and planning jobs.
Experimental investigation of ohns surface property and process parameter on ...ila vamsi krishna
This document discusses optimization of CNC milling operations. It investigates machining performance using different cutting speeds, feeds, and depths of cut with side and face milling cutters. Surface roughness was evaluated using Taguchi design of experiments and analysis of variance. The Taguchi method was used to formulate the experimental design and optimize milling parameters like speed, feed, and depth of cut. Analysis of variance and signal-to-noise ratios were used to study performance characteristics in milling operations.
5. analysis of spur gear cutting using millingNEERAJKUMAR1898
This document analyzes the process of cutting spur gears using a milling machine. It discusses how spur gears are the simplest type of gear with teeth parallel to the axis. The most common method for cutting spur gears on a milling machine is form cutting, where a cutter with the desired tooth pattern rotates around a stationary gear blank. Key parameters like pressure angle, cutting speed, feed rate, and tooth geometry are analyzed. The document also describes the specific steps for cutting a spur gear using a milling machine, including mounting the gear blank on a dividing head, selecting the proper cutter, and indexing the dividing head to cut each tooth space. Formulas for calculating gear parameters like pitch circle diameter and outside diameter are provided
This document provides information about milling machines and various milling experiments conducted using a horizontal milling machine. It begins with an introduction to milling machines, describing their versatility and various milling processes. It then describes the different types of milling machines and cutting tools used. Several experiments are outlined demonstrating how to use a dividing head to mill different numbers of sides on a workpiece, cut spur gears, and cut spline lugs. Calculations for determining indexing ratios and selecting dividing plates are provided. The document concludes with references used.
This document provides an introduction to manufacturing processes and machine tools. It defines key terms in manufacturing like speed, feed, depth of cut, and metal removal rate. It describes orthogonal and oblique cutting and different types of chips that can be produced. Factors that influence each chip type are outlined. Common tool angles used in machining are defined including back rake angle, side rake angle, end relief angle, and side relief angle. Key aspects of manufacturing like interchangeability, mass production, and higher living standards are noted.
The document provides an overview of milling operations and machines. It discusses:
1) The basic working principle of milling, where a rotating cutting tool (milling cutter) with multiple teeth machines a workpiece by moving it past the cutter.
2) The main types of milling operations including peripheral, face, and special operations like end milling and contouring.
3) The different categories of milling machines including column and knee machines, fixed bed machines, and special machines. Common machine specifications are also outlined.
Similar to Welcome to International Journal of Engineering Research and Development (IJERD) (20)
A Novel Method for Prevention of Bandwidth Distributed Denial of Service AttacksIJERD Editor
Distributed Denial of Service (DDoS) Attacks became a massive threat to the Internet. Traditional
Architecture of internet is vulnerable to the attacks like DDoS. Attacker primarily acquire his army of Zombies,
then that army will be instructed by the Attacker that when to start an attack and on whom the attack should be
done. In this paper, different techniques which are used to perform DDoS Attacks, Tools that were used to
perform Attacks and Countermeasures in order to detect the attackers and eliminate the Bandwidth Distributed
Denial of Service attacks (B-DDoS) are reviewed. DDoS Attacks were done by using various Flooding
techniques which are used in DDoS attack.
The main purpose of this paper is to design an architecture which can reduce the Bandwidth
Distributed Denial of service Attack and make the victim site or server available for the normal users by
eliminating the zombie machines. Our Primary focus of this paper is to dispute how normal machines are
turning into zombies (Bots), how attack is been initiated, DDoS attack procedure and how an organization can
save their server from being a DDoS victim. In order to present this we implemented a simulated environment
with Cisco switches, Routers, Firewall, some virtual machines and some Attack tools to display a real DDoS
attack. By using Time scheduling, Resource Limiting, System log, Access Control List and some Modular
policy Framework we stopped the attack and identified the Attacker (Bot) machines
Hearing loss is one of the most common human impairments. It is estimated that by year 2015 more
than 700 million people will suffer mild deafness. Most can be helped by hearing aid devices depending on the
severity of their hearing loss. This paper describes the implementation and characterization details of a dual
channel transmitter front end (TFE) for digital hearing aid (DHA) applications that use novel micro
electromechanical- systems (MEMS) audio transducers and ultra-low power-scalable analog-to-digital
converters (ADCs), which enable a very-low form factor, energy-efficient implementation for next-generation
DHA. The contribution of the design is the implementation of the dual channel MEMS microphones and powerscalable
ADC system.
