Course detail

Experimental Methods

FSI-HE1-KAcad. year: 2023/2024

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

Mode of study

Not applicable.

Guarantor

Ing. Miroslav Jopek, Ph.D.

Department

Institute of Manufacturing Technology (ÚST)

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.

Study aids

Not applicable.

Prerequisites and corequisites

Not applicable.

Basic literature

BROCH, J.T. Mechanical vibration and Shock Measurements. K.Larsen a Son A/S, Glostrup, Denmark, 1984. 370 s. ISBN 87 87355 36.1.
Group of authors: Metals Handbook, Volume 8, Mechanical Testing, ASM 1985.
VELES, P. Mechanické vlastnosti a skúšanie kovov. Edícia hutníckej literatúry, ALFA Bratislava, SNTL Praha, 1985.401 s. 63-559-85.
MEYERS, M. A.: Dynamic Behaviour of Materials. A Wiley-Interscience Publication, John Wiley & Soins,Inc. New York, Toronto,1994. p 668. ISBN 0-471-58262-X. (EN)

Recommended reading

Medek, J.: Experimentální metody. VUT Brno, 1993.
ČECH, J., PERNIKÁŘ, J., BENEŠ, M. Strojírenská metrologie. Skriptum VUT v Brně. PC DIR s.r.o. Brno, 1994. 166 s. ISBN 80-214-0557-0.
MELOUN, M., MILITKÝ, J. Statistické zpracování experimentálních dat. PLUS s.r.o. Praha, 1994. 839 s. ISBN 80-85297-56-6.
Forejt., M., Humár, A., Píška, M., Janíček, L.: Experimentální metody. [online]. Studijní opory pro magisterský studijní program 23-01-T Strojní inženýrství, obor strojírenská technologie - obrábění - tváření, svařování - management, VUT v Brně, Fakulta strojního inženýrství, 2003. Dostupné na World Wide Web: http://www.fme.vutbr.cz/opory/pdf/ust/Exp.metod/Experimentalni%20metody%20he2.pdf

eLearning

eLearning: currently opened course

Classification of course in study plans

  • Programme N-STG-K Master's

    specialization STG , 2. year of study, winter semester, compulsory

Type of course unit

 

Guided consultation in combined form of studies

9 hours, compulsory

Teacher / Lecturer

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

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 deformation speeds

  12. Determination of forming resistances at higher deformation speeds

  13. Experimental validation of dynamic processes using numerical simulation

Guided consultation

34 hours, optionally

Teacher / Lecturer

Ing. Miroslav Jopek, Ph.D.

Syllabus

1.Tool wear (criteria, measuring methods and equipment)
2.Heat and temperature (measuring methods, detection devices, processing)
3.Cutting forces and resistances (dynamometers, detection and evaluation of quantities)
4.Vibration (principles, experimental devices, detectors, instruments)
5.Microscopy methods (analysis of the morphology of the surface of tools and workpieces on scanning electron microscope)
6.Evaluation of properties of cutting tool materials
7.Complete evaluation of cutting tools properties
8.Experimental technological testing of bulk formability
9.Testing aimed at establishing the wear coefficient and the effect of lubricants in metal forming
10.Experimental testing of non-uniform distribution of deformation
11.Measuring the forming and ejecting forces, determining the state of stress
12.Establishing the resistance to deformation at higher strain speeds
13.Establishing the dynamic and mechanical properties of materials

Laboratory exercise

9 hours, compulsory

Teacher / Lecturer

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

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

eLearning

eLearning: currently opened course