ME 3217 Meta Cutting

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ME 3217

Metal Cutting Principles

Fall 2013

Instructor: Dr. B. Zhang Lab Sections:UTEB Room 384; Phone: 860-486-2072 Tue. 12:00-2:00 Tue. 2:00-4:00Instructor Email: [email protected] Thu. 2:00-4:00Instructor Office Hours 10:00 - 11:00 (Mon & Wed) Lab Room: CAST 128Class Hours: 11:15-12:05 (Mon & Wed) TA: Daniel CoxeClassroom: CAST 201 TA Phone: 860-501-8093

HuskyCT: All Course Materials TA Email: [email protected]

Course Description: Examination of metal cutting processes including turning, milling, drilling, andgrinding, as well as various nontraditional machining processes. Mechanics of two and threedimensional cuttings. Principles and mechanisms of wear. Tool materials. Theoretical prediction ofcutting forces and energies, as well as tool life. Chemistry of cutting fluids. Laboratory periodincluding operation of machine tools; Experimental determination of cutting energies and forces,lubrication effects and tool life, as well as CNC programming. The interrelationship between theseand practical metal cutting conditions.

Textbook:Kalpakjian & Schmid, Manufacturing Engineering and Technology, 7th Ed., Pearson, 2014.

References:

Mikell P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing,3

rdEd., Pearson Education Inc., 2008.

J.T. Black & R.A. Kohser, Materials & Processes in Manufacturing, 10th

Ed., John Wiley & Sons,Inc., 2008.

Mikell P. Groover, Fundamentals of Modern Manufacturing - Materials, Processes, and Systems

-, John Wiley & Sons, 1996.

Phillip F. Ostwald and Jairo Munoz, Manufacturing Processes and Systems, 9th Ed., John Wiley &

Sons, 1997.

Sherif D. El Wakil, Processes and Design for Manufacturing, 2nd Ed., PWS Publishing Company,1998.

Course Objectives:

The course is designed for students to

gain fundamental knowledge on various material removal processes practiced in modern industry,and analyze these processes through meetings, assignments, labs and reports;

apply such knowledge to solving problems encountered in material removal processes; perform force analyses based on cutting mechanics, and identify tool wear and predict tool life

based on Taylor tool life equation, evaluate lubrication and cooling effects of cutting fluids;

interpret the underlying physics/mechanics in material removal processes, both traditional andnontraditional;

select cutting tool materials and configure tool geometry, select machining processes andconditions for metal cutting;

balance tradeoffs involved in choosing machine tools and processes.


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Outcome Measurements: There are five components to the determination of the final grade. These arehomeworks, quizzes, lab reports, midterm exam, and final exam.

Outcome MeasurementsHomeworks (6) 18%Quizzes (5) 15%Midterm Exam 15%Final Exam 25%Lab Reports (3) 27%

100%

CLASS POLICIES:Classes will be conducted as lecture and lab sessions, covering materials as indicated in the attachedLecture Schedule. Students are encouraged to raise questions or topics for class discussion and toparticipate in such discussions. Participation (attitude, punctuality, attendance, etc.) in the class interms of regular attendance is an important component for your evaluation. As a responsible andmature individual, you are expected to be present in all classes. Failure to attend more than 50% ofpresented lectures and labs will result in failure of the class unless extenuating circumstances exist.The work in the class and the lab requires your continued attention in maintaining the regular flow ofinformation to you. If you miss any particular lab, then it becomes your responsibility to have a makeup for the lab. We will not be repeating the lab already conducted, and would expect all to be up-to-date to follow the lab sequence.

EXAM/QUIZ POLICIES:

All exams and quizzes will generally be closed book/notes. They may consist of a combination ofmultiple choices, short problems, long problems, fill in the blank and/or True/False. Students will

be allowed to bring one 8.5 11 sheet of notes for reference. Other information needed to solveproblems will be provided.

This course covers a substantial body of material. Limited class meeting time will not allow us tocover in class all of the material in the reading assignments. Exams may cover the materials in thereading assignments that were not discussed in class.

The dates and times for the exams appear in the Lecture Schedule attached. No makeup examswill be given, except for documented medical reasons, etc. Please schedule your other activitiesaccordingly. An absence on exam day results in a zero for that exam.

HOMEWORK/PROJECT POLICIES:Generally, homework is due one week after it is assigned. Students are permitted to discuss your

homework with classmates. However, I strongly encourage you to work independently. In caseswhere more than one solution is presented for a problem, the one with more errors will be graded.This holds for both homeworks and exams. Solutions will be posted onto the HuskyCT website. Nodelayed homework nor project report will be considered for any points unless a good excuse isprovided.

Homework must be neat, readable, and show all major steps; Answers must be boxed and clearly visible; Must be on 8.5 11 paper with no ragged edges; Use margins: 1" all around; Must be stapled in order of the assignment; Must have the assignment number, students name, and due date in the upper right hand corner of

the first sheet;

Must be turned in at the START of class on the due date;


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Students are encouraged to discuss the homework with their classmates. However, each studentmust provide his/her own unique solution.