Influence of tensile behaviour of slab on the structural Behaviour of shear c...IJERD Editor
-A composite beam is composed of a steel beam and a slab connected by means of shear connectors
like studs installed on the top flange of the steel beam to form a structure behaving monolithically. This study
analyzes the effects of the tensile behavior of the slab on the structural behavior of the shear connection like slip
stiffness and maximum shear force in composite beams subjected to hogging moment. The results show that the
shear studs located in the crack-concentration zones due to large hogging moments sustain significantly smaller
shear force and slip stiffness than the other zones. Moreover, the reduction of the slip stiffness in the shear
connection appears also to be closely related to the change in the tensile strain of rebar according to the increase
of the load. Further experimental and analytical studies shall be conducted considering variables such as the
reinforcement ratio and the arrangement of shear connectors to achieve efficient design of the shear connection
in composite beams subjected to hogging moment.
Gold prospecting using Remote Sensing ‘A case study of Sudan’IJERD Editor
Gold has been extracted from northeast Africa for more than 5000 years, and this may be the first
place where the metal was extracted. The Arabian-Nubian Shield (ANS) is an exposure of Precambrian
crystalline rocks on the flanks of the Red Sea. The crystalline rocks are mostly Neoproterozoic in age. ANS
includes the nations of Israel, Jordan. Egypt, Saudi Arabia, Sudan, Eritrea, Ethiopia, Yemen, and Somalia.
Arabian Nubian Shield Consists of juvenile continental crest that formed between 900 550 Ma, when intra
oceanic arc welded together along ophiolite decorated arc. Primary Au mineralization probably developed in
association with the growth of intra oceanic arc and evolution of back arc. Multiple episodes of deformation
have obscured the primary metallogenic setting, but at least some of the deposits preserve evidence that they
originate as sea floor massive sulphide deposits.
The Red Sea Hills Region is a vast span of rugged, harsh and inhospitable sector of the Earth with
inimical moon-like terrain, nevertheless since ancient times it is famed to be an abode of gold and was a major
source of wealth for the Pharaohs of ancient Egypt. The Pharaohs old workings have been periodically
rediscovered through time. Recent endeavours by the Geological Research Authority of Sudan led to the
discovery of a score of occurrences with gold and massive sulphide mineralizations. In the nineties of the
previous century the Geological Research Authority of Sudan (GRAS) in cooperation with BRGM utilized
satellite data of Landsat TM using spectral ratio technique to map possible mineralized zones in the Red Sea
Hills of Sudan. The outcome of the study mapped a gossan type gold mineralization. Band ratio technique was
applied to Arbaat area and a signature of alteration zone was detected. The alteration zones are commonly
associated with mineralization. The alteration zones are commonly associated with mineralization. A filed check
confirmed the existence of stock work of gold bearing quartz in the alteration zone. Another type of gold
mineralization that was discovered using remote sensing is the gold associated with metachert in the Atmur
Desert.
Reducing Corrosion Rate by Welding DesignIJERD Editor
This document summarizes a study on reducing corrosion rates in steel through welding design. The researchers tested different welding groove designs (X, V, 1/2X, 1/2V) and preheating temperatures (400°C, 500°C, 600°C) on ferritic malleable iron samples. Testing found that X and V groove designs with 500°C and 600°C preheating had corrosion rates of 0.5-0.69% weight loss after 14 days, compared to 0.57-0.76% for 400°C preheating. Higher preheating reduced residual stresses which decreased corrosion. Residual stresses were 1.7 MPa for optimal X groove and 600°C
Router 1X3 – RTL Design and VerificationIJERD Editor
Routing is the process of moving a packet of data from source to destination and enables messages
to pass from one computer to another and eventually reach the target machine. A router is a networking device
that forwards data packets between computer networks. It is connected to two or more data lines from different
networks (as opposed to a network switch, which connects data lines from one single network). This paper,
mainly emphasizes upon the study of router device, it‟s top level architecture, and how various sub-modules of
router i.e. Register, FIFO, FSM and Synchronizer are synthesized, and simulated and finally connected to its top
module.
Active Power Exchange in Distributed Power-Flow Controller (DPFC) At Third Ha...IJERD Editor
This paper presents a component within the flexible ac-transmission system (FACTS) family, called
distributed power-flow controller (DPFC). The DPFC is derived from the unified power-flow controller (UPFC)
with an eliminated common dc link. The DPFC has the same control capabilities as the UPFC, which comprise
the adjustment of the line impedance, the transmission angle, and the bus voltage. The active power exchange
between the shunt and series converters, which is through the common dc link in the UPFC, is now through the
transmission lines at the third-harmonic frequency. DPFC multiple small-size single-phase converters which
reduces the cost of equipment, no voltage isolation between phases, increases redundancy and there by
reliability increases. The principle and analysis of the DPFC are presented in this paper and the corresponding
simulation results that are carried out on a scaled prototype are also shown.
