Experimental Methods (FSI-HE1-K)

Academic year 2018/2019
Supervisor: prof. Ing. Milan Forejt, CSc.  
Supervising institute: ÚST all courses guaranted by this institute
Teaching language: Czech
Aims of the course unit:
The goal of the subject is to acquaint the students with special experimental methods, which are necessary when evaluating the functional properties of cutting and forming tools, machinability and formability of materials, in the area of manufacture and research. The significance and application of technical measuring and testing in the development of the machining and metal-forming technologies are emphasized.
Learning outcomes and competences:
Students will be able to creatively participate in performing and evaluating of required experiments in the technological processes of machining and metal-forming. They will be able to recognize proper measuring methods and equipment with automated outputs and evaluation by the help of computer technique.
Prerequisites:
Students are expected to have the knowledge of the theory and technology of machining and forming, fundamentals of metrology (with orientation to measuring of the geometry) and measuring of temperature and mechanical quantities (tensometry).
Course contents:
The course deals with the basic methods of measuring and evaluating the side-effects of machining and metal-forming. They include mechanical testing, qualitative and quantitative evaluation of wear, measuring of cutting forces and resistance, metal-forming and ejecting forces, resistance to plastic strain, strain rates, temperature & heat, and oscillation. The evaluation is dealt with the viewpoint of individual methods of machining and metal-forming and the operating conditions of the tool. Applications of the methods of light and electron microscopy when evaluating the morphology of the surface of tools and workpieces are discussed too.
Teaching methods and criteria:
The course is taught through lectures explaining the basic principles and theory of the discipline. Teaching is suplemented by practical laboratory work.
Assesment methods and criteria linked to learning outcomes:
Conditions for awarding of the course-unit credit: participation in exercises, fulfilling the assignments, and submitting written reports of required content and graphic forms. If these conditions are not satisfied, the tutor may define alternative conditions, in justified cases. In the examination, which is written and oral, the theoretical knowledge of lectured problems of machining and metal-forming is checked. It is classificated to the ECTS grading scale.When awarding the mark, the evaluation of the student by the tutor can be taken into account.
Controlled participation in lessons:
- Attendance in lectures is recommended. Attendance in exercises is compulsory. Attendance at lessons is required and checked by the tutor. One absence can be compensated by attending a seminar with another group, or by elaboration of substitute tasks. Longer absence is may be compensated for via special tasks by the agreement with the tutor.
The attendance to the seminar is regularly checked and the participation in the lesson is recorded.
Type of course unit:
    Guided consultation  1 × 9 hrs. optionally                  
    Laboratory exercise  1 × 9 hrs. compulsory                  
    Controlled Self-study  1 × 34 hrs. optionally                  
Course curriculum:
    Guided consultation 1.Tool wear (criteria, measuring methods and equipment)
2.Heat and temperature (measuring methods, detection devices, processing)
3.Cutting forces and resistances (dynamometers, detection and evaluation of quantities)
4.Vibration (principles, experimental devices, detectors, instruments)
5.Microscopy methods (analysis of the morphology of the surface of tools and workpieces on scanning electron microscope)
6.Evaluation of properties of cutting tool materials
7.Complete evaluation of cutting tools properties
8.Experimental technological testing of bulk formability
9.Testing aimed at establishing the wear coefficient and the effect of lubricants in metal forming
10.Experimental testing of non-uniform distribution of deformation
11.Measuring the forming and ejecting forces, determining the state of stress
12.Establishing the resistance to deformation at higher strain speeds
13.Establishing the dynamic and mechanical properties of materials
    Laboratory exercise 1.Measuring the tool wear in the course of operation, data evaluation
2.Establishing the tool life/cutting speed dependence from the wear values
3.Analysis of cutting properties of drills
4.Analysis of cutting properties of milling cutters
5.Establishing the torque when cutting the thread with a nut tap
6.Analysis of energetic and thermal phenomena in grinding
7.Analysis of properties of processing liquids
8.Complex upsetting test, evaluation of the resistance to deformation, deformation work, and rate of deformation
9.Establishing the wear coefficient during the metal-forming process
10.Evaluation of strain by the macro-network method
11.Establishing the impact forces and stress in the Taylor test
12.Conducting the Taylor test on an air gun and evaluating the test
13.Establishing the dynamic-mechanical properties of materials by the method of Hopkinson bar test
    Controlled Self-study 1.Tool wear (criteria, measuring methods and equipment)
2.Heat and temperature (measuring methods, detection devices, processing)
3.Cutting forces and resistances (dynamometers, detection and evaluation of quantities)
4.Vibration (principles, experimental devices, detectors, instruments)
5.Microscopy methods (analysis of the morphology of the surface of tools and workpieces on scanning electron microscope)
6.Evaluation of properties of cutting tool materials
7.Complete evaluation of cutting tools properties
8.Experimental technological testing of bulk formability
9.Testing aimed at establishing the wear coefficient and the effect of lubricants in metal forming
10.Experimental testing of non-uniform distribution of deformation
11.Measuring the forming and ejecting forces, determining the state of stress
12.Establishing the resistance to deformation at higher strain speeds
13.Establishing the dynamic and mechanical properties of materials
Literature - fundamental:
1. BROCH, J.T. Mechanical vibration and Shock Measurements. K.Larsen a Son A/S, Glostrup, Denmark, 1984. 370 s. ISBN 87 87355 36.1.
2. Group of authors: Metals Handbook, Volume 8, Mechanical Testing, ASM 1985.
3. VELES, P. Mechanické vlastnosti a skúšanie kovov. Edícia hutníckej literatúry, ALFA Bratislava, SNTL Praha, 1985.401 s. 63-559-85.
4. MEYERS, M. A.: Dynamic Behaviour of Materials. A Wiley-Interscience Publication, John Wiley & Soins,Inc. New York, Toronto,1994. p 668. ISBN 0-471-58262-X.
Literature - recommended:
1. Medek, J.: Experimentální metody. VUT Brno, 1993.
2. ČECH, J., PERNIKÁŘ, J., BENEŠ, M. Strojírenská metrologie. Skriptum VUT v Brně. PC DIR s.r.o. Brno, 1994. 166 s. ISBN 80-214-0557-0.
3. MELOUN, M., MILITKÝ, J. Statistické zpracování experimentálních dat. PLUS s.r.o. Praha, 1994. 839 s. ISBN 80-85297-56-6.
4. Forejt., M., Humár, A., Píška, M., Janíček, L.: Experimentální metody. [online]. Studijní opory pro magisterský studijní program 23-01-T Strojní inženýrství, obor strojírenská technologie - obrábění - tváření, svařování - management, VUT v Brně, Fakulta strojního inženýrství, 2003. Dostupné na World Wide Web: http://www.fme.vutbr.cz/opory/pdf/ust/Exp.metod/Experimentalni%20metody%20he2.pdf
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
M2I-K combined study M-STG Manufacturing Technology -- Cr,Ex 6 Compulsory 2 2 W
M2I-K combined study M-STM Manufacturing Technology and Management in Industry -- Cr,Ex 4 Compulsory-optional 2 2 W