Advanced
Machining Processes
ME 2500
Covers mechanics of 2-D and 3-D cutting, leading to force
and surface-generation models for turning, facing, boring, face milling, end
milling, and drilling. Final project
involves integration of models for process performance and machining economics
to design a process. Includes
motivation for and methods of practical application of developed models.
Undergraduate students with interest in design and/or
manufacturing, especially with interests in the automotive, aerospace,
machine-tool or heavy/construction/farm equipment industries, including both
OEMs and suppliers.
Graduate students working in manufacturing processes,
especially those working in machining processes.
Graduate students with interests in working in the
machine-tool, cutting tool, or their end-user (automotive, aerospace, etc.
manufacturing) industries.
·
To teach the mechanistic modeling technique for
manufacturing processes using static models of machining processes to
illustrate.
·
To teach the use of design of experiments and how to
interpret the data through semi-empirical model building.
·
To teach basic geometry, mechanics and thermal issues
associated with chip formation.
·
To teach the effects of tooth shape on machining
force components and surface finish.
·
To teach the effects of process kinematics on force
signatures and surface finish.
1.
Understand the basic techniques of mechanistic modeling
with its application to manufacturing processes.
2.
Be able to plan and diagnose machining processes used
in practice via a qualitative understanding of their thermo-mechanical
behavior.
3.
Understand the mechanical aspects of orthogonal
cutting mechanics.
4.
Understand the thermal aspects of orthogonal cutting
mechanics.
5.
Be able to extend, through mechanistic modeling
techniques, the orthogonal-model concepts to oblique cutting.
6.
Be able to extend, through mechanistic modeling
techniques, the orthogonal and oblique cutting concepts to three-dimensional
processes used in practice.
7.
Be able to model, in an industrially-useful manner,
forces for three-dimensional machining processes used in practice.
8.
Be able to model the deterministic components of
surface generation for three-dimensional machining processes used in practice.
9.
Be able to calibrate empirical force models by
designing an experiment, conducting the experiment, and identifying model
parameters.
10.
Understand the practical aspects of tool wear and
tool life, and their influence on economics.
|
An Introduction to
Machining Processes 1 Machining Process Modeling and Analysis 1.1 General
Terminology 1.2 Motivation
for Process Modeling 1.3 Economics 1.4 The
Mechanistic Modeling Approach 1.5 Static vs. Dynamic Modeling 2 Orthogonal Cutting-Process Mechanics 2.1 Orthogonal
Cutting-Process Geometry 2.2 Chip
Characterization 2.3 Force –
Process-Geometry Relations 2.4 Stress
and Strain 2.5 Specific Energy
and Force Prediction 2.6 Empirical Specific Energy Modeling |
3 Fundamental Three-Dimensional Processes 3.1 The
Oblique Cutting Process 3.2 The
Turning and Facing Processes 3.3 The Boring Process 4 More Geometrically Complex Machining Processes 4.1 The Face
Milling Process 4.2 The End
Milling Process 4.3 The Drilling Process 5 Machined Surface Characterization 5.1 Overview 5.2 Surface
Error Components 5.3 Surface
Characterization Parameters 5.4 Turning,
Boring, Drilling, and Face Milling 5.5 End Milling |
6 Thermal Energy and Temperature 6.1 Thermal
Energy Generation 6.2 Cutting
Temperature Models 7 Tool Wear, Tool Life and Machining Economics 7.1 Tool Wear
in Cutting 7.2 Tool Life
Models for Cutting 7.3 A Time,
Cost and Profit Model 7.4 Economics-Based Optimization 8 Reality Issues in Machining 8.1 Chip
Control 8.2 Tool
Materials and Selection 8.3 Cutting
Fluids 8.4 Vibration and Chatter |