Week 1:
1.1 Introduction and Importance of Machining: Introduction to manufacturing, Top-down and bottom-up approaches, Machining and Various Machining Processes.
1.2 Principles of Metal Cutting: Shear zone, Chip formation, chip thickness measurements, machining mechanics of ductile and brittle materials.
Week 2:
2.1 Cutting tool: Tool Geometry, Tool signature.
2.2 Cutting forces and Cutting velocities : Cutting forces, Merchant Circle, Empirical Models, Chip thickness ratio, Cutting velocities, Strain rates, Mathematical formulations.
Week 3:
3.1 Tribology, Surface roughness in Machining: Chip-tool tribology, tool-workpiece tribology, Sticking and sliding zone, types of lubrication, Surface roughness, Materials removal rate, Machinability.
3.2 Thermal Aspects of Machining: Cutting temperature, Measurement of temperature, heat generation, heat distribution, metallurgical and microstructural study.
Week 4:
4.1 Tool Wear and Tool life: Carter wear, flank wear, nose wear, other tool wears, tool life criteria.
4.2 Tool Materials and Coatings: Coating materials, PVD, CVD, RF, Laser coatings, Tool texturing.
Week 5:
5.1 Cutting Fluids: Classification, Functions, Types of lubrication, Cutting fluid additives, Emissions, Health Hazards, Rheology and Biodegradability.
5.2 Cutting fluid application: Standoff distance, angle of impingement, contact angle, area of cooling, Solid lubricants.
5.3 Eco-friendly cutting fluids: Development of eco-friendly cutting fluids, bio degradation of these fluids, COD, BOD, HRT, Advantages of sustainable cutting fluids over mineral oil based cutting fluids.
Week 6:
6.1 Multipoint Machining Processes: Milling, Drilling, Broaching, Tapping, Sawing, Gear Cutting.
Week 7:
7.1 Abrasive machining processes: Grinding wheel specification, classification, Thermal aspects, Lapping, Honing, Super finishing, Drag finishing, vibratory finishing, Applications.
7.2 Cutting fluids for abrasive machining processes: Cutting fluids in grinding, honing, super-finishing.
Week 8:
8.1 Machining of Advanced Materials: Machining of Biomaterials, Aero Space materials, Smart Materials.
8.2 Advances in Metal Cutting: Hard Machining, High Speed Machining, Diamond Turning, Double tool Machining, Machining with rotary tools, Thin wall machining, Laser Assisted Machining.
8.3 Cutting fluids machining advanced materials: Cutting fluids for machining advanced materials, high speed machining, hard machining.
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