Machining of cast materials (FSI-POL)

Academic year 2022/2023
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. Cast materials in engineering, types, production, handling, use.
2. Properties of cast materials, machinability.
3. Material additions on castings, technological construction, effects on machining.
4. Milling theory. Company catalogs. Videos from real processes.
5. Drilling theory. Company catalogs. Videos from real processes.
6. Turning theory. Company catalogs. Videos from real processes.
7. Technology of machining non-rotating shapes of castings. Machines, clamps, tools.
8. Technology of machining rotary shapes of castings. Machines, clamps, tools.
9. CNC machines for machining castings. Machine equipment. Manual adjustment of castings.
10. Control processes in piece and series production, gauges, frequency.
11. Production equipment costs. Automation and robotics.
12. Management and organization of production processes. Solution of production outages.
13. Presentation of semester work. Credit.
    Laboratory exercise

1. Assignment of drawings of components for semester work (pulleys, lid, valve).
2. Casting design for specified drawings, ie semi-finished product for machining.
3. Creating a construction drawing of a casting.
4. Project of a specific milling operation. Demonstrations in the school workshop.
5. Project of a specific drilling operation. Demonstrations in the school workshop.
6. Project of a specific turning operation. Demonstrations in the school workshop.
7. Design of technological process for non-rotating shape casting.
8. Design of technological process for rotary casting.
9. Block diagram of NC program for more complex casting (gearbox, lever).
10. Evaluation of the quality of machined surfaces, quantities Ra, Rz.
11. Statistical capture of deviations of produced dimensions.
12. Compilation of process diagrams. Proof of alternative technology.
13. Presentation of semester work. Credit.
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.
5. HUMÁR, Anton. Materiály pro řezné nástroje. 1. vyd. Praha: MM publishing, s. r. o., 2008. 240 s. ISBN 978-80-254-2250-2.
6. FOREJT, Milan a Miroslav PÍŠKA. Teorie obrábění, tváření a nástroje. 1. vyd. Brno: CERM, s. r. o., 2006. 225 s. ISBN 80-214-2374-9.
7. ZEMČÍK, Oskar. Nástroje a přípravky pro obrábění. 1. vyd. Brno: CERM, s. r. o., 2003. 193 s. ISBN 80-214-2336-6.
8. PTÁČEK, Luděk et al. Nauka o materiálu I. 2. vyd. Brno: CERM, s. r. o., 2003. 516 s. ISBN 80-720-4283-1.
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  
CŽV full-time study CZV Bases of Mechanical Engineering -- Cr,Ex 5 Compulsory 1 1 W
N-SLE-P full-time study --- no specialisation -- Cr,Ex 5 Compulsory 2 1 W