Copying of homework answers of any kind will be treated as academic dishonesty.ACADEMIC INTEGRITY:

Cheating of any kind on examinations and/or plagiarism of reports or projects is strictly prohibited.Any one caught passing off the work of others as their own (i.e., copying from a book/journal or cutand past from internet sources without appropriate citation) runs the risk of immediately failing thecourse and expulsion from the class and the University. For more institutional rules regardingacademic honesty, please read the University policy on Academic Integrity in UndergraduateEducation and Research.(http://www.dosa.uconn.edu/student_code.cfm).

SPECIAL NEEDS:The Americans with disability Act of 1990 provides protection from illegal discrimination forqualified individuals with disabilities. Students requesting instructional accommodations due to

disabilities must arrange for such accommodation through the Center for Students with Disabilities.The Center is located in 233 Glenbrook Road, Unit 4174, Wilbur Cross Building, Room 201, Storrs,(860) 486-2020 (Voice); (860) 486-2077 (TDD); (860) 486-4412 (FAX).


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Lecture Schedule

Week Day Date Topics Reading

1 Mon 8/26 Course Information & Introduction Chap. 21Wed 8/28 Fundamentals of Machining Chap. 21

2 Mon 9/2 Labor Day (No Class)

Wed 9/4 Fundamentals of Machining Chap. 21

3 Mon 9/9 Fundamentals of Machining Chap. 21

Wed 9/11 Fundamentals of Machining Chap. 21

4 Mon 9/16 Fundamentals of Machining Chap. 21

Wed 9/18 Cutting Tool Materials & Cutting Fluids Chap. 22

5 Mon 9/23 Cutting Tool Materials & Cutting Fluids Chap. 22

Wed 9/25 Machining Processes: Turning and Hole Making Chap. 23

6 Mon 9/30 Machining Processes: Turning and Hole Making Chap. 23

Wed 10/2 Machining Processes: Milling and Others Chap. 24

7 Mon 10/7 Machining Processes: Milling and Others Chap. 24

Wed 10/9 Midterm Exam

8 Mon 10/14 Review of Midterm Exam Chap. 37

Wed 10/16 Automation of Manufacturing Processes Chap. 37

9 Mon 10/21 Automation of Manufacturing Processes Chap. 37

Wed 10/23 Automation of Manufacturing Processes Chap. 3710 Mon 10/28 Machining Centers & Machine Tool Structures Chap. 25

Wed 10/30 Machining Centers & Machine Tool Structures Chap. 25

11 Mon 11/4 Abrasive Processes & Finishing Operations Chap. 26

Wed 11/6 Abrasive Machining & Finishing Operations Chap. 26

12 Mon 11/11 Abrasive Machining & Finishing Operations Chap. 26

Wed 11/13 Abrasive Machining & Finishing Operations Chap. 26

13 Mon 11/18 Advanced Machining Processes and Equipment Chap. 27

Wed 11/20 Advanced Machining Processes and Equipment Chap. 27

14 Thanksgiving Recess

15 Mon 12/2 Advanced Machining Processes and Equipment Chap. 27

Wed 12/4 Review for Final Exam Chap. 27

16 Wed 12/11 Final Examination 10:30-12:30NOTE 1: All class assignments and announcements are posted on HuskyCT.

NOTE 2: All homework assignments and due dates will be announced in the class.NOTE 3: Cell phones and other communications devices are to be set on vibration mode during class & exams.


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Lab Schedule

Week Date Topics

1 8/26-8/30 No Lab

2 9/2-9/6 Lab Safety and Machine Shop Tour

3 9/9-9/13 Machine Shop Operations (Metrology)

4 9/16-9/20 Machine Shop Practice (Measurement) Measurement due

5 9/23-/927 Machine Shop Practice (Tool Grinding)

6 9/30-10/4 Machine Shop Practice (Tool Grinding)

7 10/7-10/11 Machine Shop Practice (Lathe Operation)

8 10/14-10/18 Machine Shop Practice (Tensile Specimen)

9 10/21-10/25 Preparation for Experiments

10 10/28-11/1 Experiments 1, 2, 3 by Groups A, B, C

11 11/4-11/8 Experiments 2, 3, 1 by Groups A, B, C 1st report due

12 11/11-11/15 Experiments 3, 1, 2 by Groups A, B, C 1st report back

2nd

report due

13 11/18-11/22 Catch up 3rd report due

14 11/25-11/29 Thanksgiving Recess

15 12/2-12/6 Reading

16 12/11 Final Examination 10:30-12:30


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Machine Shop Safety Acknowledgement

General rules to follow:

Wearing eye protection in designated working areas; No loose fitting sweaters or clothing; No short pants or sandals; Removing rings, jewelry and ties before working; Being in full control of your machine at all times; Seeking help anytime when you feel not OK; Reporting any accident or broken tool immediately; Cleaning of tools, machines, and work areas after use;

Some Nevers

Never operate a machine unless you know what each switch, lever, knob, etc. does; Never operate a machine unless all guards are in place; Never make measurements or adjustments while the machine is running; Never touch the workpiece surface while the machine is running; Never attempt to remove metal chips or cuttings with your hands; Never disengage your brain during operation.

ME 3217 Meta Cutting

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