Course details

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Material Removal

Teaching:

ECTS:

Level:

Semester:

Prerequisites:

None

Load:

Lectures	Exercises	Laboratory exercises	Project laboratory	Physical education excercises	Field exercises	Seminar	Design exercises	Practicum
30		11	0	0	4	0	0	0

Course objectives:

Introduction with basics of cutting theory and material removal processes. Introduction with basics of machine tools, cutting tool and accessories.

Student responsibilities:

Grading and evaluation of student work over the course of instruction and at a final exam:

Colloquiums 60%. Written exam 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.

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; - 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. Significance, development and classification of material removal processes. Motions and machining parameters.

2. Basic geometry of cutting tool and workpiece. Cutting tool materials.

3. Basics of theory of cutting, orthogonal cutting and chip forming.

4. Dynamics of material removal processes. Heat at material removal.

5. Coolant. Tool wear and tool life. Vibrations in metal removal process.

6. Material removal processes - planning, broaching, sawing, turning.

7. Material removal processes - turning.

8. Material removal processes - drilling, counter sinking, reaming, deep hole drilling.

9. Material removal processes - milling.

10. Material removal processes - grinding.

11. Material removal processes - honning and lapping.

12. Nonconvencional machining processes - EDM, ECM, USM and jet machining.

13. High speed and high efficiency machining.

14. High precision machining and micro machining.

15. Rapid prototyping. Modern trends in material removal.

Exercises

1. Introduction with basics of machining and machine tools in the lab. Kinematics of machine tools, cutting tools and accessories.

2. Introduction with basics of machining and machine tools in the lab. Kinematics of machine tools, cutting tools and accessories.

3. Introduction with basics of machining and machine tools in the lab. Kinematics of machine tools, cutting tools and accessories.

4. Introduction with basics of machining and machine tools in the lab. Kinematics of machine tools, cutting tools and accessories.

5. Measuring of cutting forces at turning.

6. Measuring of cutting forces at drilling.

7. Measuring of cutting power at turning and drilling.

8. Tool life testing.

9. Vibration measuring at up-cut and down-cut milling.

10. Measuring of heat removed by chip.

11. Measuring of surface roughness at grinding.

12. Visit to the company which uses nonconventional machining processes.

13. Visit to the company which uses non-conventional machining processes.

14. Examples of high speed milling of metal and non metal materials.

15. Watching of movies with different machining processes.

Compulsory literature:

Šavar, Š.: Obrada odvajanjem čestica, Školska knjiga, Zagreb 1991.
Zdenković, R.; Obrada metala skidanjem, Školska knjiga, zagreb, 1991.
Ekinović, S.: Obrada rezanjem, ISBN 9958-42-062-7, Zenica, 2001

Recommended literature:

Science Direct Website: Annals of the CIRP, Elsevier
J.P. Davim: Machining: Fundamentals and Recent Advances, Springer Verlag, 2008
Klocke F.: Manufacturing Processes 1, Spinger, 2011
Klocke F.: Manufacturing Processes 2, Spinger, 2011