ME 3217

Metal Cutting Principles

Fall 2013 Instructor: Dr. B. Zhang UTEB Room 384; Phone: 860-486-2072 Instructor Email: zhang@engr.uconn.edu Instructor Office Hours 10:00 - 11:00 (Mon & Wed) Class Hours: 11:15-12:05 (Mon & Wed) Classroom: CAST 201 HuskyCT: All Course Materials Lab Sections: Tue. 12:00-2:00 Tue. 2:00-4:00 Thu. 2:00-4:00 Lab Room: CAST 128 TA: Daniel Coxe TA Phone: 860-501-8093 TA Email: Daniel.coxe@uconn.edu

Course Description: Examination of metal cutting processes including turning, milling, drilling, and grinding, as well as various nontraditional machining processes. Mechanics of two and three dimensional cuttings. Principles and mechanisms of wear. Tool materials. Theoretical prediction of cutting forces and energies, as well as tool life. Chemistry of cutting fluids. Laboratory period including operation of machine tools; Experimental determination of cutting energies and forces, lubrication effects and tool life, as well as CNC programming. The interrelationship between these and practical metal cutting conditions. Textbook: Kalpakjian & Schmid, Manufacturing Engineering and Technology, 7th Ed., Pearson, 2014. References: Mikell P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing, 3rd Ed., Pearson Education Inc., 2008. J.T. Black & R.A. Kohser, Materials & Processes in Manufacturing, 10th Ed., John Wiley & Sons, Inc., 2008. Mikell P. Groover, Fundamentals of Modern Manufacturing - Materials, Processes, and Systems -, John Wiley & Sons, 1996. Phillip F. Ostwald and Jairo Munoz, Manufacturing Processes and Systems, 9th Ed., John Wiley & Sons, 1997. Sherif D. El Wakil, Processes and Design for Manufacturing, 2nd Ed., PWS Publishing Company, 1998. Course Objectives: The course is designed for students to gain fundamental knowledge on various material removal processes practiced in modern industry, and analyze these processes through meetings, assignments, labs and reports; apply such knowledge to solving problems encountered in material removal processes; perform force analyses based on cutting mechanics, and identify tool wear and predict tool life based on Taylor tool life equation, evaluate lubrication and cooling effects of cutting fluids; interpret the underlying physics/mechanics in material removal processes, both traditional and nontraditional; select cutting tool materials and configure tool geometry, select machining processes and conditions for metal cutting; balance tradeoffs involved in choosing machine tools and processes. 1

Outcome Measurements: There are five components to the determination of the final grade. These are homeworks, quizzes, lab reports, midterm exam, and final exam. Outcome Measurements Homeworks (6) Quizzes (5) Midterm Exam Final Exam Lab Reports (3) 18% 15% 15% 25% 27% 100% CLASS POLICIES: Classes will be conducted as lecture and lab sessions, covering materials as indicated in the attached Lecture Schedule. Students are encouraged to raise questions or topics for class discussion and to participate in such discussions. Participation (attitude, punctuality, attendance, etc.) in the class in terms of regular attendance is an important component for your evaluation. As a responsible and mature individual, you are expected to be present in all classes. Failure to attend more than 50% of presented lectures and labs will result in failure of the class unless extenuating circumstances exist. The work in the class and the lab requires your continued attention in maintaining the regular flow of information to you. If you miss any particular lab, then it becomes your responsibility to have a make up for the lab. We will not be repeating the lab already conducted, and would expect all to be up-todate to follow the lab sequence. EXAM/QUIZ POLICIES: All exams and quizzes will generally be closed book/notes. They may consist of a combination of multiple choices, short problems, long problems, fill in the blank and/or True/False. Students will be allowed to bring one 8.5 11 sheet of notes for reference. Other information needed to solve problems will be provided. This course covers a substantial body of material. Limited class meeting time will not allow us to cover in class all of the material in the reading assignments. Exams may cover the materials in the reading assignments that were not discussed in class. The dates and times for the exams appear in the Lecture Schedule attached. No makeup exams will be given, except for documented medical reasons, etc. Please schedule your other activities accordingly. An absence on exam day results in a zero for that exam. HOMEWORK/PROJECT POLICIES: Generally, homework is due one week after it is assigned. Students are permitted to discuss your homework with classmates. However, I strongly encourage you to work independently. In cases where more than one solution is presented for a problem, the one with more errors will be graded. This holds for both homeworks and exams. Solutions will be posted onto the HuskyCT website. No delayed homework nor project report will be considered for any points unless a good excuse is provided. Homework must be neat, readable, and show all major steps; Answers must be boxed and clearly visible; Must be on 8.5 11 paper with no ragged edges; Use margins: 1" all around; Must be stapled in order of the assignment; Must have the assignment number, students name, and due date in the upper right hand corner of the first sheet; Must be turned in at the START of class on the due date; 2

Students are encouraged to discuss the homework with their classmates. However, each student must provide his/her own unique solution. Copying of homework answers of any kind will be treated as academic dishonesty.

ACADEMIC INTEGRITY: Cheating of any kind on examinations and/or plagiarism of reports or projects is strictly prohibited. Any one caught passing off the work of others as their own (i.e., copying from a book/journal or cut and past from internet sources without appropriate citation) runs the risk of immediately failing the course and expulsion from the class and the University. For more institutional rules regarding academic honesty, please read the University policy on Academic Integrity in Undergraduate Education and Research. (http://www.dosa.uconn.edu/student_code.cfm). SPECIAL NEEDS: The Americans with disability Act of 1990 provides protection from illegal discrimination for qualified individuals with disabilities. Students requesting instructional accommodations due to disabilities must arrange for such accommodation through the Center for Students with Disabilities. The Center is located in 233 Glenbrook Road, Unit 4174, Wilbur Cross Building, Room 201, Storrs, (860) 486-2020 (Voice); (860) 486-2077 (TDD); (860) 486-4412 (FAX).

Lecture Schedule
Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Mon Wed Wed 12/2 12/4 12/11 Day Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Mon Wed Date 8/26 8/28 9/2 9/4 9/9 9/11 9/16 9/18 9/23 9/25 9/30 10/2 10/7 10/9 10/14 10/16 10/21 10/23 10/28 10/30 11/4 11/6 11/11 11/13 11/18 11/20 Topics Course Information & Introduction Fundamentals of Machining Labor Day (No Class) Fundamentals of Machining Fundamentals of Machining Fundamentals of Machining Fundamentals of Machining Cutting Tool Materials & Cutting Fluids Cutting Tool Materials & Cutting Fluids Machining Processes: Turning and Hole Making Machining Processes: Turning and Hole Making Machining Processes: Milling and Others Machining Processes: Milling and Others Midterm Exam Review of Midterm Exam Automation of Manufacturing Processes Automation of Manufacturing Processes Automation of Manufacturing Processes Machining Centers & Machine Tool Structures Machining Centers & Machine Tool Structures Abrasive Processes & Finishing Operations Abrasive Machining & Finishing Operations Abrasive Machining & Finishing Operations Abrasive Machining & Finishing Operations Advanced Machining Processes and Equipment Advanced Machining Processes and Equipment Thanksgiving Recess Advanced Machining Processes and Equipment Review for Final Exam Final Examination Chap. 27 Chap. 27 10:30-12:30 Chap. 37 Chap. 37 Chap. 37 Chap. 37 Chap. 25 Chap. 25 Chap. 26 Chap. 26 Chap. 26 Chap. 26 Chap. 27 Chap. 27 Chap. 21 Chap. 21 Chap. 21 Chap. 21 Chap. 22 Chap. 22 Chap. 23 Chap. 23 Chap. 24 Chap. 24 Reading Chap. 21 Chap. 21

NOTE 1: All class assignments and announcements are posted on HuskyCT. NOTE 2: All homework assignments and due dates will be announced in the class. NOTE 3: Cell phones and other communications devices are to be set on vibration mode during class & exams.

Lab Schedule
Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Date 8/26-8/30 9/2-9/6 9/9-9/13 9/16-9/20 9/23-/927 9/30-10/4 10/7-10/11 10/14-10/18 10/21-10/25 10/28-11/1 11/4-11/8 11/11-11/15 11/18-11/22 11/25-11/29 12/2-12/6 12/11 Topics No Lab Lab Safety and Machine Shop Tour Machine Shop Operations (Metrology) Machine Shop Practice (Measurement) Machine Shop Practice (Tool Grinding) Machine Shop Practice (Tool Grinding) Machine Shop Practice (Lathe Operation) Machine Shop Practice (Tensile Specimen) Preparation for Experiments Experiments 1, 2, 3 by Groups A, B, C Experiments 2, 3, 1 by Groups A, B, C Experiments 3, 1, 2 by Groups A, B, C Catch up Thanksgiving Recess Reading Final Examination 10:30-12:30 1st report due 1st report back 2nd report due 3rd report due Measurement due

Machine Shop Safety Acknowledgement

General rules to follow: Wearing eye protection in designated working areas; No loose fitting sweaters or clothing; No short pants or sandals; Removing rings, jewelry and ties before working; Being in full control of your machine at all times; Seeking help anytime when you feel not OK; Reporting any accident or broken tool immediately; Cleaning of tools, machines, and work areas after use;

Some Nevers Never operate a machine unless you know what each switch, lever, knob, etc. does; Never operate a machine unless all guards are in place; Never make measurements or adjustments while the machine is running; Never touch the workpiece surface while the machine is running; Never attempt to remove metal chips or cuttings with your hands; Never disengage your brain during operation.