Course code: MM207E02

Semester: 7th - Direction: Design & Manufacturing

Specialization Category: OCD2

Course Hours: 4

ECTS: 4

i. Learning outcomes

Upon successful completion of this course, the student will be able to:

• Recognize and select cutting tools and fluids, suitable for different machining processes and materials' grades.
• Predict the cutting surface quality based on machining parameters, via advanced statistics techniques (Taguchi, Artificial Neural Networks).
• Evaluate per material grade, the morphology and characteristics of the removed material, in order to propose optimisation actions (e.g. chemical composition differentiation) that could lead to machinability amelioration.

ii. General competences

• Search, extraction, analysis and synthesis of scientific data and knowledge, using screening of large scientific databases.
• Decision making on the particular item of materials selection
• Understanding the requirements for generic approaches in a worldwide environment.
• Capability of performing individual working case studies
• Capability of performing team-working case studies
• Ability to approach the trans-scientific and multi-disciplinary character of various engineering applications

iii. Syllabus

This course is focused on providing deeper knowledge on conventional material removal techniques, based on the use of cutting tools of specific geometry that operate under simple or multiple contact with the workpiece. In this perspective, special emphasis is given in the Merchant theory for the calculation of the forces developed at the cutting neighbourhood, the techniques for direct and indirect evaluation of the machining process, as well as the effects of primary and secondary motion on the process stability. Finally, the morphology and the characteristics of the removed material are used for the optimisation of the cutting tools lifetime per machined material grade.

iv. Student performance evaluation

Theory: Intermediate assessment and written final examination. Laboratory: evaluation of practical skills and multiple-choice exams.

v. Suggested bibliography

• Kalpakjian S., Schimd S. (2019) Manufacturing Engineering and Technology. Tsiolas publications.
• Schey, J.A. (2000). Introduction to Manufacturing Processes. McGraw-Hill Education.
• Handbook of Workability and Process Design (2003). G.E. Dieter, H.A. Kuhn, S.L. Semiatin (editors), ASM International.