1. Instructional Design Document Machining Mechanics STAM Interactive Solutions

2. Demo Outline (For reference) ‏ Topic NumberTopic NamePage Type 1Piispanen’s Card ModelAnimated page 2Variables in Orthogonal CuttingAnimated page 3Kinematics of Orthogonal CuttingAnimated page 4Forces in Orthogonal CuttingAnimated page 5Merchant’s Force CircleAnimated page 6Energy Dissipation in CuttingAnimated page 7Cutting TemperaturesAnimated page 8SimulationInteractive page

3. Changes Suggested by Prof. Ramesh SinghChanges reflected on slide no. 1Focus on “Machining Mechanics”, specifically on the influence of Machining Mechanics on tool-selection and machine sizing All slides 2Voiceover for initial slide to stress that the question is whether a process is feasible given a depth of cut and cutting speed – relate this to power required for machining and temperature of the tool. Point out that to figure out the former, we need to know the forces on the tool / workpiece, and the subsequent slides will explore this for orthogonal cutting. Slide 5 3Omit chip-formation entirely: instead, use material from slides 3, 11, 12, 13, 17 and 19 of lecture notes at me.iitb.ac.in/~ramesh/me338/machining2.pdf. Slides 6 - 14 4Voiceover must mention that forces should be compared with the properties of the workpiece (shear-stress, for eg.,) since the workpiece must “fail” under the forces applied by the tool. Slide 10 5Display the forces Ns, Fs, Ft, F and N on both the tool and the chip and the workpiece Slides 9 & 10 6Conclude with graphical display of heat dissipationSlide 14 7References · Don’t cite the wikipedia · Add books as given Slide 16 Change Log (as per the minutes pdf) ‏

4. Note to the reviewer: The visuals shown on each slide will be graphically enhanced to make explanation easier to follow.

5. Machining Mechanics Advanced Manufacturing Process I & II In the process of workpiece machining, as the depth of cut and the cutting speed increase, cutting forces rise and so does the temperature of the tool and the power consumed by the machining process. This demo outlines these aspects of orthogonal cutting. It also explores the influence of machining mechanics on tool selection and machine sizing.

6. Machining Mechanics Advanced Manufacturing Process I & II Piispanen’s Card Model

7. Machining Mechanics Advanced Manufacturing Process I & II Variables in Orthogonal Cutting

8. Machining Mechanics Advanced Manufacturing Process I & II Kinematics of Orthogonal Cutting

9. Machining Mechanics Advanced Manufacturing Process I & II Forces in Orthogonal Cutting

10. Machining Mechanics Advanced Manufacturing Process I & II Forces in Orthogonal Cutting

11. Machining Mechanics Advanced Manufacturing Process I & II Merchant’s Force Circle

12. Machining Mechanics Advanced Manufacturing Process I & II Energy Dissipation in Cutting

13. Machining Mechanics Advanced Manufacturing Process I & II Energy Dissipation in Cutting Cutting Power: Shear Zone Power: Friction Zone Power:

14. Machining Mechanics Advanced Manufacturing Process I & II Cutting Temperatures Heat transfer to environment is negligible

15. Machining Mechanics Advanced Manufacturing Process I & II Rake Angle (α): Width of Cut/Pass: Cutting Speed (V): Cutting Force (Fc): Undeformed Chip Thickness (to): Vary the cutting speed. degrees 10 2 m/s 0.25 mm 2.5 Deformed Chip Thickness (tc): 0.83 mm 890 N Thrust Force (Ft): 667 N Cutting Power (Pc): W Cutting Power Meter (%) ‏ 0 100 40 50 30 20 10 80 70 60 90 Simulation (Range = 0.1 to 4) ‏ (Constant) ‏ Shear Zone Power (Pc): W

16. Machining Mechanics Advanced Manufacturing Process I & II Resources Books: Serope Kalpakjian & Steven R. Schmid, “Manufacturing Process for Engineering Materials”, Section 6.3 – Rolling Process Ghosh & Malik, “Manufacturing Science”

17. Machining Mechanics Advanced Manufacturing Process I & II Shaping Single-point Multi- point Neither Planning Single-point Multi- point Neither Turning Single-point Multi- point Neither Boring Single-point Multi- point Neither Milling Single-point Multi- point Neither Drilling Single-point Multi- point Neither Grinding Single-point Multi- point Neither Honing Single-point Multi- point Neither Identify the type of cutting process for each of the following:

18. Machining Mechanics Advanced Manufacturing Process I & II Machining grey cast iron produces continuous chips with BUE continuous chips without BUE discontinuous chips of irregular shape and size discontinuous chips of regular shape and size

19. Machining Mechanics Advanced Manufacturing Process I & II A low rake angle is desirable because it reduces the power consumed not desirable because it weakens the tool desirable because it reduces BUE not desirable at all

20. Machining Mechanics Advanced Manufacturing Process I & II The thickness of the chip is independent of cutting speed depth of cut tool material rake angle

21. Machining Mechanics Advanced Manufacturing Process I & II The cutting forces affect the power required the design of the machine tool the accuracy of the machined workpiece depends on the process parameters