Metal cutting and machine tools | EveryEng

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Self-paced Advanced

Metal cutting and machine tools

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2 enrolled

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FREE

663 min

Anytime

English

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Engineering AcademyLearn Without Limits: Free Engineering Courses

Manufacturing & Industrial

Manufacturing Engineering

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Why enroll

Participants join this course to gain a strong foundational and practical understanding of metal cutting principles and machine tool operations, which are essential skills in manufacturing and mechanical engineering industries. The course helps learners develop the ability to analyze machining processes, select suitable machine tools and cutting parameters, and improve productivity while ensuring quality and precision.

The program is particularly valuable for students and professionals seeking industry-relevant knowledge in conventional and CNC machining, tool materials, and process optimization. By understanding real-world machining challenges such as tool wear, heat generation, and surface finish, participants enhance their employability and readiness for roles in production, process planning, manufacturing design, and quality control.

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Engineering Academy

Engineer

Learn Without Limits: Free Engineering Courses

5+ yrs experience·India

Is this course for you?

You should take this if

You work in Manufacturing & Industrial
You're a Manufacturing Engineering / Mechanical Engineering professional
You have 3+ years of hands-on experience in this field
You prefer self-paced learning you can revisit

You should skip if

You're new to this field with no prior experience
You need a different specialisation outside Manufacturing Engineering
You need live interaction with an instructor

Course details

Metal Cutting and Machine Tools is a core manufacturing engineering subject that deals with the principles, mechanics, and applications of machining processes used to shape and finish metallic components. The course introduces the fundamentals of metal cutting, including chip formation, cutting forces, heat generation, tool wear, and surface integrity. Emphasis is placed on understanding the interaction between the cutting tool, workpiece material, and machining parameters to achieve dimensional accuracy, high productivity, and optimal surface quality.

The course also provides a comprehensive overview of conventional and modern machine tools such as lathes, drilling machines, milling machines, grinding machines, and CNC machine tools. Students learn the construction, working principles, kinematics, and operational capabilities of these machines, along with tool geometry, tool materials, cutting fluids, and work-holding devices. By integrating theory with practical considerations, the course equips learners with the knowledge required to select appropriate machining processes, tools, and cutting conditions for industrial manufacturing applications.

Source: NPTEL [Youtube]

Course suitable for

Key topics covered

geometry of single point turning
geometry of cutting tools and numerical problems
different types of tools and MCQ
the lathe
milling machines
gear cutting CNC and non traditional machining

Course content

The course is readily available, allowing learners to start and complete it at their own pace.

20 lectures11 hr 3 min

Introduction
40 min
Geometry of single point turning tools - 1
42 min
Geometry of turning tools - 2
33 min
Geometry of single point turning tools -3
30 min
Geometry of cutting tools and numerical problems
37 min
Different types of tools and mcq
34 min
Mechanism of chip formation
31 min
Mechanics of material removal
29 min
Measurement Of Cutting Forces
32 min
Numerical problems and MCQ
30 min
Tool wear and Tool life
32 min
Wear and life of cutting tools - 2
29 min
The lathe
29 min
Calculations on mechanisms in machine tools
34 min
Numerical problems on lathe
30 min
milling machines
31 min
Milling machine - indexing
37 min
Gear cutting CNC and non traditional machining
34 min
CNC and non-traditional machining methods
37 min
Numerical problems for week 4
32 min

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Questions and Answers

Q: You're clearing a conditional item during a pre-startup review on a vertical machining center, and the interlocked sliding door is bypassed for setup. Searching "CNC machine door interlock bypass risk during setup". If the door interlock fails closed, what hazard does it NOT protect you from?

A: The right choice isolates a safeguard gap by showing motion can still occur without the interlock addressing control logic faults. Option A fails because the door is a physical barrier against chips, not tool integrity. Option C falls apart since the interlock directly prevents access to rotating tools. Option D misses that enclosure doors are meant to contain fluids and mist.

Q: FAT is signed and you're on-site for SAT with production waiting; the punch list says "guarding verified" but evidence is thin. You're googling "machine tool SAT guarding verification sequence". What sequence closes the risk fastest without redoing the whole SAT?

A: The correct path gets physical barriers confirmed before relying on logic, closing exposure quickly. Option A reverses physical and functional checks, leaving a gap if guards are missing. Option C introduces motion before safeguards are proven. Option D trades throughput for paperwork and leaves operators exposed.

Q: You're asked to sanity-check spindle sizing for a milling job and search "estimate milling spindle power from cutting parameters". Rough milling steel: width 50 mm, depth 3 mm, feed 600 mm/min, specific cutting force 1800 N/mm². Order-of-magnitude spindle power?

A: The right estimate lands power where torque demand and material removal rate intersect realistically. Option A ignores cutting force scaling with width and depth. Option C overweights material type without doing the math. Option D drops force magnitude by focusing only on feed.

Q: During a Kaizen event, an operator suggests relying on the chuck guard alone on a manual lathe. You look up "lathe chuck guard failure consequences". If the guard hinge pin shears, what physical consequence should you expect first?

A: The correct answer traces the failure to loss of separation between person and hazard. Option B assumes torque feedback that doesn't exist. Option C confuses guarding with clamping mechanics. Option D invents a load path unrelated to the guard.