Mechanics of chip formation, cutting processes, finishing operations, non-traditional machining processes. Production rates calculation, machining economics. Automation of processes, programming of manufacture. Engineering metrology. Assembly techniques. Introduction to process planing.
Goals of study
To give students knowledge with methods of technology of machining.
Conditions for obtaining assessment
100 % Seminars presence.
Problems to examination
Major changes in the world of goods manufacturing.
Product life cycle.
Manufacturing cost in the selling price.
The main tasks of a design and manufacturing engineer.
Chip formation - continuous and discontinuous chip formation.
Primary deformation zone - shear angle.
Built-up edge formation.
Chip thickness compression ratio (cutting ratio).
Chip volume ratio.
Chip breaking diagrams.
Specific cutting force, specific cutting power, dependence on tensile strength.
Dependence of specific cutting force on feed (or nominal thickness of cut).
Distribution of heat generated in cutting.
The main sources of heat in cutting.
Workpiece material flow due to cutting radius.
Cutting temperature as a function of cutting conditions.
Temperature distribution for low and high cutting speeds in a cutting tool.
Work-tool thermocouple circuit.
Tool wear mechanisms.
Tool wear forms.
Relation between hardness of tool materials and temperature.
Development of flank and crater wear with cutting time.
Tool life, Taylor‘s equation, the determination of Taylor’s equation.
Relation among tool life and cutting conditions.
The main factors influencing surface finish and surface integrity.
Work hardening of machined surface, residual stresses.
Tool materials and their main characteristics.
Tool steels, cast cobalt alloys.
Diamond, cubic boron nitrite.
Forms of the contact between the work and tool - influence on cutting fluids effect.
Cutting fluids classification.
Vibrations in machining.
Optimization of cutting conditions - the step by step procedure.
The cost per product calculation
Optimum tool life.
Optimum choice of a machine tool., critical production batch.
Broaching - process schema, tool and workpiece geometry produced.
Broaching - broaching machines, tolerances and surface finish.
External thread machining - threading on a lathe.
External thread machining -threading with threading dies.
External thread machining - milling threads.
External thread machining - grinding.
Internal thread machining - threading on a lathe.
Internal thread machining - thread taping.
Spur and helical gears cutting - form milling.
Spur and helical gears cutting - hobbing.
Spur and helical gears cutting - shaping.
Spur and helical gears cutting - broaching.
Spur and helical gears finishing - shaving.
Spur and helical gears finishing - grinding.
Spur and helical gears finishing - roll finishing, lapping. Teeth rounding.
Strait bevel gears cutting - form milling, involute-generating milling.
Strait bevel gears cutting - shaping, master form shaping, broaching.