Lecture Notes

B.Sc. Manufacturing

Part 2

Guidelines:

Active participation in lectures and practical classes. Absence from practical classes should not exceed 40%! The complete absence of attendance at practical classes will result in a permanent refusal to sign.
Complete all mandatory laboratory exercises. The method and date of the replacement will be determined in the last two weeks of the study period, depending on the number of students.
Preparation of the requested reports related to the laboratory exercises.
Writing the mid-term exam at least at a sufficient level. The duration of the final exam is 60 minutes, and it is evaluated with a grade from 1 to 5. An excellent exam can improve the exam grade by 1 grade.

Note: Students may only work on machines, equipment and measuring instruments in the presence and with the permission of the lecturers, instructors or departmental staff. The prerequisite for participating in the laboratory exercises is knowledge of the work safety instructions and the signing of the protocol.

Lecture 1 - Overview of Machining

L.:An overview of the theoretical foundations of mechanical engineering technology. Systematization of machining procedures, repetition of the basic concepts of cutting processes.

P.:Presentation of the semester program and tasks. Work safety training. Introduction to basic machining procedures.

Lecture 2 - Turning

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L.:Theoretical foundations of turning. Turning movement conditions, chip cross-section, technological data, and their calculation. Typical operation elements, machines used, tools. Characteristics, tools and machines of planning and shaping.

P.:Technological documentation: process plan, operation plan and their development.

Lecture 3 - Drilling and Hole Making

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L.: Drilling, hole machining. Characteristics and movement conditions of drilling. Tools for hole machining: central drill, screw drill, countersink, reamer. Edge geometry of the drill. Mechanical equipment for hole processing. Theoretical foundations of the milling process. Cutting conditions of mantle milling and face milling. Milling tools. Milling machine equipment.

P.:Calculation of cutting parameters. Practical example for calculation of the cutting parameters of a given process. Cutting forces and their calculation.

Lecture 4 - Grinding and Abrasive Machining

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L.: Characteristics and division of abrasive machining the processes that take place between the grain and the workpiece during grinding. Technological data and characteristic procedures of grinding. Structure and materials of grinding wheels. Grinding wheel wear and control. Short and long stroke reaming and mirroring.

P.: Turning: process introduction, learning how to operate a traditional lathe machine.

Lecture 5 - Slotting, Broaching

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L.:Machining of torque-transfer surfaces: slots, splines. Slotting, broaching. Structure of the broaching tool, chip cross-section and material removal, types of broaching.

P.:Turning: producing a rotational part on the lathe machine by every student.

Lecture 6 - Surface Hardening

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L.:The essence and purpose of mechanical surface hardening processes. Burnishing, rolling, hammering, peening. Characteristic parameters and their effect on the properties of the machined layer.

P.:Slot machining, spline machining in practice.

Lecture 7 - EDM

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L.:The essence of EDM, the characteristics of the processes taking place during the spark process, tool materials, rinsing techniques, dielectrics, electrode depletion. Variants, main parameters and factors of EDM.

P.:Milling: process introduction, learning how to operate a traditional milling machine.

Lecture 8 - Other Machining Processes

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L.:Abrasive waterjet cutting, laser and plasma beam processing.

P.:Milling: practicing the operation of the milling machine.

Lecture 9 - Other Machining Processes

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L.:Abrasive waterjet cutting, laser and plasma beam processing.

P.:Milling: practicing the operation of the milling machine.

Lecture 10 - Other Machining Processes

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L.:Electrolytic processing. Chemical separation. Processing with ultrasound. Thermal material removal.

P.:Hole making: learning how to use the tools and machines.

Lecture 11 - Specific Machining Processes - Thread Manuf.

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L.:Thread manufacturing methods.

P.:Thread manufacturing in practice.

Lecture 12 - Specific Machining Processes - Gear Manuf.

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L.:Machining of gears.

P.:Gear machining in practice: showcase of different gear machining processes. In-planning: factory visit in Diósgyőr Gear Manufacturing Ltd.

Lecture 13 - CNC

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L.:CNC machining basics.

P.:CNC machining in practice.

Conditions for obtaining the semester signature:

Active participation in lectures and practical classes. Absence from practical classes should not exceed 40%! The complete absence of attendance at practical classes will result in a permanent refusal to sign.
Complete all mandatory laboratory exercises. The method and date of the replacement will be determined in the last two weeks of the study period, depending on the number of students.
Preparation of the requested reports related to the laboratory exercises.
Writing the mid-term exam at least at a sufficient level. The duration of the final exam is 60 minutes, and it is evaluated with a grade from 1 to 5. An excellent exam can improve the exam grade by 1 grade.

Literature

1. Mandatory:

·Milton C. Shaw: Metal Cutting Principles, CBS, 2003, p.594, ISBN 9788123901367

·E.M. Trent & P.K. Wright: Metal Cutting, 4th edition, Butterworth-Heinemann, 2000, p 446, ISBN 9780750670692

2. Recommended:

·El-Hofy, Hassan: Fundamentals of machining processes: conventional and nonconventional processes, Second Edition, CRC Press, 2014, ISBN 9781466577022

·D.A Stephenson & J.S. Agapiou: Metal Cutting Theory and Practice, Second Edition, CRC Press, 2005, p.864, ISBN 0-8247-5888-9

· B. L. Juneja: Fundamentals of Metal Cutting and Machine Tools, New Age International, 2003, p.614

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