Course detail

Machining of cast materials

FSI-POLAcad. year: 2023/2024

The subject is devoted to the improvement of student´s knowledge in the field of machining of cast materials.

Language of instruction

Czech

Number of ECTS credits

5

Mode of study

Not applicable.

Guarantor

Ing. Karel Osička, Ph.D.

Department

Institute of Manufacturing Technology (ÚST)

Entry knowledge

Knowledge obtained in the course of previous study, namely in the fields of theory and technology of machining, material science, metrology, mathematics, physics, structures and properties of cast materials.

Rules for evaluation and completion of the course

Course unit credit requirements:
-participation in the exercises,
-delivery of assigned papers.
The exam will be written and oral and the resulting classification will be in accordance with Article 12 and 13 of the current BUT Study and Examination Regulations.

Attendance at all exercising. Substitution in other exercising, or essay of current assignment.

Aims

The goal of the subject involves the application of material science, construction of machines and equipment, methods of checking materials when machining metal materials with conventional and CNC technology.


Students will acquire knowledge of qualified technological process selection, including foundry technology. They will be able to select proper clamping of workpieces, production (cutting) conditions, cutting tools and materials, do workpiece checks, calculate production times and production costs.

Study aids

Not applicable.

Prerequisites and corequisites

Not applicable.

Basic literature

AB SANDVIK COROMANT - SANDVIK CZ s.r.o. Příručka obrábění - Kniha pro praktiky. (Přel. z: Modern Metal Sutting - A Practical Handbook. Překlad M. Kudela.), 1. vyd. Praha: Scientia, s. r. o.,1997. 857s., ed. J. Machač, J. Řasa. ISBN 91-97 22 99-4-6. (CS)
WALKER, J.R. Machining Fundamentals. The Goodheart-Wilcox Company, Inc., Tinlez Park, Illinois, 7th ed., 2004, pp. 640, ISBN 1-59070-249-2. (EN)
TRENT, E.M., WRIGHT, P.K. Metal Cutting. Fourth Edition. Butterworth-Heinemann. Boston, Oxford, Auckland, Johannesburg, Melbourne, New Delhi, 2000. pp. 446. ISBN 0-7506-7069-X. (EN)
HUMÁR, Anton. a Miroslav PÍŠKA, Moderní řezné nástroje a nástrojové materiály. MM Průmyslové spektrum. Speciální vydání včetně CD, Praha: 2004, 110 s., ISSN 1212-2572. (CS)
HUMÁR, Anton. Materiály pro řezné nástroje. 1. vyd. Praha: MM publishing, s. r. o., 2008. 240 s. ISBN 978-80-254-2250-2. (CS)
FOREJT, Milan a Miroslav PÍŠKA. Teorie obrábění, tváření a nástroje. 1. vyd. Brno: CERM, s. r. o., 2006. 225 s. ISBN 80-214-2374-9. (CS)
ZEMČÍK, Oskar. Nástroje a přípravky pro obrábění. 1. vyd. Brno: CERM, s. r. o., 2003. 193 s. ISBN 80-214-2336-6. (CS)
PTÁČEK, Luděk et al. Nauka o materiálu I. 2. vyd. Brno: CERM, s. r. o., 2003. 516 s. ISBN 80-720-4283-1. (CS)

Recommended reading

FOREJT, Milan a Miroslav PÍŠKA. Teorie obrábění, tváření a nástroje. 1. vydání. Brno: Akademické nakladatelství CERM, s.r.o., 2006, 225 s. ISBN 80-214-2374-9. (CS)

Classification of course in study plans

  • Programme N-SLE-P Master's, 1. year of study, winter semester, compulsory

Type of course unit

 

Lecture

26 hours, optionally

Teacher / Lecturer

Ing. Milan Kalivoda
Ing. Karla Maradová
Ing. Jana Rozehnalová, M.Sc.
doc. Ing. Antonín Záděra, Ph.D.

Syllabus

1. Cast materials in engineering, types, production, handling, use.
2. Properties of cast materials, machinability.
3. Material additions on castings, technological construction, effects on machining.
4. Milling theory. Company catalogs. Videos from real processes.
5. Drilling theory. Company catalogs. Videos from real processes.
6. Turning theory. Company catalogs. Videos from real processes.
7. Technology of machining non-rotating shapes of castings. Machines, clamps, tools.
8. Technology of machining rotary shapes of castings. Machines, clamps, tools.
9. CNC machines for machining castings. Machine equipment. Manual adjustment of castings.
10. Control processes in piece and series production, gauges, frequency.
11. Production equipment costs. Automation and robotics.
12. Management and organization of production processes. Solution of production outages.
13. Presentation of semester work. Credit.

Laboratory exercise

26 hours, compulsory

Teacher / Lecturer

Ing. Milan Kalivoda
Ing. Karla Maradová
Ing. Jana Rozehnalová, M.Sc.
doc. Ing. Antonín Záděra, Ph.D.

Syllabus

1. Assignment of drawings of components for semester work (pulleys, lid, valve).
2. Casting design for specified drawings, ie semi-finished product for machining.
3. Creating a construction drawing of a casting.
4. Project of a specific milling operation. Demonstrations in the school workshop.
5. Project of a specific drilling operation. Demonstrations in the school workshop.
6. Project of a specific turning operation. Demonstrations in the school workshop.
7. Design of technological process for non-rotating shape casting.
8. Design of technological process for rotary casting.
9. Block diagram of NC program for more complex casting (gearbox, lever).
10. Evaluation of the quality of machined surfaces, quantities Ra, Rz.
11. Statistical capture of deviations of produced dimensions.
12. Compilation of process diagrams. Proof of alternative technology.
13. Presentation of semester work. Credit.