Mitigation of Voltage Sag/Swell with Fuzzy Control Reduced Rating DVRIJERD Editor
Power quality has been an issue that is becoming increasingly pivotal in industrial electricity
consumers point of view in recent times. Modern industries employ Sensitive power electronic equipments,
control devices and non-linear loads as part of automated processes to increase energy efficiency and
productivity. Voltage disturbances are the most common power quality problem due to this the use of a large
numbers of sophisticated and sensitive electronic equipment in industrial systems is increased. This paper
discusses the design and simulation of dynamic voltage restorer for improvement of power quality and
reduce the harmonics distortion of sensitive loads. Power quality problem is occurring at non-standard
voltage, current and frequency. Electronic devices are very sensitive loads. In power system voltage sag,
swell, flicker and harmonics are some of the problem to the sensitive load. The compensation capability
of a DVR depends primarily on the maximum voltage injection ability and the amount of stored
energy available within the restorer. This device is connected in series with the distribution feeder at
medium voltage. A fuzzy logic control is used to produce the gate pulses for control circuit of DVR and the
circuit is simulated by using MATLAB/SIMULINK software.
Study on the Fused Deposition Modelling In Additive ManufacturingIJERD Editor
Additive manufacturing process, also popularly known as 3-D printing, is a process where a product
is created in a succession of layers. It is based on a novel materials incremental manufacturing philosophy.
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final shape of a product, 3-D printing develops the product from scratch thus obviating the necessity to cut away
materials. This prevents wastage of raw materials. Commonly used raw materials for the process are ABS
plastic, PLA and nylon. Recently the use of gold, bronze and wood has also been implemented. The complexity
factor of this process is 0% as in any object of any shape and size can be manufactured.
Spyware triggering system by particular string valueIJERD Editor
This computer programme can be used for good and bad purpose in hacking or in any general
purpose. We can say it is next step for hacking techniques such as keylogger and spyware. Once in this system if
user or hacker store particular string as a input after that software continually compare typing activity of user
with that stored string and if it is match then launch spyware programme.
A Blind Steganalysis on JPEG Gray Level Image Based on Statistical Features a...IJERD Editor
This paper presents a blind steganalysis technique to effectively attack the JPEG steganographic
schemes i.e. Jsteg, F5, Outguess and DWT Based. The proposed method exploits the correlations between
block-DCTcoefficients from intra-block and inter-block relation and the statistical moments of characteristic
functions of the test image is selected as features. The features are extracted from the BDCT JPEG 2-array.
Support Vector Machine with cross-validation is implemented for the classification.The proposed scheme gives
improved outcome in attacking.
Secure Image Transmission for Cloud Storage System Using Hybrid SchemeIJERD Editor
- Data over the cloud is transferred or transmitted between servers and users. Privacy of that
data is very important as it belongs to personal information. If data get hacked by the hacker, can be
used to defame a person’s social data. Sometimes delay are held during data transmission. i.e. Mobile
communication, bandwidth is low. Hence compression algorithms are proposed for fast and efficient
transmission, encryption is used for security purposes and blurring is used by providing additional
layers of security. These algorithms are hybridized for having a robust and efficient security and
transmission over cloud storage system.
Application of Buckley-Leverett Equation in Modeling the Radius of Invasion i...IJERD Editor
A thorough review of existing literature indicates that the Buckley-Leverett equation only analyzes
waterflood practices directly without any adjustments on real reservoir scenarios. By doing so, quite a number
of errors are introduced into these analyses. Also, for most waterflood scenarios, a radial investigation is more
appropriate than a simplified linear system. This study investigates the adoption of the Buckley-Leverett
equation to estimate the radius invasion of the displacing fluid during waterflooding. The model is also adopted
for a Microbial flood and a comparative analysis is conducted for both waterflooding and microbial flooding.
Results shown from the analysis doesn’t only records a success in determining the radial distance of the leading
edge of water during the flooding process, but also gives a clearer understanding of the applicability of
microbes to enhance oil production through in-situ production of bio-products like bio surfactans, biogenic
gases, bio acids etc.
Gesture Gaming on the World Wide Web Using an Ordinary Web CameraIJERD Editor
- Gesture gaming is a method by which users having a laptop/pc/x-box play games using natural or
bodily gestures. This paper presents a way of playing free flash games on the internet using an ordinary webcam
with the help of open source technologies. Emphasis in human activity recognition is given on the pose
estimation and the consistency in the pose of the player. These are estimated with the help of an ordinary web
camera having different resolutions from VGA to 20mps. Our work involved giving a 10 second documentary to
the user on how to play a particular game using gestures and what are the various kinds of gestures that can be
performed in front of the system. The initial inputs of the RGB values for the gesture component is obtained by
instructing the user to place his component in a red box in about 10 seconds after the short documentary before
the game is finished. Later the system opens the concerned game on the internet on popular flash game sites like
miniclip, games arcade, GameStop etc and loads the game clicking at various places and brings the state to a
place where the user is to perform only gestures to start playing the game. At any point of time the user can call
off the game by hitting the esc key and the program will release all of the controls and return to the desktop. It
was noted that the results obtained using an ordinary webcam matched that of the Kinect and the users could
relive the gaming experience of the free flash games on the net. Therefore effective in game advertising could
also be achieved thus resulting in a disruptive growth to the advertising firms.
