Programs Bachelor of Mechanical Engineering (NQF Level 8)
Subject Name Metal Cutting and Machine Tools
Subject Code ME322
Duration 13 Teaching Weeks, 1 Examination Week and 1 Mid Sem Week.
Contact Hours 6 hours per week (4 Lec/1 Tut/1 Lab)
Credit Points 20
Delivery Mode On campus
Prerequisites ME314- Manufacturing Processes and Design
Co requisites Nil
Academic Staff TBA
Synopsis
Metal Cutting and Machine Tools enables students to demonstrate tool geometry and define tool angles in different systems. Students will be able to differentiate between Oblique and Orthogonal cutting and illustrate the mechanism of chip formation in machining ductile and brittle materials. They will gain knowledge on constructional details and application of various types of machine tools along with their relative advantages and disadvantages. They will be introduced to various gear manufacturing and surface finishing process. They will be able to explain various non-traditional machining process and their applications. They will be aware of fundamentals of CNC part programming. Various principles for designing of cutting tools and Jigs and fixtures will be introduced to the students.
Subject Topics
- Theory of Metal Cutting
- Geometry and Design of Single Point Cutting Tools
- Features and Specifications of Machine Tools, Jigs and Fixtures
- Manufacturing of Gears
- Non-traditional Machining Practices
- CNC Machine Tools in Advanced Machining Practices
Subject Learning Outcomes (SLOs)
After completing this unit students will be able to
- Design cutting tools and assess their lives.
- Differentiate between Oblique and Orthogonal cutting and illustrate the mechanism of chip formation in machining ductile and brittle materials.
- Estimate machining times required for various products.
- Manufacture gears.
- Demonstrate an understanding of non-traditional machine tools and their application in machining and surface finishing process.
- Write part programming codes to cut simple geometries in CNC Machine tools.
- Working in teams to undertake laboratory exercises, analysing and discussing the outcomes and communicate those via professional reports
Assessment Tasks and Weightings
To obtain a pass grade in this Subject at least 50% overall must be achieved, and at least 40% achieved in the final examination. Students must also refer to the Subject Assessment Details.
Assessment 1–Lab/Project Concept Report: A team based or individual component report outlining individual or team formation. Team based report outlining formation and member roles, project selection, team and member action plan and a schedule of future activities to achieve the outcome. The report contributes 20% towards the final grade for the subject.
Assessment 2 – Assignments: The assignments are intended to support students achieving the learning outcomes for the Subject and will contribute 20% towards the final grade for the subject.
Assessment 3 – Class Test: The Test contributes 20% towards the final grade for the subject and evaluates progress towards achievement of learning outcomes.
Assessment 4– Final Examination (E): The individual components of final examination enable final evaluation of achievement of learning outcomes and contribute 40% towards the final grade for the subject
It is important that all students familiarise themselves with the University of Technology Assessment Guidelines including those on plagiarism in the Academic Integrity Policy at:
http://asix.unitech.ac.pg/apps/pnguot/?q=unitech/policies
Subject Mapping
Subject Learning Outcomes (SLO) are mapped to each of the PNG National Qualifications Framework (NQF), Course Learning Outcomes (CLO), Unitech Graduate Attributes (GA), Assessment Tasks (AT) and Engineers Australia (EA) Stage 1 Competencies.
| SLO | SLO to NQF | SLO to CLO | SLO to GA | SLO to AT | SLO to EA Stage 1 Competencies |
| 1 | Applications, Knowledge and skills | 1, 2 and 6 | 2, 4 and 6 | 2,3,4 | 1.2, 1.3 and 2.3 |
| 2 | Applications, Knowledge and skills | 2, 3 | 1 and 6 | 2,3,4 | 1.1, 1.3, 1.4, 2.1, 2.3 |
| 3 | Applications, Knowledge and skills | 1, 3, 4, 5, 6 | 2 and 6 | 2,3,4 | 1.2, 1.3, 2.2 |
| 4 | Applications, Knowledge and skills | 2, 3, 4 | 1 and 4 | 2,3,4 | 1.3, 1.4, 1.5, 2.1, 2.2, 3.3 |
| 5 | Applications, Knowledge and skills | 3, 4, 6, 9 | 1, 4 and 6 | 2,3,4 | 1.4, 1.5, 1.6, 2.2, 3.3 |
| 6 | Applications, Knowledge and skills | 3, 4, 6, 9 | 1, 4 and 6 | 2,3,4 | 1.4, 1.5, 1.6, 2.2, 3.3 |
| 7 | Applications, Knowledge and skills | 6, 7, 8 | 2, 3, 5 and 6 | 1 | 2.4, 3.2, 3.5, 3.6 |
Engineers Australia Stage 1 Competencies
| 1. KNOWLEDGE AND SKILL BASE | 2.ENGINEERING APPLICATION ABILITY | 3. PROFESSIONAL AND PERSONAL ATTRIBUTES |
| 1.1 Comprehensive, theory-based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the engineering discipline. | 2.1 Application of established engineering methods to complex engineering problem solving. | 3.1 Ethical conduct and professional accountability. |
| 1.2 Conceptual understanding of the mathematics, numerical analysis, statistics, and computer and information sciences which underpin the engineering discipline. | 2.2 Fluent application of engineering techniques, tools and resources. | 3.2 Effective oral and written communication in professional and lay domains. |
| 1.3 In-depth understanding of specialist bodies of knowledge within the engineering discipline. | 2.3 Application of systematic engineering synthesis and design processes. | 3.3 Creative, innovative and pro-active demeanour. |
| 1.4 Discernment of knowledge development and research directions within the engineering discipline. | 2.4 Application of systematic approaches to the conduct and management of engineering projects. | 3.4 Professional use and management of information. |
| 1.5 Knowledge of engineering design practice and contextual factors impacting the engineering discipline. | 3.5 Orderly management of self, and professional conduct. | |
| 1.6 Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the specific discipline | 3.6 Effective team membership and team leadership. |
Graduate Statement
The mechanical engineering graduate will have the skills and ability to systematically apply the engineering knowledge in an ethical and morally responsible manner in providing practical and sustainable solutions to engineering problems while upholding a level of sensitivity to social, cultural, legal and environmental issues in society.
