Course details

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Material Removal Processes

Teaching: Partially in English - lessons & excercies held in Croatian, materials & exam in English
ECTS: 5
Level: UnderGraduate
Semester: Winter
Prerequisites:
None
Load:
Lectures Exercises Laboratory exercises Project laboratory Physical education excercises Field exercises Seminar Design exercises Practicum
30 24 0 0 2 0 0 0
Course objectives:
Expand the knowledge of cutting teory. Accept the criterions and methods for material machinability determination and cutting parameters needed to correct material removal processes planning. Introduce the new material removal processes.
Student responsibilities:
Grading and evaluation of student work over the course of instruction and at a final exam:
Colloquiums 40%. Seminar 20%. Oral exam 20%.
Methods of monitoring quality that ensure acquisition of exit competences:
Initial testing. Students preparation of experiment. Discussion of the experimental results and interactions of influencing parameters. Student survey.
Upon successful completion of the course, students will be able to (learning outcomes):
After successful adopt of this course, the student will be able to: - explain the meaning of the coefficient of deformation and relative shear on the process of chip forming; - calculate the angle of the shear plane based on the coefficient of deformation and tool geometry; - calculate the theoretical surface roughness on the basis of feed and tool geometry; - estimate the cutting forces; - define the basic and additional machinability criteria; - optimize cutting speed according to the criteria of productivity and cost-effectiveness; - establish criteria for the selection of cutting data; - analyze the advantages and requirements of the application"s high speed machining, hard machining and dry machining; - compare WJM, laser and EDM technologies;
Lectures
1. Theory of cutting. Deformation of material and chip forming. Velocity diagram. The shear strain.
2. The shear strain and compression ratio. Shear plane angle. Shear plane intensity. Forces at orthogonal cutting.
3. Shear angle applying Merchant approach, and shear angle applying minimum energy principle.
4. Tool wear and tool life (T, Lv, Lf). Quality of machined surface-teoretical roughness.
5. Chip types and forms. Parameters influencing chip forms.
6. Cutting speed optimization on maximal productivity criteria and minimal cost criteria.
7. Machinability of material. Machinability criterias. Structure of material removal process. Process planning.
8. Methods for cutting parameters determination. Criterias for selection of cutting parameters.
9. Characteristics and cutting parameters in grinding, honing, lapping and superfinishing.
10. Characteristics and cutting parameters in turn-milling.
11. Characteristics and cutting parameters in non-conventional machining.
12. High-speed material removal processes: characteristics and cutting tools.
13. High speed milling, high speed drilling, DRY machining, hard machining.
14. Jet machining and rapid prototyping.
15. Trends in material removal processes.
Exercises
1. Basic geometry of cutting tool-estimation and grinding.
2. Chip forms and determination of compression ratio at machining of steel materials.
3. Chip forms and determination of compression ratio at machining of unferrous materials.
4. Determination of parameters for tool life Taylor equation.
5. Examples for tool life determination with T, Lv, Lf parameters.
6. Determination of teoretical and actual roughness of machined surfaces.
7. Cutting tool identification.
8. Cutting process planning for chosen part.
9. Machining of chosen part on machine tools in Laboratory.
10. Technology planning and manufacturing of chosen part on machine tools in Laboratory.
11. Production line of famous cutting tool factories (alata (SANDVIK, ISCAR, SECO, TIZIT...).
12. Production line of famous cutting tool factories (alata (SANDVIK, ISCAR, SECO, TIZIT...).
13. Company visit- toolshop.
14. Company visit- toolshop.
15. Abrasive water jet machining.
Compulsory literature:
H. Tschätsch: Applied Machining Technology, Springer Verlag 2009
Šavar, Š. Obrada odvajanjem čestica, Školska knjiga, Zagreb, 1991.
Ekinović, S.: Obrada rezanjem, ISBN 9958-42-062-7, Zenica, 2001
D.A. Stephenson, J.S. Agapiou: Metal cutting theory and practice, CRC Taylor & Francis, 2006
Recommended literature:
Science Direct Website: Annals of the CIRP, Elsevier
J.P. Davim: Machining: Fundamentals and Recent Advances, Springer Verlag, 2008,
Erdel, B.: High-speed Machining, Society of Manufacturing Engineers, 2003

Faculty of Mechanical Engineering
and Naval Architecture
Ivana Lučića 5
10002 Zagreb, p.p. 102
Croatia
MB 3276546
OIB 22910368449
PIC 996827485
IBAN HR4723600001101346933
tel: +385 1 6168 222
fax: +385 1 6156 940
University of Zagreb
Ministry of Science and Education