Course syllabus

Course-PM

MTT107 MTT107 Metal cutting lp2 HT22 (7.5 hp)

Course is offered by the department of Industrial and Materials Science

Contact details

Examiner                                  Amir Malakizadi (AM), Chalmers (amir.malakizadi@chalmers.se)

Lecturers                                    Peter Krajnik (PK), Chalmers (peter.krajnik@chalmers.se)

Guest lecturers                        Susanne Norgren (SN), Sandvik Coromant (susanne.m.norgren@sandvik.com)

                                                   Sören Hägglund (SH), Seco Tools (soren.hagglund@secotools.com)

                                                   Rachid M’Saoubi (RS), Seco Tools (rachid.Msaoubi@secotools.com)

                                                   Anders Liljerehn, Sandvik Coromant (anders.c.liljerehn@sandvik.com)

                                                   Chris Graham (CG), Element Six (Chris.Graham@e6.com)    

                                                   Bharath Mandara (BM), Volvo Cars (bharath.mandara@volvocars.com)

Student  administration:         Hanije Safakar, Chalmers (hanije@chalmers.se)

Course purpose

Learning outcomes (after completion of the course the student should be able to)

• Understand the basics of applied metrology, workpiece quality and functional surfaces.
• Recognize diverse machining operations and gain insight into their industrial applications.
• Learn the basic concepts of machine tools and process-machine interactions.
• Obtain knowledge of cutting tools and cutting-tool materials.
• Gain an understanding of machining with abrasives - including grinding and fine-finishing technology.
• Apply modelling of machining operations using numerical and empirical methods.
• Use laboratory equipment to assess machining quality.
• Apply sustainability aspects to manufacturing technology.
• Learn about production engineering management and investment projects.
• Develop teamwork skills in an engineering context to solve real-life industrial manufacturing problems.

Schedule

TimeEdit

Course literature

• Klocke, F., 2011. Manufacturing Processes 1 – Cutting. Springer-Verlag Berlin Heidelberg.
• Klocke, F., 2009. Manufacturing Processes 2 – Grinding, honing, lapping. Springer-Verlag Berlin Heidelberg.
• Toenshoff, H.K. and Denkena, B., 2013. Basics of cutting and abrasive processes. Springer-Verlag Berlin Heidelberg.
• Trent, E.M. and Wright, P.K., 2000. Metal cutting. Butterworth-Heinemann.
• Tschätsch H., 2010, Applied Machining Technology. Springer Science & Business Media.

Course design

The course includes lectures, case studies, tutorials/lab exercises, group assignments and presentations. A typical case study will examine scientific development and industrial end-use of manufacturing processes and machines. The group assignments will form the basis for developing team-based engineering skills, needed to solve real manufacturing problems in the industry. For this, a study visit to a manufacturing plant will be organized to experience machining on a large scale. The course has strong links with the Chalmers Centre for Metal Cutting Research (MCR) and is designed to usefully propagate the current state-of-the-art in manufacturing. Therefore, guest lectures from experts in the industry (e.g., Sandvik Coromant, Seco Tools and Element Six) will provide students with a unique opportunity to learn key competencies required in real-world production. The course has no exam; therefore, the attendance of lectures (min. 80%) and lab exercises (100%) is compulsory. The lectures will be given in English. Prior knowledge of MATLAB programming is helpful, but not necessary. A short introduction to MATLAB will be given.

The course consists of one lab/tutorial (Finite Element Modelling of the cutting process), three assignments: 1. modelling of cutting forces in the turning process and 2. tool life estimation, 3. Tool wear monitoring – basics of signal processing. The course also includes a demonstration of machining processes and experimental activities for metal-cutting research. Reports are to be prepared and handed in for all assignments (through the course home page; or as agreed with the teacher). The deadlines for submission of assignments will be decided during the course. 

Changes made since the last occasion

Additional sessions can be added to teach MATLAB software upon request. A few lectures were updated. In particular, the lab was revised to engage the students more and lectures on tool wear monitoring and robotic machining are included. An expert from Volvo Cars is invited to give a lecture on Robotic machining. 

Learning objectives and syllabus

Learning objectives:

• Understand the basics of applied metrology, workpiece quality and functional surfaces.
• Recognize diverse machining operations and gain insight into their industrial applications.
• Learn the basic concepts of machine tools and process-machine interactions.
• Obtain knowledge of cutting tools and cutting-tool materials.
• Gain an understanding of machining with abrasives - including grinding and fine-finishing technology.
• Apply modelling of machining operations using numerical and empirical methods.
• Use laboratory equipment to assess machining quality.
• Apply sustainability aspects to manufacturing technology.
• Learn about production engineering management and investments projects.
• Develop teamwork skills in an engineering context to solve real-life industrial manufacturing problems.

Link to the syllabus on Studieportalen.

Study plan

Examination form

The grading of the course will be on a pass/fail basis. 80% attendance at lectures is required. Attendance and passing of labs/assignments including reports is a specific requirement of the course. Additionally, students should answer a short quiz from the previous lecture/topic (two questions) at the beginning of some lectures and acquire 50% of the total score. Industry assignments also include compulsory (online) attendance and presentations. Additional studies-assignment may be applicable for those students who fail to fulfill the requirements above; these will be consulted individually with the course examiner.