Machining of cast materials (FSI-POL)

Academic year 2019/2020
Supervisor: Ing. Karel Osička, Ph.D.  
Supervising institute: ÚST all courses guaranted by this institute
Teaching language: Czech
Aims of the course unit:
The goal of the subject involves the application of material science, construction of machines and equipment, methods of checking materials when machining metal materials with conventional and CNC technology.
Learning outcomes and competences:
Students will acquire knowledge of qualified technological process selection, including foundry technology. They will be able to select proper clamping of workpieces, production (cutting) conditions, cutting tools and materials, do workpiece checks, calculate production times and production costs.
Prerequisites:
Knowledge obtained in the course of previous study, namely in the fields of theory and technology of machining, material science, metrology, mathematics, physics, structures and properties of cast materials.
Course contents:
The subject is devoted to the improvement of student´s knowledge in the field of machining of cast materials.
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:
Course unit credit requirements:
-participation in the exercises,
-delivery of assigned papers.
The exam will be written and oral and the resulting classification will be in accordance with Article 12 and 13 of the current BUT Study and Examination Regulations.
Controlled participation in lessons:
Attendance at all exercising. Substitution in other exercising, or essay of current assignment.
Type of course unit:
    Lecture  13 × 2 hrs. optionally                  
    Laboratory exercise  13 × 2 hrs. compulsory                  
Course curriculum:
    Lecture 1. Basics of machining technology
2. Turning (cutting charts)
3. Milling (cutter)
4. Drilling
5. Analysis of machining allowances for castings, inter-operative additions
6. Cutting forces and machining performance of bark and interrupted cuttings
7. Definition and selection of technological bases, clamping of castings
8. Grinding - treatment of castings
9. Fundamentals of technological procedures, sequence of technological operations
10. Technology processes, rotating components
11. Technology processes, non-rotational components
12. Machining technology on CNC machines - choice of technology, basics of programming.
13. Machinability of cast materials - cast iron, steel, light (Cl, Mg) alloys, heat alloys, refractory alloys, titanium alloys
    Laboratory exercise 1. Basic technological calculations for machining vc, f, fz, gauge
2. Cochipping coefficient of chips,
3. Tool geometry, cutting charts (construction calculations)
4. Cutting materials for machining metal castings, selection of cutting conditions from databases - work with the catalog
5. Machining allowances for castings, calculation of inter-operational allowances
6. Cutting force calculations
7. Cutting forces, methodology for determining coefficients
8. Machinability factor
9. Technological process of machining of cast parts
10. Technological process of machining of cast parts
11. Technological process of machining of cast parts
12. Presentation of seminar papers
13. Determination of production costs and time, optimization
Literature - fundamental:
1. AB SANDVIK COROMANT - SANDVIK CZ s.r.o. Příručka obrábění - Kniha pro praktiky. (Přel. z: Modern Metal Sutting - A Practical Handbook. Překlad M. Kudela.), 1. vyd. Praha: Scientia, s. r. o.,1997. 857s., ed. J. Machač, J. Řasa. ISBN 91-97 22 99-4-6.
2. WALKER, J.R. Machining Fundamentals. The Goodheart-Wilcox Company, Inc., Tinlez Park, Illinois, 7th ed., 2004, pp. 640, ISBN 1-59070-249-2.
3. TRENT, E.M., WRIGHT, P.K. Metal Cutting. Fourth Edition. Butterworth-Heinemann. Boston, Oxford, Auckland, Johannesburg, Melbourne, New Delhi, 2000. pp. 446. ISBN 0-7506-7069-X.
4. HUMÁR, Anton. a Miroslav PÍŠKA, Moderní řezné nástroje a nástrojové materiály. MM Průmyslové spektrum. Speciální vydání včetně CD, Praha: 2004, 110 s., ISSN 1212-2572.
Literature - recommended:
1. FOREJT, Milan a Miroslav PÍŠKA. Teorie obrábění, tváření a nástroje. 1. vydání. Brno: Akademické nakladatelství CERM, s.r.o., 2006, 225 s. ISBN 80-214-2374-9.
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
M2I-P full-time study M-SLE Foundry Technology -- Cr,Ex 5 Compulsory 2 1 W