Hardware Analysis of Resonant Frequency Converter Using Isolated Circuits And...IJERD Editor
-LLC resonant frequency converter is basically a combo of series as well as parallel resonant ckt. For
LCC resonant converter it is associated with a disadvantage that, though it has two resonant frequencies, the
lower resonant frequency is in ZCS region[5]. For this application, we are not able to design the converter
working at this resonant frequency. LLC resonant converter existed for a very long time but because of
unknown characteristic of this converter it was used as a series resonant converter with basically a passive
(resistive) load. . Here, it was designed to operate in switching frequency higher than resonant frequency of the
series resonant tank of Lr and Cr converter acts very similar to Series Resonant Converter. The benefit of LLC
resonant converter is narrow switching frequency range with light load[6] . Basically, the control ckt plays a
very imp. role and hence 555 Timer used here provides a perfect square wave as the control ckt provides no
slew rate which makes the square wave really strong and impenetrable. The dead band circuit provides the
exclusive dead band in micro seconds so as to avoid the simultaneous firing of two pairs of IGBT’s where one
pair switches off and the other on for a slightest period of time. Hence, the isolator ckt here is associated with
each and every ckt used because it acts as a driver and an isolation to each of the IGBT is provided with one
exclusive transformer supply[3]. The IGBT’s are fired using the appropriate signal using the previous boards
and hence at last a high frequency rectifier ckt with a filtering capacitor is used to get an exact dc
waveform .The basic goal of this particular analysis is to observe the wave forms and characteristics of
converters with differently positioned passive elements in the form of tank circuits.
Simulated Analysis of Resonant Frequency Converter Using Different Tank Circu...IJERD Editor
LLC resonant frequency converter is basically a combo of series as well as parallel resonant ckt. For
LCC resonant converter it is associated with a disadvantage that, though it has two resonant frequencies, the
lower resonant frequency is in ZCS region [5]. For this application, we are not able to design the converter
working at this resonant frequency. LLC resonant converter existed for a very long time but because of
unknown characteristic of this converter it was used as a series resonant converter with basically a passive
(resistive) load. . Here, it was designed to operate in switching frequency higher than resonant frequency of the
series resonant tank of Lr and Cr converter acts very similar to Series Resonant Converter. The benefit of LLC
resonant converter is narrow switching frequency range with light load[6] . Basically, the control ckt plays a
very imp. role and hence 555 Timer used here provides a perfect square wave as the control ckt provides no
slew rate which makes the square wave really strong and impenetrable. The dead band circuit provides the
exclusive dead band in micro seconds so as to avoid the simultaneous firing of two pairs of IGBT’s where one
pair switches off and the other on for a slightest period of time. Hence, the isolator ckt here is associated with
each and every ckt used because it acts as a driver and an isolation to each of the IGBT is provided with one
exclusive transformer supply[3]. The IGBT’s are fired using the appropriate signal using the previous boards
and hence at last a high frequency rectifier ckt with a filtering capacitor is used to get an exact dc
waveform .The basic goal of this particular analysis is to observe the wave forms and characteristics of
converters with differently positioned passive elements in the form of tank circuits. The supported simulation
is done through PSIM 6.0 software tool
Amateurs Radio operator, also known as HAM communicates with other HAMs through Radio
waves. Wireless communication in which Moon is used as natural satellite is called Moon-bounce or EME
(Earth -Moon-Earth) technique. Long distance communication (DXing) using Very High Frequency (VHF)
operated amateur HAM radio was difficult. Even with the modest setup having good transceiver, power
amplifier and high gain antenna with high directivity, VHF DXing is possible. Generally 2X11 YAGI antenna
along with rotor to set horizontal and vertical angle is used. Moon tracking software gives exact location,
visibility of Moon at both the stations and other vital data to acquire real time position of moon.
“MS-Extractor: An Innovative Approach to Extract Microsatellites on „Y‟ Chrom...IJERD Editor
Simple Sequence Repeats (SSR), also known as Microsatellites, have been extensively used as
molecular markers due to their abundance and high degree of polymorphism. The nucleotide sequences of
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crucial. However, Microsatellites repeat count is compared, if they differ largely, he has some disorder. The Y
chromosome likely contains 50 to 60 genes that provide instructions for making proteins. Because only males
have the Y chromosome, the genes on this chromosome tend to be involved in male sex determination and
development. Several Microsatellite Extractors exist and they fail to extract microsatellites on large data sets of
giga bytes and tera bytes in size. The proposed tool “MS-Extractor: An Innovative Approach to extract
Microsatellites on „Y‟ Chromosome” can extract both Perfect as well as Imperfect Microsatellites from large
data sets of human genome „Y‟. The proposed system uses string matching with sliding window approach to
locate Microsatellites and extracts them.
