Course syllabus

Course-PM

MTT108  Metal cutting lp2 HT24 (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

Guest lecturers                        Denis Boing (DB), Sandvik Coromant denis.boing@sandvik.com

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

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

                                                   Luis Franca(LF), Element Six luiz.franca@e6.com

                                                   Philipp Hoier (PH), Chalmers hoierp@chalmers.se

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

Books / eBooks (Available online at Chalmers library):

• Smith, G. T., 2008, Cutting tool technology: industrial handbook. London: Springer
• 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. 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. Hence, the final (industry) assignment is collaboratively developed in partnership with prominent manufacturing enterprises. Furthermore, 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), and three assignments: 1. tool life estimation, 2. modelling of cutting forces in the turning process, and 3. tool condition monitoring – basics of signal processing. The course also includes two demonstrations of machining processes (turning and milling) and measured experimental data will be the base for assignments 2 and 3. Reports are to be prepared and handed in for all assignments through the course home page.

Changes made since the last occasion

A few lectures were updated (cast irons, cutting data optimisation). In particular, an additional lab is designed to demonstrate how to cope with chatter and vibration in milling + a new lab/demonstration on CAD/CAM in SolidWorks to show how one can optimise the machining process as (one of) the last steps in the value-chain.

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 investment 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 basis of 3, 4, and 5. 80% attendance at lectures is required. Attendance and passing of labs/assignments including reports, is a specific requirement of the course to achieve grade 3. To acquire grades 4 and 5, students should attain >60% and >80% of total points from the handed-in exercises, covering the content of the previous lectures. Additional studies-assignment may be applicable for those students who fail to fulfil the requirements above; these will be consulted individually with the course examiner.