The objective of the course “Process Development for Machining Metallic Components” is to enable students to descripe essential machining processes for metallic parts. Based on mechanical and materials fundamentals, the course covers all machining methods.

Within this course, students learn theoretical and application aspects of the following topics:

• Orthogonal cutting (cutting forces, rake angle, friction, tool wear)
• Turning and drilling (tool geometry, chip formation, setup times, productivity)
• Milling (face, contour, profile milling; high-speed milling)
• Grinding (wheel composition, thermal effects, surface integrity)
• Honing, lapping, polishing (tolerances, microstructure, surface quality)
• Process chains (raw part → rough machining → finish; handover parameters)
• Modeling and simulation (FEM-based modeling; empirical models)
• Chip formation simulation (numerical prediction of chip shape and breakage)
• Large-scale modeling (wear modeling; sensor integration)
• CNC machining and machine dynamics (G-/M-Codes; axis dynamics; chatter avoidance).

The acquired knowledge is supplemented by practical lectures from industry, which offer valuable insights into current applications, challenges and innovations in machining methods.

Learning Outcomes:

The students ...

• can describe the fundamental mechanisms and characteristic features of individual machining processes (orthogonal cutting, turning, drilling, milling, grinding, honing, lapping, polishing).
• are able to classify machining methods by their operating principle (geometry-defined vs. geometry-indeterminate) and categorize them based on technical parameters (cutting force, feed rate, material removal rate).
• can select an appropriate process for given component requirements (material, geometry, tolerance) and justify their choice.
• are capable of identifying interactions between individual steps in a multi-stage process chain and integrating them effectively.
• can evaluate machining processes with respect to technical factors (material behavior, tool wear, surface integrity) and economic considerations (setup time, productivity, cost metrics) and develop an optimized process strategy.
• are able to apply basic modeling and simulation methods (FEM-based models, empirical approaches) to estimate cutting forces, temperatures, and tool life.
• can interpret numerical chip-formation simulations and use them for process optimization and tool design.
• understand the fundamentals of CNC programming (G- and M-codes) and can analyze machine-dynamic effects (axis dynamics, vibration phenomena, chatter) to ensure stable machining.
  
  

Workload:

regular attendance: 21 hours
self-study: 99 hours

Medien:
Skript zur Veranstaltung wird über ilias (https://ilias.studium.kit.edu/)
bereitgestellt.

Media:
Lecture notes will be provided in ilias (https://ilias.studium.kit.edu/).