Importance of Measurements in Smart GridIJERD Editor
- The need to get reliable supply, independence from fossil fuels, and capability to provide clean
energy at a fixed and lower cost, the existing power grid structure is transforming into Smart Grid. The
development of a smart energy distribution grid is a current goal of many nations. A Smart Grid should have
new capabilities such as self-healing, high reliability, energy management, and real-time pricing. This new era
of smart future grid will lead to major changes in existing technologies at generation, transmission and
distribution levels. The incorporation of renewable energy resources and distribution generators in the existing
grid will increase the complexity, optimization problems and instability of the system. This will lead to a
paradigm shift in the instrumentation and control requirements for Smart Grids for high quality, stable and
reliable electricity supply of power. The monitoring of the grid system state and stability relies on the
availability of reliable measurement of data. In this paper the measurement areas that highlight new
measurement challenges, development of the Smart Meters and the critical parameters of electric energy to be
monitored for improving the reliability of power systems has been discussed.
Study of Macro level Properties of SCC using GGBS and Lime stone powderIJERD Editor
The document summarizes a study on the use of ground granulated blast furnace slag (GGBS) and limestone powder to replace cement in self-compacting concrete (SCC). Tests were conducted on SCC mixes with 0-50% replacement of cement with GGBS and 0-20% replacement with limestone powder. The results showed that replacing 30% of cement with GGBS and 15% with limestone powder produced SCC with the highest compressive strength of 46MPa, meeting fresh property requirements. The study concluded that this ternary blend of cement, GGBS and limestone powder can improve SCC properties while reducing costs.
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https://www.oeconsulting.com.sg/training-presentations]
This presentation is a curated compilation of PowerPoint diagrams and templates designed to illustrate 20 different digital transformation frameworks and models. These frameworks are based on recent industry trends and best practices, ensuring that the content remains relevant and up-to-date.
Key highlights include Microsoft's Digital Transformation Framework, which focuses on driving innovation and efficiency, and McKinsey's Ten Guiding Principles, which provide strategic insights for successful digital transformation. Additionally, Forrester's framework emphasizes enhancing customer experiences and modernizing IT infrastructure, while IDC's MaturityScape helps assess and develop organizational digital maturity. MIT's framework explores cutting-edge strategies for achieving digital success.
These materials are perfect for enhancing your business or classroom presentations, offering visual aids to supplement your insights. Please note that while comprehensive, these slides are intended as supplementary resources and may not be complete for standalone instructional purposes.
Frameworks/Models included:
Microsoft’s Digital Transformation Framework
McKinsey’s Ten Guiding Principles of Digital Transformation
Forrester’s Digital Transformation Framework
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MIT’s Digital Transformation Framework
Gartner’s Digital Transformation Framework
Accenture’s Digital Strategy & Enterprise Frameworks
Deloitte’s Digital Industrial Transformation Framework
Capgemini’s Digital Transformation Framework
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Cisco’s Digital Transformation Framework
Cognizant’s Digital Transformation Framework
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Design Thinking Framework
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How are Lilac French Bulldogs Beauty Charming the World and Capturing Hearts....Lacey Max
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years in a row, the Labrador Retriever has dropped to second place
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United States as of 2022. The stylish puppy has ascended the
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color choices.”
The APCO Geopolitical Radar - Q3 2024 The Global Operating Environment for Bu...APCO
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Welcome to International Journal of Engineering Research and Development (IJERD)
1. International Journal of Engineering Research and Development
e-ISSN: 2278-067X, p-ISSN: 2278-800X, www.ijerd.com
Volume 6, Issue 7 (April 2013), PP.80-87
Modeling and Analysis of a Plain Milling Cutter Using
Finite Element Analysis
Gummadi. RatnaKumar1, Tippa Bhimasankara Rao2
1
PG Student, Department of Mechanical Engineering, Nimra Institute of Science and Technology
2
HOD, Department of Mechanical Engineering, Nimra Institute of Science and Technology, Vijayawada, AP,
INDIA
Abstract:- Milling machine is one of the important machining operations. In this operation the work piece is fed
against a rotating cylindrical tool. The rotating tool consists of multiple cutting edges (multipoint cutting tool).
