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Pakirappa Metal Cutting and Machine Tool Engineering: A Comprehensive Guide for Beginners




Metal cutting and machine tool engineering are two important branches of mechanical engineering that deal with the processes of shaping, machining, and finishing metal parts using various tools and machines. Metal cutting involves the removal of unwanted material from a workpiece by means of cutting tools, such as drills, lathes, milling machines, etc. Machine tool engineering involves the design, development, operation, and maintenance of machine tools, such as CNC machines, robots, etc.


One of the most popular and comprehensive books on metal cutting and machine tool engineering is Pakirappa Metal Cutting and Machine Tool Engineering: A Comprehensive Guide for Beginners by Dr. S. Pakirappa. This book covers the fundamental concepts, principles, and applications of metal cutting and machine tool engineering in a simple and easy-to-understand manner. The book is divided into 12 chapters, each covering a specific topic related to metal cutting and machine tool engineering.


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Chapter 1: Introduction to Metal Cutting and Machine Tool Engineering




This chapter introduces the basic concepts and definitions of metal cutting and machine tool engineering, such as types of metal cutting operations, types of machine tools, classification of cutting tools, cutting tool materials, cutting fluids, chip formation, cutting forces, power consumption, tool wear, tool life, surface finish, etc.


Chapter 2: Theory of Metal Cutting




This chapter explains the theoretical aspects of metal cutting, such as geometry of single-point and multi-point cutting tools, orthogonal and oblique cutting, mechanics of chip formation, shear angle, shear strain, shear stress, friction angle, friction coefficient, rake angle, clearance angle, cutting speed, feed rate, depth of cut, etc.


Chapter 3: Cutting Tool Materials




This chapter describes the properties and characteristics of various cutting tool materials, such as high carbon steel, high speed steel, cast alloys, cemented carbides, ceramics, cermets, diamond, cubic boron nitride (CBN), etc. The chapter also discusses the factors affecting the selection of cutting tool materials, such as cost, performance, availability, machinability, etc.


Chapter 4: Cutting Fluids




This chapter discusses the functions and types of cutting fluids used in metal cutting operations, such as cooling fluids (water-based), lubricating fluids (oil-based), extreme pressure fluids (sulfur-based), synthetic fluids (chemical-based), etc. The chapter also explains the methods of application and disposal of cutting fluids.


Chapter 5: Cutting Forces and Power Consumption




This chapter analyzes the forces acting on the cutting tool and the workpiece during metal cutting operations, such as tangential force (Ft), radial force (Fr), axial force (Fa), resultant force (R), thrust force (Fz), etc. The chapter also calculates the power consumption (P) during metal cutting operations using various formulas.


Chapter 6: Tool Wear and Tool Life




This chapter examines the causes and types of tool wear that occur during metal cutting operations, such as flank wear (VB), crater wear (KT), nose wear (RN), notch wear (VBn), chipping wear (CH), thermal wear (TH), etc. The chapter also estimates the tool life (T) using various empirical equations based on Taylor's tool life equation.


Chapter 7: Surface Finish and Machinability




This chapter evaluates the quality and accuracy of the machined surface using various parameters, such as surface roughness (Ra), surface waviness (Wt), surface lay (L), surface texture (T), etc. The chapter also assesses the ease and difficulty of machining a given material using various factors, such as material hardness (HRC), material strength (UTS), material ductility (%EL), material toughness (KIC), etc.


Chapter 8: Turning and Boring Operations




This chapter describes the turning and boring operations performed on a lathe machine using single-point cutting tools. The chapter covers the types and components of lathe machines, such as center lathe, capstan lathe, turret lathe, CNC lathe, etc. The chapter also explains the types and applications of turning and boring operations, such as straight turning, taper turning, thread turning, facing, parting off, grooving, drilling, reaming, tapping, boring, counterboring, etc.


Chapter 9: Drilling and Reaming Operations




This chapter describes the drilling and reaming operations performed on a drilling machine using multi-point cutting tools. The chapter covers the types and components of drilling machines, such as bench drill, pillar drill, radial drill, gang drill, multi-spindle drill, CNC drill, etc. The chapter also explains the types and applications of drilling and reaming operations, such as through drilling, blind drilling, step drilling, core drilling, counter drilling, spot facing, reaming, etc.


Chapter 10: Milling and Shaping Operations




This chapter describes the milling and shaping operations performed on a milling machine and a shaping machine using multi-point cutting tools. The chapter covers the types and components of milling machines and shaping machines, such as horizontal milling machine, vertical milling machine, universal milling machine, planner milling machine, CNC milling machine, shaping machine, slotting machine, etc. The chapter also explains the types and applications of milling and shaping operations, such as plain milling, face milling, end milling, angular milling, form milling, gear milling, thread milling, keyway milling, spline milling, etc.


Chapter 11: Grinding and Honing Operations




This chapter describes the grinding and honing operations performed on a grinding machine and a honing machine using abrasive tools. The chapter covers the types and components of grinding machines and honing machines, such as surface grinding machine, cylindrical grinding machine, centerless grinding machine, internal grinding machine, tool and cutter grinding machine, CNC grinding machine, honing machine, etc. The chapter also explains the types and applications of grinding and honing operations, such as rough grinding, finish grinding, precision grinding, superfinishing, lapping, polishing, etc.


Chapter 12: Non-Traditional Machining Processes




This chapter describes the non-traditional machining processes that use unconventional sources of energy to remove material from the workpiece. The chapter covers the types and principles of non-traditional machining processes, such as ultrasonic machining (USM), electrochemical machining (ECM), electrodischarge machining (EDM), laser beam machining (LBM), electron beam machining (EBM), plasma arc machining (PAM), water jet machining (WJM), etc. The chapter also explains the advantages and disadvantages of non-traditional machining processes over conventional machining processes.


References




  • Pakirappa Metal Cutting And Machine Tool Engg by Jennifer Newberry on SoundCloud



  • Pakirappa Metal Cutting and Machine Tool Engineering: A Comp



  • Pakirappa Metal Cutting And Machine Tool Engg by Brandi Smith on SoundCloud





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