Machining and Forming Theory and Tools (FSI-GTN)

Academic year 2021/2022
Supervisor: prof. Ing. Milan Forejt, CSc.  
Supervising institute: ÚST all courses guaranted by this institute
Teaching language: Czech
Aims of the course unit:
The objective of the course is for students to master the methods of setting up a computation model necessary for an engineering design of machining technology and metal-forming technology
Learning outcomes and competences:
The knowledge gained enables proposing a technological process of machining or metal-forming, together with the first design and determination of the dimensions of machining or metal-forming tools and the selection of necessary machines.
Prerequisites:
Successful completion of the course is conditional on the knowledge of applied mathematics and physics, materials science, elasticity, strength, and plasticity, and a grasp of the machining and metal-forming technologies.
Course contents:
The course is divided into two parts: theory of machining plus tools, and theory of metal forming plus tools. In the first part, students gain the basic knowledge in the area of taking chips, machining methods and experimentally established relations in the theory of machining. The principles of designing cutting tools are discussed, as well as the optimization of the cutting process, the choice of cutting materials and their effect on the durability and service life of tools. In the second part the students acquire the basic knowledge of and skills in mathematically describing metal-forming processes while applying the physical, chemical, mechanical and thermodynamic principles of the transition of metallic bodies from elastic into plastic state in the course of their plastic deformation into the required shape. Within this subject the loading of the metal-forming tools is dealt with and provisions are made for a first design of the forming machine.
Teaching methods and criteria:
The course is taught through lectures explaining the basic principles and theory of the discipline. Exercises are focused on practical topics presented in lectures.
Assesment methods and criteria linked to learning outcomes:
Conditions of awarding the course-unit credit: participation in exercises, working out the reports set, acceptance of the reports. In justified cases the teacher may set a make-up exercise program. The examination is public, testing the knowledge from both parts of the course, focused on machining and metal-forming.
The exam will have written preparation and oral part. It is classificated to the ECTS grading scale.
Controlled participation in lessons:
Attendance in lectures is recommended.
Attendance in exercises is compulsory.
The attendance to the seminar is regularly checked and the participation in the lesson is recorded.
Absence from laboratory exercises is compensated during course for via make-up topics of exercises and consultations.
Type of course unit:
    Lecture  13 × 2 hrs. optionally                  
    Exercise  13 × 2 hrs. compulsory                  
Course curriculum:
    Lecture 1. Fundamentals of depicting cutting tools.
2. Physical and technological parameters of the cutting process.
3. Mechanism of chip taking, phenomena accompanying the deformation process.
4. Dynamics of the cutting process, force relations for machining methods.
5. Cutting materials and their application.
6. Durability and service life of cutting tools. Optimization of the cutting process.
7. Physical substance of plastic deformation.
8. Formability of metals and alloys. Resistance to deformation.
9. Conditions of the appearance of plastic deformation. Principles of metal-forming.
10. Theory of plastic deformation. Analysis of the deformation process.
11. Methods for solving metal-forming processes.
12. Basic operations of the solid cold and hot metal forming.
13. Basic operations of sheet metal forming.
    Exercise 1. Geometry of the tool edge.
2.Evaluation of experimental dependence relations.
3.Cutting forces, torques and performance in machining.
4.Practical and direct measuring of cutting forces.
5.Calculation of temperature parameters in machining.
6.Establishing the dependence of tool durability on cutting speed. 7.Evaluating the deformation parameters and deformation rates. 8.Evaluating the curves of resistance to deformation.
9.Calculating the resistance to deformation and deformation forces in upsetting.
10.State of stress and forces acting in forward extrusion.
11.Die forging, calculation of forging forces.
12.State of stress, forces and number of drawing operations.
13.State of stress and forces in current and precise shearing.
Literature - fundamental:
1. DAVIS, Joseph R. a Steven R.LAMPMAN. Machining. 9. ed. Metals Park, Ohio: American Society for Metals, 1989. ISBN 08-717-0022-0.
2. MIELNIK, Edward M. Metalworking science and engineering. New York: McGraw-Hill, c1991, 976 p. McGraw-Hill. ISBN 0-704-1904-3.
3. HUMÁR, Anton. Slinuté karbidy a řezná keramika pro obrábění. 1.vyd. Brno: CCB s.r.o. 1995. 266 s. ISBN 80-85825-10-4.
4. BEŇO, Jozef. Teória rezania kovov. Košice: Vienala, 1999, 256 s. ISBN 80-709-9429-0.
5. LANGE, Kurt. Handbook of Metal Forming. New York: McGraw-Hill, c 1985.ISBN 0-07-036285-8
Literature - recommended:
1. FOREJT, Milan a Miroslav PÍŠKA. Teorie obrábění, tváření a nástroje. Brno: A N CERM, 2006. 226 s. ISBN 80-214-2374-9. ( dotisk 2008, 2012, 2015, 2018)
2. FOREJT, Milan. Teorie tváření a nástroje: Učeb. texty. 1.vyd. Brno: Nakl. VUT, 1991, 187 s. ISBN 80-214-0294-6.
3. CHLADIL, Jan a Anton HUMÁR. Teorie obrábění-příklady a cvičení. 1.vyd. Brno: Nakladatelství VUT. 1991.
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
N-VSR-P full-time study --- no specialisation -- Cr,Ex 4 Compulsory-optional 2 1 S