MFGG 403 Material Removal Processes
Winter Term 2003

2001 catalog data: Credit (3-2-4) Three hours of lecture and one two-hour lab

Prerequisites: MFGG-370 Engineering Materials

This course presents the fundamental theoretical and operational concepts of machining. The course focuses on the modeling of cutting operations and tool materials, selection, and uses. Significant topics include: the orthogonal cutting model, Taylor’s tool wear model, criteria for tool selection, and operating characteristics of computer numerically controlled lathes and milling machines. Laboratories are designed to illustrate theoretical concepts and methods for solving practical engineering machining problems.

Textbook(s): Theory and Practice of Material Removal, Judson and Throop, GMI, 1970

References: None

Coordinator(s): W.L. Scheller II, Associate Professor of Manufacturing Engineering

Course learning objectives:

A student who successfully completes this course will be able to

1. Design a study to determine expected life of a cutting tool. (Program Outcomes: A, B, L; MFGG

PEOs: 1, 2, 3, 7)

2. Analyze a machining operation using Merchant’s Orthogonal Cutting Model (Program Outcomes: A,P;

MFGG PEOs: 1, 2, 3, 7)

3. Design a machining operation considering all appropriate parameters (Program Outcomes: B, P;

MFGG PEOs: 1, 2, 3, 7)

4. Collect and analyze data from a tool monitoring system. (Program Outcomes: B, P; MFGG PEOs:

1, 2, 3, 7)

5. Perform continuous improvement of a machining process (putter project). (Program Outcomes: P, Q;

MFGG PEOs: 1, 2, 3, 7)

Prerequisites by topic:

1. Metal cutting methods

2. Metal cutting machines

3. Basic cutting tool composition

4. Basic cutting tool geometries

5. Manual machining

6. Material properties of metals

Topics covered:

1. Orthogonal Cutting Model

2. Taylor’s Tool Life Model

3. Effects of tool geometry

4. Tool monitoring methods

5. Role and uses of cutting fluids

6. Production using CNC machine tools

Schedule: Three lecture sections of 60 minutes per week and one laboratory section of 120

Minutes

Computer usage: Haas CNC Controller

MS Excel

Laboratory projects: 1. Orthogonal Cutting

2. Tool Wear

3. Face Milling and End Milling Forces

4. Machining of a Stainless Steel Putter

Relationship to professional component: Four credits of engineering topics

Prepared by: W.L. Scheller II Date: June 2, 2000