Mechanical Engineering 443, Metal Cutting

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Catalog description

Theory and applications of metal cutting; Basic principles and significant features of current research; Chip formation mechanics in orthogonal and oblique cutting, tool wear and fracture; Cutting process and machine tool structural dynamics; Stability analysis of the machining process, chatter vibrations, and chatter suppression; Surface generation and characterization; Pragmatic considerations related to micro-scale, precision and high-speed machining.

Prerequisite: MECH ENG 340-1,2 or consent of instructor.

Who takes it

This course is primarily aimed at graduate students in engineering and sciences who are interested in the fundamentals and applications of material removal processes as part of their preparation for in-depth study or to gain basic expertise in advanced techniques for process implementation in demanding precision manufacturing tasks. Advanced undergraduates can also enroll with the consent of the instructor.

What it's about

The course discusses current theoretical and pragmatic advances in material removal processes research and technology. The theoretical considerations will revolve around the principles and significant features of material removal processes considered through mechanistic, mechanics- and molecular-dynamics-based models, machine tool structural dynamics, and self-excited dynamic instabilities in manufacturing processes in general and metal removal in particular. On the pragmatic side, in addition to an overview of current practices, issues related to emerging technologies will be discussed with a particular focus on micro/meso-scale, precision, and high speed machining operations and processes.

Mini Syllabus:

  • Mechanics of chip formation in orthogonal and oblique cutting
  • Cutting dynamics - Analytical and experimental methods
  • Machine tool structural dynamics - Analytical and experimental methods
  • Theory of linear and non-linear chatter
  • Tools, tool materials, and tool life
  • Pragmatic issues (economics, design for machining, selection of cutting conditions)
  • Emerging technologies

Lectures:

The course meets two days per week for 90-minute lectures.

Assessment/Evaluation:

Weekly problem sets (or mini-project) a midterm and a final exam. All exams will be open book and open notes.

Textbook:

Handouts.

Contact:

Instructor: Kornel F. Ehmann
e-mail: k-ehmann@northwestern.edu