Mechanical Engineering Course Learning Outcomes
The following table is included to demonstrate to mechanical engineering students that their Course Learning Outcomes address allEA Stage 1 Competencies.
The mapping matrix for all subject learning outcomes within the Course, against EA Stage 1 Competencies, provides more detailed information. That matrix is provided separately to students.
| Course Learning Outcome | Engineers Australia Stage 1 Competencies |
| 1. Possession of a deep understanding of the sciences, math, information systems and engineering fundamentals that underpin the mechanical engineering discipline. | 1.1, 1.2 |
| 2. An in-depth understanding of the body of knowledge that forms the mechanical engineering discipline. | 1.2, 1.3 |
| 3. Collection, synthesis and application of information within the mechanical and related engineering disciplines. | 1.4, 1.5, 2.1, 2.3, 2.4, 3.4 |
| 4. Undertaking research, analysis & evaluation of ideas and concepts within mechanical engineering. | 1.3, 1.4, 1.6, 2.1, 2.3, 2.4, 3.2, 3.4 |
| 5. Applying problem solving skills to complex mechanical engineering systems and processes. | 1.1, 1.2, 1.3, 1.4, 1.5, 2.1, 2.2, 2.3 |
| 6. Undertake mechanical engineering design and manage engineering projects. | 1.6, 2.2, 2.4, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6 |
| 7. Communication via multiple media to diverse audiences, undertaking team roles, teamwork and providing team leadership. | 2.4, 3.2, 3.3, 3.4, 3.5, 3.6 |
| 8. Behaving in an ethical and professional manner and respecting others. | 1.6, 2.4, 3.1, 3.4, 3.5, 3.6 |
| 9. Being cognisant of the importance of sustainability and the environmental impact of engineering. | 1.5, 1.6, 3.1, 3.3, 3.4 |
Unitech Graduate Attributes
| Attribute | Academic dimension | Personal Dimension | Transferable Dimension |
| Lifelong learner | Sustained intellectual curiosity and use of feedback to reflect on their own work. | Sets aspirational goals for personal improvement and career growth. | Takes responsibility for one’s learning and development. |
| Critical thinker | Uses rules of inference to analyse complex issues and find solutions. | Calmly uses logic and critical thinking, and not emotion, in all situations. | Ability to find solutions to problems by using logical and imaginative thinking. |
| Effective communicator | Ability to discuss and debate issues articulately and confidently and convincingly. | Character of producing high quality written essays and oral presentations. | Ability to communicate and negotiate with others and to listen to them. |
| Cultural modernist | Familiarity with international standards and world cultures and human rights. | Tolerance of the religions and cultures of others. | Ability to work in a multicultural setting and comprehension and tolerance of religious and cultural differences. |
| Moral uprightness | Understand and act upon the ethical responsibilities of their actions. | Character of acting in a morally upright way in all situations. | Professional behaviour at all times. |
| Technologically savvy | Familiarity and use of technologies appropriately. | Keeping up to date with innovations. | Character of accepting new technology and quickly adapting to it. |
Student Workload
The total workload for the subject for the ‘average’ student is a nominal 150 hours, based on a 15-week semester with 13 weeks of teaching as per the PNG National Qualification Framework.
Subject Text
S. Kalpakjian and S.R. Schmid, Manufacturing Engineering and Technology, 6th Ed., Pearson Education (Singapore) Pvt. Ltd., 2010.
References
P.N.Rao, Manufacturing Technology Volume II, 3rd Ed., McGraw Hill Education (India) Private limited, 2013
Readings
A B Chattopadhayay, Machining and Machine Tools, 3rd Ed., Wiley, 2011.
YouTube Clips
The following YouTube Clips should help augment your weekly lectures.
Single point cutting tool geometry at:
Mechanics of Metal Cutting at:
Non Traditional Machining Process at:
Relevant Unitech Policies
It is important that all students familiarise themselves with the PNGUOT Assessment Guidelines including those on plagiarism and other relevant policies. These policies are viewed by visiting the PNGUOT website: