Machine Tools and Metrology (PCMET402) Syllabus

Machining: basic machine tools, single and multi-point cutting tools, tool geometry and materials, mechanics of chip formation — orthogonal and oblique cutting, shear angle, velocity relationship, Merchant's analysis of cutting forces, cutting power estimation, tool life and wear, economics of machining.

Lathe: types, parts, specifications, operations, accessories, process parameters, machining time calculations. Shaping, planing and slotting machines: classification, types of operations. Drilling machines: operations, drill bit nomenclature, process parameters, machining time and cutting forces. Milling machines: types, operations, cutter types and nomenclature, process parameters, indexing head and indexing methods. Grinding: types, operations, cutting forces, grinding wheels, honing and lapping. Broaching: machines, cutters, internal/external broaching. Gear generation: gear hobbing. Work holding: jigs and fixtures.

Metrology: need for inspection, accuracy and precision, calibration, errors in measurement, standards of measurement. Limits, fits and tolerances: principle of interchangeability, selective assembly, classification of tolerance, types of fit, hole basis and shaft basis systems, system of limits and fits. Limit gauging: classification of gauges, Taylor's principle, gauge tolerance and wear allowance.

Angular measurements: autocollimator, angle dekkor. Comparators: dial indicators, electrical/electronic and pneumatic comparators. Interferometry: principle of interference, optical flats, NPL flatness interferometer, Pitter-NPL gauge interferometer, laser interferometers. Gear measurement: gear tooth terminology, errors in spur gears. Screw thread measurement: measurement of major/minor/effective diameters (2-wire and 3-wire methods). Surface roughness measurement: stylus probe instruments. Geometric form measurement: straightness, flatness, roundness, coordinate-measuring machine (CMM) concepts.