Cutting Technologies

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

General characterization

Code

10477

Credits

6.0

Responsible teacher

Carla Maria Moreira Machado, Telmo Jorge Gomes dos Santos

Hours

Weekly - 5

Total - 70

Teaching language

Português

Prerequisites

It is required to have completed the course Tecnologias e Processos Mecânicos

Bibliography

Pamies Teixeira Fundamentos físicos do corte dos metais
Mario Rossi Estampado en frio de la chapa
Dino Ferraresi Fundamentos da usinagem dos metais
Tool and Manufacturing Engineers Handbook – Vol 1 Machining, SME
Oehler, Kaiser Herramientas de Troquelar, Estampar y Embutir
J. Rodrigues, Paulo Martins, Tecnologia Mecânica
Die Design Handbook SME 3ª Ed

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.

Development of a project where the studetn designs a tool to manufacture a sheet metal component.

Evaluation method

Taking into account the situation of the Covid-19 pandemic that made normal classroom teaching unfeasible, the evaluation is expected to be carried out remotely, so the minimum classification requirement in the EvaluationTest has been removed.

The continuous evaluation system will be maintained, as well as the respective dates established at the beginning of the semester;

The course is constituted by two independent modules: Machining and experimental analysis techniques; Blanking, drawing and other deformation technologies.

Machining: Test T1 (50%)

Blanking and drawing: Project P2 (50%).

The Project P2 is group work (4 elements) and is eliminatory. The frequency in the course is conditioned by the classification of P2 > 10 values.

NF = 0,5*T1 + 0.5*P2

As for the exams:

The Final Exam (ER) deals with the subject of the two blocks and is subject to a minimum score of 7.5.

If ER > 7.5 the final grade will be: NF = 0.5 * ER + 0.5 * P2

If ER < 7.5: NF = ER, and the grade of the project is available for 1 academic year.

Subject matter

Module 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.

Programs

Programs where the course is taught: