Cutting Technologies
Code
10477
Academic unit
Faculdade de Ciências e Tecnologia
Department
Departamento de Engenharia Mecânica e Industrial
Credits
6.0
Teacher in charge
Carla Maria Moreira Machado, Jorge Joaquim Pamies Teixeira
Weekly hours
5
Total hours
70
Teaching language
Português
Objectives
Description:
The course aims at providing the students with fundamental knowledge on machining (cutting metals and non metals) and experimental analysis techniques [First Module ] and on blanking, drawing and other deformation technologies [Second Module].
Knowledge:
Students are expected to acquire scientific and technical knowledge on the physical mechanisms of cutting technologies, both in terms of conventional cutting and High Speed Cutting, relating the different phenomena (vibrations, chattering, tool wear, etc). Additionally, it is also expected that they get hold of the new trends and the state of art of cutting technologies as well as new analysis tools (e.g. simulation).
In the second module, dedicated to blanking and forming technologies, it also expected that the students acquire the necessary knowledge as to be able to develop new tools and new processes. The inclusion of the state of art software tools for simulation and design are explained and used.
Do:
- Process planning for machining: selection of cutting parameters, tools and fixtures.
- Optimization of cutting operations following criteria of minimum cost and maximum production.
-Experimental analyis of cutting
- Blanking and Drawing tool design (simple and progressive)
Soft skills:
- Team work in laboratory environment
- Develop critical thinking
- Develop technical written skills
Prerequisites
It is required to have completed the course Tecnologias e Processos Mecânicos
Subject matter
M odule 1: Chip Removal Processes
Machining processes and controling variables. Quantitative factors in material removal. Operational elements of machining tools. Model of orthogonal cutting. Specific cutting energy. Modelling cutting forces and cutting power. Temperature development on cutting operations: empirical and heat transfer models. Tool wear mechanisms and tool life. Tool materials , coatings and coating technologies. Surface finishing in machining. Cutting operations optimization. Introductio n to non-conventional technologies: Electroerosion (EDM), Ultra sound machinig and ultra sound assisted machining. Abrasive flow machining.
Module 2: Blanking and Drawing
Processes and equipments. Matrices and dies. General principles of tool design. Tooling Materials and heat treatments. Design of a complete tool to produce a case study workpiece.
Bibliography
Pamies Teixeira, “Fundamentos físicos do corte dos metais”, Edinova, 2001
Y. Altintas, "Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations and CNC Design", Cambridge Univ. Press., ISBN 0-52165973-6, 2000. Mario Rossi, “Estampado en frio de la chapa”, Hoelpi, 1970.
Dino Ferraresi, “Fundamentos da usinagem dos metais, Edgar Blucher, 1977
Tool and Manufacturing Engineers Handbook – Vol 1 Machining, SME, 1983
A. Dias dos Santos, J. Ferreira Duarte, A. Barata da Rocha, Tecnologia da Embutidura, ISBN: 972-8826-03-06 Oehler, Kaiser, “Herramientas de Troquelar, Estampar y Embutir” Ed. Gustavo Gili, 1977.
J. Rodrigues, Paulo Martins, Tecnologia Mecânica: Tecnologia da Deformação Plástica, Escolar Editora, ISBN 972-592-185-2. “Die Design Handbook” SME 3ª Ed.
F. Provenza “Estampos” Ed. F. Provenza, 1991
Teaching method
Lectures with the presentation of the fundamentals of metal cutting.
Tutorials with the resolution of problems that simulate real situation of process planning for cutting.
Lab sessions and Homework assignement on developing a complete process plan to machine a given component.
Development of a project where the studetn designs a tool to manufacture a sheet metal component.
Evaluation method
The course is constituted by two independent modules:
Machining and experimental analysis techniques;
Blanking, drawing and other deformation technologies.
Each of these modules, with equal weight, is evaluated by 1 Test and 1 Practical work.
Machining: Test T1.1 (20%), Work TP1.1 (30%)
Blanking and drawing: Test T2.1 (20%) and Work TP2.1 (30%).
The practical works are eliminatory and the grade should be => 10.0
The T1.1 OR T2.1 test has a minimum grade requirement of 7.5 values.
The Final Exam (ER) deals with the subject matter of the two modules and is subject to the minimum grade of 7.5.
The final grade: NF = 0.2 (T1.1 + T2.1) + 0.3 (TP1.1 + TP2.1) or
If ER> = 7.5 NF = 0.4 ER + 0.3 (TP1.1 + TP2.1)
Otherwise NF = ER, with the grade of the papers available for 1 academic year