Machining Introduction, Cutting & Feed Motion, Generatrix & Directrix |Machining1|PT| Mechanical Eng

The video is a part of topic Orthogonal Machining under the course of Production Techniques, Manufacturing Processes and Industrial Process in Mechanical Engineering & Industrial Engineering.
This video gives introduction to machining topic in general and explains other manufacturing process. It then explains the cutting and feed motion, and the generatrix and directrix.
The topic of orthogonal machining comes under a main topic of types of manufacturing processes where the other processes are casting, metal forming, powder metallurgy, polymer processing and joining process ( Welding, Fasteners, etc). The machining includes orthogonal machining, non orthogonal machining, economics of machining and unconventional machining.
This part explains the orthogonal machining which is the base for the realistic or true machining processes such as turning, milling, cutting, facing, shaping and planning. The topic includes types of motion in machine tools - cutting motion ( generatrix ) and feed motion ( directrix ). It includes the mechanics of chip formation and the chip formation and removal model which is piispanen model saying chip flows as stack of card. The topic then has difference between orthogonal machining and non orthogonal machining defined using velocity vector and cutting edge. It also includes detailed understanding of tool geometry which includes the type of cutting tool, parts of tool - Active & Passive ( Shank ), faces in cutting tool - face, rake surface, flank ( side flank and end flank ), angles in cutting tool - end cutting edge angle, side cutting edge angle, main cutting edge angle, end relief angle or end clearance angle, side relief angle or side clearance angle, back rake angle ( positive rake angle and negative rake angle ) and side rake angle, nose, nose radius, and cutting tip. It also includes the orthogonal machining transition surface geometry, definition of dynamic shear plane angle and shear strain. It gives complete mathematical step by step derivation and proof for the formula of dynamic shear plane angle and formula of shear strain. It also includes the understanding of cutting and deformation zones which are primary shear zone ( or primary deformation zone ) and secondary shear zone area ( or secondary deformation zone ). It also includes the forces involved in orthogonal machining which are cutting force, shear force, thrust force, normal force, and total equivalent force. It gives the analysis of cutting forces during orthogonal machining including the assumptions made for modelling. It also includes the complete step by step procedure to derive the cutting forces and the force triangle. The topic then has optimization for required power for machining in which the minimum power condition is used and minimum cutting force is derived which results into Merchant's first solution and Merchant's circle. For all this, the output parameters which are cutting force and power required for machining dependency is studies with input parameters which are machining parameters - velocity, depth of cut, feed rate, shear plane angle, shear strain, r ratio ( uncut chip thickness to cut chip thickness ) and material property constant - friction between chip and tool rake surface. It also includes the components of main forces in different directions and how to control forces. The orthogonal machining topic then has modified Merchant's solution ( or Merchant's Second Solution ) which takes modified shear strength value and hardness consideration. At last it should have Lee and Shaffer solution and Stabler Solution, and these are all solution are compared to get the best and most realistic solution applicable in the shop floor. In all the sub topic of the orthogonal machining, numerical example questions must be solved for clear understanding and application of formula involved.

[@arijitbardhan8980]

Please show the calculation of chip length

[@dhyandpatel132]

Hello,
I have studied and understood the machining operations during my course work.
And what I had came across is that chip length - uncut or cut is usually a measurable parameter of the operation. We would rather use the value of these chip length to find the chip thickness.
If you need a relation between these quantities - uncut chip length, cut chip length, uncut chip thickness and cut chip thickness, you can use the relationship of chip thickness ratio.