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 [1st Module ] and on blanking, drawing and other deformation technologies [2nd 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 - 4
Total - 68
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
The classes are of a theoretical-practical nature, therefore they consist of exposing the subject and developing the ability to apply knowledge and critical analysis through solving real problems related to machining processes. Contact with equipment is also privileged through laboratory classes.
Evaluation method
The UC is composed of two distinct and independent modules: Module 1 - Machining and Module 2 - Blanking, drawing and other deformation technologies.
Module 1 Assessment: T1 Test (50%).
Module 2 Assessment: P2 Tool Design (50%).
The P2 tool project is group work (5 elements).
Students can choose to take the course through Continuous Assessment or through an Exam (ER).
Final grade by Continuous Assessment: NF = 0.5*T1 + 0.5*P2
The student will be approved if the weighted average (NF) is equal to or greater than 9.5 points.
Final grade by Exam: NF = ER
The Exam (ER) covers the material from both modules.
In case of failure, the project grade (PF) will remain valid for at least 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.