Normally axis of rotation of feed given to the work piece. Milling operation is distinguished from other
machining operations on the basis of orientation between the tool axis and the feed direction; however, in other
operations like drilling, turning, etc. the tool is fed in the direction parallel to axis of rotation. The cutting tool
used in milling operation is called milling cutter, which consists of multiple edges called teeth. The machine tool
that performs the milling operations by producing required relative motion between work piece and tool is
called milling machine. It provides the required relative motion under very controlled conditions. These
conditions will be discussed later in this unit as milling speed, feed rate and depth of cut. Normally, the milling
operation creates plane surfaces. Other geometries can also be created by milling machine. Milling operation is
considered an interrupted cutting operation teeth of milling cutter enter and exit the work during each
revolution. This interrupted cutting action subjects the teeth to a cycle of impact force and thermal shock on
every rotation. The tool material and cutter geometry must be designed to bear the above stated conditions.
In this project work the design aspects of plain milling cutter is analyzed. The objective considered is the design
and meshing of plain milling cutter and to analyze various stress components acting on it. Various designing
strategies are considered to design the effective plain milling cutter like diameter, thickness, face width etc. The
design and analysis is carried out using software’s like CATIA V5 and ANSYS. In this study the design and
analysis is carried out for two different cutter materials and they are High Speed Steel and Tungsten Carbide. In
this analysis the loads acting on the cutter and speed is varied and the results obtained are compared.
Keywords: - Plain Milling, Surface Milling.
I. INTRODUCTION
Milling is a process of producing flat and complex shapes with the use of multi-tooth cutting tool,
which is called a milling cutter and the cutting edges are called teeth. The axis of rotation of the cutting tool is
perpendicular to the direction of feed, either parallel or perpendicular to the machined surface. The machine tool
that traditionally performs this operation is a milling machine. Milling is an interrupted cutting operation: the
teeth of the milling cutter enter and exit the work during each revolution. This interrupted cutting action subjects
the teeth to a cycle of impact force and thermal shock on every rotation. The tool material and cutter geometry
must be designed to withstand these conditions. Cutting fluids are essential for most milling operations. The
cutter is lifted to show the chips, and the work, transient, and machined surfaces. The cutter design being
presented in this paper is useful for single point as well as for multi-point cutters such as those used for turning
and milling. In fact, the design principles for both single and multi-point cutters are similar. The design
parameters such as rake angle, clearance angle of tooth, and height of tooth are common in both single point and
multi-point cutters. Additionally, parameters such as speed of rotation, feed, and depth of cut are also similar.
However, parameters such as diameter of the cutter, number of teeth on the cutter, and angular spacing of teeth
are exclusively associated with milling cutters. In the family of milling operations such as plain milling, slot
milling, side milling, end milling, face milling, and form milling, design parameters differ only in their
numerical values. In every case, the teeth of milling cutters have cutting edges and angles related to edges. In
effect each tool acts like single point tool mounted on a cylindrical hub. The teeth on the milling cutters are
mostly evenly spaced.
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Fig1. Working motions of plain milling operation Fig.2 Depth of cut of plain milling cutter
II. TYPES OF MILLING PROCESSES
There are two basic types of milling, are as follows
Down (climb) milling: It is type of milling in which the cutter rotation is in the same direction as the motion
of the work piece being fed. In down milling, the cutting force is directed into the work table, which allows
thinner work parts to be machined. Better surface finish is obtained but the stress load on the teeth is abrupt,
which may damage the cutter. In conventional milling, friction and rubbing occur as the insert enters into
the cut, resulting in chip welding and heat dissipation into the insert and work piece. Resultant forces in
conventional milling are against the direction of the feed. Work-hardening is also likely to occur.
Fig.3 Down Milling (Climb Milling) Fig.4 Up cut Milling (Conventional Milling)
Up (conventional) milling: It is the type of milling in which the work piece is moving towards the cutter,
opposing the cutter direction of rotation. In up milling, the cutting force tends to lift the work piece. The
work conditions for the cutter are more favourable. Because the cutter does not start to cut when it makes
contact (cutting at zero cut is impossible), the surface has a natural waviness. The insert enters the work
piece material with some chip load and produces a chip that thins as it exits the cut. This reduces the heat by
dissipating it into the chip. Work-hardening is minimized. Climb milling is preferred over conventional
milling in most situations.
III. CUTTING CONDITIONS IN MILLING
In milling, each tooth on a tool removes part of the stock in the form of a chip. The basic interface
between tool and work part is pictured below. This shows a only a few teeth of a peripheral milling cutter.
Fig.5 26-teeth Plain Milling Cutter Used for Peripheral or Slab Milling
Cutting velocity V is the peripheral speed of the cutter is defined by V = πDN
Where D is the cutter outer diameter and N is the rotational speed of the cutter.
As in the case of turning, cutting speed V is first calculated or selected from appropriate reference sources and
then the rotational speed of the cutter N, which is used to adjust milling machine controls, is calculated. Cutting
speeds are usually in the range of 0.1~4 m/s, lower for difficult-to-cut materials and for rough cuts, and higher
for non-ferrous easy-to-cut materials like aluminum and for finishing cuts.
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Cutting Speed
Cutting speed of a milling cutter is its peripheral linear speed resulting from operation. It is expressed in meters
per minute. The cutting speed can be derived from the above formula. Spindle speed of a milling machine is
selected to give the desired peripheral speed of cutter.V = (πdn)/1000
Where d = Diameter of milling cutter in mm, V = Cutting speed (linear) in meter per minute, and n = Cutter
speed in revolution per minute.
Feed Rate
It is the rate with which the work piece under process advances under the revolving milling cutter. It is known
that revolving cutter remains stationary and feed is given to the work piece through worktable. Generally feed is
expressed in three ways
Feed per Tooth
It is the distance traveled by the work piece (its advance) between engagement by the two successive teeth. It is
expressed as mm/tooth (ft).
Feed per Revolution
Travel of work piece during one revolution of milling cutter. It is expressed as mm/rev. and denoted by f(rev).
Feed per Unit of Time
Feed can also be expressed as feed/minute or feed/sec. It is the distance advances by the work piece in
unit time (fm).
Above described three feed rates are mutually convertible.
f m × n×frev
Where n = rpm of cutter.
It can be extended further as
f m n f rev z n ft where z = Number of teeth in milling cutter
Feed rate (F) is defined as the rate of travel of the work piece in mm/min. But most tool suppliers recommend it
as the movement per tooth of the cutter (f). Thus,
F = f. u. N
where -- F= table feed in mm/min
f= movement per tooth of cutter in mm
u= number of teeth of cutter
N = R.P.M. of the cutter
IV. MILLING OPERATIONS
Owing to the variety of shapes possible and its high production rates, milling is one of the most
versatile and widely used machining operations. The geometric form created by milling fall into three major
groups:
Plane surfaces: the surface is linear in all three dimensions. The simplest and most convenient type of
surface;
Two-dimensional surfaces: the shape of the surface changes in the direction of two of the axes and is linear
along the third axis. Examples include cams;
Three-dimensional surfaces: the shape of the surface changes in all three directions. Examples include die
cavities, gas turbine blades, propellers, casting patterns, etc.
V. PLAIN MILLING OF FLAT SURFACES
Peripheral milling: In peripheral milling, also called plain milling, the axis of the cutter is parallel to the
surface being machined, and the operation is performed by cutting edges on the outside periphery of the
cutter. The primary motion is the rotation of the cutter. The feed is imparted to the work piece. The basic
form of peripheral milling in which the cutter width extends beyond the work piece on both sides is called
slab milling.
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Fig.6 Slab or plain milling cutter
Face milling: In face milling, cutter is perpendicular to the machined surface. The cutter axis is vertical, but
in the newer CNC machines it often is horizontal. In face milling, machining is performed by teeth on both
the end and periphery of the face-milling cutter. Again up and down types of milling are available,
depending on directions of the cutter rotation and feed. Face milling is usually applied for rough machining
of large surfaces. Surface finish is worse than in peripheral milling, and feed marks are inevitable. One
advantage of the face milling is the high production rate because the cutter diameter is large and as a result
the material removal rate is high. Face milling with large diameter cutters requires significant machine
power.
Fig.7 Flat surface of a plain milling cutter
The end mill has helical cutting edges carried over onto the cylindrical cutter surface. End mills with flat
ends (so called squire-end mills) are used to produce pockets, closed or end key slots, etc.:
VI. MILLING CUTTER NOMENCLATURE
Figure 8 show two views of a common milling cutter with its parts and angles identified. These parts and angles
in some form are common to all cutter types.
The pitch refers to the angular distance between like or adjacent teeth.
The pitch is determined by the number of teeth. The tooth face is the forward facing surface of the tooth
that forms the cutting edge.
The cutting edge is the angle on each tooth that performs the cutting.
The land is the narrow surface behind the cutting edge on each tooth.
The rake angle is the angle formed between the face of the tooth and the centreline of the cutter. The rake
angle defines the cutting edge and provides a path for chips that are cut from the work piece.
The primary clearance angle is the angle of the land of each tooth measured from a line tangent to the
centreline of the cutter at the cutting edge. This angle prevents each tooth from rubbing against the work
piece after it makes its cut.
This angle defines the land of each tooth and provides additional clearance for passage of cutting oil and
chips.
The hole diameter determines the size of the arbor necessary to mount the milling cutter.
Plain milling cutters that are more than 3/4 inch in width are usually made with spiral or helical teeth. A
plain spiral-tooth milling cutter produces a better and smoother finish and requires less power to operate. A
plain helical-tooth milling cutter is especially desirable when milling an uneven surface or one with holes in
it.
