436-440 Material Removal Processes 2

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Objectives:

On completion, students should understand:

• the basic cutting action, performance, capabilities and latest development in abrasive processes;

• the development and computerisation of fundamental mechanics of cutting models for the major machining operations such as milling for tool design and performance prediction;

• the fundamentals of tool wear, tool-life and computer based optimisation of single and multi-pass machining operations for use in process planning.

Content:

Abrasive processes: grinding, honing, lapping and super finishing. Bulk material removal processes: mechanics of cutting; analyses of single point and multi point tool processes; machining with form tools, turning, drilling, milling and rotary tool operations. Wear theories and tool-life. Machinability of materials. Computer-aided prediction of machining performance. Economics of material removal processes: objective functions and constrained optimisation of process variables for single and multi-pass machining operations such as turning, drilling and milling. Computer-aided optimisation for off-line process planning and canned cycles for CNC machine tool controllers.

Assessment: