Course detail

Experimental Methods

FSI-HE1 Acad. year: 2023/2024 Winter semester

The course deals with the basic methods of measuring and evaluating the side-effects of machining and metal-forming. They include mechanical testing, qualitative and quantitative evaluation of wear, measuring of cutting forces and resistance, metal-forming and ejecting forces, resistance to plastic strain, strain rates, temperature & heat, and oscillation. The evaluation is dealt with the viewpoint of individual methods of machining and metal-forming and the operating conditions of the tool. Applications of the methods of light and electron microscopy when evaluating the morphology of the surface of tools and workpieces are discussed too.

Language of instruction

Czech

Number of ECTS credits

5

Supervisor

Ing. Miroslav Jopek, Ph.D.

Department

Institute of Manufacturing Technology

Entry knowledge

Students are expected to have the knowledge of the theory and technology of machining and forming, fundamentals of metrology (with orientation to measuring of the geometry) and measuring of temperature and mechanical quantities (tensometry).

Rules for evaluation and completion of the course

Conditions for awarding of the course-unit credit: participation in exercises, fulfilling the assignments, and submitting written reports of required content and graphic forms. If these conditions are not satisfied, the tutor may define alternative conditions, in justified cases. In the examination, which is written and oral, the theoretical knowledge of lectured problems of machining and metal-forming is checked. It is classificated to the ECTS grading scale.When awarding the mark, the evaluation of the student by the tutor can be taken into account.
- Attendance in lectures is recommended. Attendance in exercises is compulsory. Attendance at lessons is required and checked by the tutor. One absence can be compensated by attending a seminar with another group, or by elaboration of substitute tasks. Longer absence is may be compensated for via special tasks by the agreement with the tutor.
The attendance to the seminar is regularly checked and the participation in the lesson is recorded.

Aims

The goal of the subject is to acquaint the students with special experimental methods, which are necessary when evaluating the functional properties of cutting and forming tools, machinability and formability of materials, in the area of manufacture and research. The significance and application of technical measuring and testing in the development of the machining and metal-forming technologies are emphasized.
Students will be able to creatively participate in performing and evaluating of required experiments in the technological processes of machining and metal-forming. They will be able to recognize proper measuring methods and equipment with automated outputs and evaluation by the help of computer technique.

The study programmes with the given course

Programme N-STG-P: Manufacturing Technology, Master's
specialization STG: Manufacturing Technology, compulsory

Type of course unit

 

Lecture

26 hours, optionally

Teacher / Lecturer

Ing. Zdeněk Fiala, Ph.D.
prof. Ing. Milan Forejt, CSc.
Ing. Miroslav Jopek, Ph.D.

Syllabus



  1. Oscillation (principles, experimental devices, sensors, signal processing instruments)




  2. Cutting forces and resistances (dynamometers, measurement and evaluation of parameters, data processing)




  3. Tool wear (criteria, measuring methods and equipment, processing of measured values), comprehensive assessment of cutting tool properties




  4. Microscopic methods (analysis of the surface morphology of the tool and workpiece using scanning electron microscopy – SEM)




  5. Heat and temperature, measurement of high-speed processes (measurement methods, sensing instruments, data processing)




  6. Demonstration of practical application of experimental methods in industrial practice




  7. Experimental technological tests of bulk formability




  8. Tests for determining friction coefficients and the influence of lubricants in forming




  9. Experimental determination of material mechanical properties under dynamic loading conditions




  10. Demonstration of practical application of experimental methods in industrial practice




  11. Measurement of forming forces, determination of stress at higher strain rates




  12. Determination of forming resistances at higher strain rates




  13. Experimental validation of dynamic processes using numerical simulation



Laboratory exercise

26 hours, compulsory

Teacher / Lecturer

Ing. Zdeněk Fiala, Ph.D.
Ing. Martin Harant
Ing. Miroslav Jopek, Ph.D.
Ing. Petr Svoboda

Syllabus

1.Measuring the tool wear in the course of operation, data evaluation
2.Establishing the tool life/cutting speed dependence from the wear values
3.Analysis of cutting properties of drills
4.Analysis of cutting properties of milling cutters
5.Establishing the torque when cutting the thread with a nut tap
6.Analysis of energetic and thermal phenomena in grinding
7.Analysis of properties of processing liquids
8.Complex upsetting test, evaluation of the resistance to deformation, deformation work, and rate of deformation
9.Establishing the wear coefficient during the metal-forming process
10.Evaluation of strain by the macro-network method
11.Establishing the impact forces and stress in the Taylor test
12.Conducting the Taylor test on an air gun and evaluating the test
13.Establishing the dynamic-mechanical properties of materials by the method of Hopkinson bar test