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Fig.8 Nomenclature of 2d plain milling cutter Fig.8 Nomenclature of 3d plain milling cutter
VII. MODELING OF PLAIN MILLING CUTTER USING CATIA
CATIA V5 is used to model the plain milling cutter and various views are presented in Fig. (9)
Fig.9 3D of the plain milling cutter Fig.10 Model of the cutter in wire frame
VIII. ANALYSIS OF PLAIN MILLING CUTTER
Fig.11 Meshed model of the cutter Fig.12 Geometry of the cutter
Fig.12 Meshed model of symmetry cutter Fig.13 Loads applied on the symmetry of the cutter
IX. RESULTS AND DISCUSSION
Analysis of Milling Cutter:
The milling cutter is a symmetrical body hence the analysis is carried out considering a single tooth of
the cutter. Here, the analysis is done for 5 different spindle speeds ranging from 50 to 2000 rpm. The loads at
these speeds are calculated and the corresponding Stresses acting on the tooth are found.
Stress and deformation of the cutter at speed 50 rpm
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Fig.14 Deformation of the cutter at speed 50 rpm Fig.15 Stress at speed 50 rpm
Case 1: For W=2101.911 N, Here the speed is 50rpm for which the load is 2101.911 N. The following image
represents FEA based stress and strain variations
Stress and deformation of the symmetry at speed 50 rpm
Fig.16 Stress of the symmetry at speed 50 rpm Fig.17 Deformation of the symmetry at speed 50 rpm
Case 2: For W=1050.955 N, Here the speed is 100 rpm for which the load is 1050.955 N. The following image
represents FEA based stress and strain variations
Stress and deformation of the symmetry at speed 100 rpm
Fig.18 Stress of the symmetry at speed 100 rpm Fig.19 Deformation of the symmetry at speed 100
rpm
Case 3: For W=210.1911 N, Here the speed is 500 rpm for which the load is 210.1911 N. The following image
represents FEA based stress and strain variations
Stress and deformation of symmetry at speed 500 rpm
Fig.20 Stress of symmetry at speed 500 rpm Fig.21 Deformation of symmetry at speed 500 rpm
Case 4: For W=105.0955 N, Here the speed is 1000 rpm for which the load is 105.0955 N. The following image
represents FEA based stress and strain variations
Stress and deformation of symmetry at speed 1000 rpm
Fig 22 Stress of symmetry at speed 1000 rpm Fig.23 Deformation of symmetry at speed 1000 rpm
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Case 5: For W=52.5477 N, Here the speed is 2000 rpm for which the load is 52.5477 N. The following image
represents FEA based stress and strain variations
Stress and deformation of symmetry at speed 2000 rpm
Fig.23 Stress of symmetry at speed 2000 rpm Fig.24 Deformation of symmetry at speed 2000 rpm
X. RESULTS OBTAINED
S.NO DIA SPEED POWER LOAD STRESS STRESS
(Ansys, (Theoretical)
Results)
1 100 50 5.50E+02 2101.911 4521 4056
2 100 100 5.50E+02 1050.955 2261 2207
3 100 500 5.50E+02 210.1911 2243 2220
4 100 1000 5.50E+02 105.0955 226.049 223.5
5 100 2000 5.50E+02 52.54777 112.485 108.19
Table.1 Results obtained from the analysis
Graphs between Load and Stresses:
Figure 25 Represents variation in stress with respect to variation in load for both FEA model and theoretical
results
LOAD vs STRESS
5000
4500
4000
3500 STRESS
3000
STRESS
(THEORITICAL
2500 )
2000
1500
1000
500
0
0 1000 2000 3000
LOAD
Fig.25 Plot Load Vs Stresses
XI. CONCLUSIONS
The model of the cutter is designed in CATIA and analysis is carried out using ANSYS. The results
obtained are tabulated in the result table 3.
The input parameters taken for the analysis are diameter of cutter, speed, power and load in which diameter
and power are kept constant and the speed and load are varied.
The output values for stress and deformation obtained at different loads and speeds are tabulated in table
no:3
From the results table, it is observed that the stress and deformation of the cutter are decreasing with
increase in the speed i.e. they are inversely proportional to each other.
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In this analysis the loads acting on the cutter and speed is varied and the results obtained are compared.
XII. REFERENCES
[1]. N and K. Jha and Kathryn Hornik, “Integrated computer-aided optimal design and FEA
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USA
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[4]. Davies, R. Bonding cemented carbide milling cutter inserts. Proceedings of Materials Selection &
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Tool Design and Research Conference, April 22-24, 1985, pp. 315-320.
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34, 37-38, 41.
[8]. Draghici, G. and Paltinea, C. Calculation by convex mathematical programming of the
optimal cutting condition when cylindrical milling. Int. J. Mach. Tool Des. Res. xxxx, 14, 143-160.
[9]. R. T. Coelho, A. Braghini Jr., C. M. O. Valente and G. C. Medalha on Experimental
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