ME 4610/5610 Advanced Machining Processes

Course Schedule
Spring 2017
Day (#) Topic (Slide #) Description # Lec. Assignments
M 01/09 Course Information Format, Grading, Policies, Goals, Expectations 2/3
1.1 General Terminology (39) History of the content (UIUC, CAT, GM, Ford,
Delphi)
Machine-tool system breakdown and related terms 1/3
W 01/11 (1) 1.1 General Terminology (39) continued 1/3
1.2 Motivation for Process How, when and where process models are used 1/3
Modeling (1014) (examples of practical production problems)
1.3 Economics (1518) Market and machining economics considerations 1/3
F 01/13 (2) 1.4 The Mechanistic Modeling Complex vs. simple models and a compromise 1/3
Approach (1924)
2.1 Orthogonal Cutting Real process vs. that assumed for modeling and 1/3
Process Geometry (3138) analysis
Fundamental process geometry 1/3
M 01/16 (3) MLK Day No Class Read Sec. 1.5, Static vs.
Dynamic Modeling (25-28)
Review of Common Machine
Tools & Machining
Processes (App. A)
W 01/18 (4) 2.1 Orthogonal Cutting Velocity relations 1/3
Process Geometry (3940) Example(s) 1/3
2.2 Chip Characterizations Classifications/types of chips and their 1/3
(4146) descriptions; Show & tell chips
F 01/20 (5) 2.3 Force Process-Geometry Mathematical relations and geometrical diagram 2/3 Assign HW1 (See Problem
Relations (4757) method Manual, Prob. 1.1, 2.3)
Example(s) 1/3
M 01/23 (6) 2.4 Stress and Strain (5868) Shear plane stresses and force-strength issues 1/3
Mohrs Circle interpretation 1/3
Rake face stresses and force-strength issues 1/3
W 01/25 (7) Quiz 1 1/3
2.4 Stress and Strain, contd Shear strain visualization and quantification 1/3
(6972) Example(s) 1/3
F 01/27 (8) 2.5 Specific Energy and Force Power, machinability and material removal rate 2/3
Prediction (7382) Merchants energy analysis 1/3
M 01/30 (9) 2.5 Specific Energy and Force Force modeling 2/3 HW1 Due (1.1, 2.3)
Prediction, contd (8395) Size effect in metal cutting 1/3 Assign HW2 (2.7, 2.12)

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Day (#) Topic (Slide #)
W 02/01 (10) 2.5 Specific Energy and Force
Prediction, contd
2.6 Empirical Specific Energy
Modeling (9699)
F 02/03 Catch up
M 02/06 (11) 2.6 Empirical Specific Energy
Modeling, contd (100103)
W 02/08 (12) Quiz 2
3.1 The Oblique Cutting
Process (106113)
F 02/10 (13) Winter Carnival
M 02/13 (14) 3.1 The Oblique Cutting
Process, contd (114122)
W 02/15 (15) 3.2 The Turning and Facing
Processes (127137)
F 02/17 (16) 3.2 The Turning and Facing
Processes, contd (138145)
M 02/20 (17) 3.2 The Turning and Facing
Processes, contd (146147)
Course Schedule
Description # Lec. Assignments
Example(s) 2/3
Model forms 1/3
Model forms, contd 1/3 HW2 Due (2.7, 2.12)
Interpretation of effects 1/3 Assign HW3 (2.13, 2.15)
Statistical significance 1/3
1/3
Tool orientation and rake angles 1/3
Flow angles and chip ratio 1/3
Stay Warm!
Velocities and effective angles 1/3 HW3 Due (2.13, 2.15)
Oblique cutting props 1/3 Assign HW4 (3.1, 3.2, bonus
Force relations 1/3 for one image each of (a) a
lathe grooving tool and (b)
end-grooving/trepanning
tool)
Read slides 123-126
Types of machines machine type vs. process 1/3 Review slides 135137
type
3-D geometry and relation to 2-D orthogonal 1/3
cutting
Inclination and rake angles 1/3
Show & tell lathe tools, inserts
3-D edge representation for zero corner radius 1/3
Practical model usage examples (dim. accuracy vs. 1/3
finish; challenges with matl/castings)
3-D edge representation for non-zero corner radius 1/3
Force model calibration 2/3 HW4 Due (3.1, 3.2, bonus)
Empirical methods application outside machining 1/3 Assign HW5 (3.3, 3.4, bonus
for one image each of (a) the
work area of a mill-turn/turn-
mill machine and (b-d) CAT,
HSK, and Capto adaptors)
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 Course Schedule
Day (#) Topic (Slide #) Description # Lec. Assignments
W 02/22 (18) Quiz 3 1/3
3.2 The Turning and Facing Force relations 1/3
Processes, contd (148157) Equivalent lead angle and simple prediction 1/3
methods
F 02/24 (19) 3.2 The Turning and Facing More complex equivalent lead angle prediction 1/3
Processes, contd (158178) methods
Mechanistic modification of the size-effect method 1/3
Summary of key concepts and material removal 1/3
rate
The facing process
M 02/27 (20) 3.3 The Boring Process (179 Similarity to and difference from turning 1/3 HW5 Due (3.3, 3.4, bonus)
190) Forces 1/3
Show & tell cylinder bores, CBTs, ISO 1/3
cartridges
W 03/01 (21) Exam 1 Covers Chapters 1.13.2 (HW15; Q 13)
Review session (TBD)
F 03/03 (22) 3.4 Modeling the Effects of Overview 1/3
Runout (191-202) Feed and depth throw 1/3
Axis offsets and tilt 1/3
M 03/06 Spring Break Relax and Enjoy!
W 03/08 Spring Break Relax and Enjoy!
F 03/10 Spring Break Relax and Enjoy!
M 03/13 (23) 4.1 The Face Milling Process Similarity to and difference from turning and boring 1/3
(205220) Tooth-local and global forces 2/3
W 03/15 (24) Return Exam 1 2/3 Assign HW6 (3.5, 4.1, double
4.1 The Face Milling Process, Miscellaneous factors that affect forces 1/3 bonus for one image each of
contd (221223) (a) indexable shoulder face
mill, (b) indexable 45 lead
face mill, (c-d) inserted/
indexable end mill and ball
end mill)
F 03/17 (25) 4.2 The End Milling Process Basics multi-tooth, where cutting occurs, 1/3
(224237) geometry 1/3
Force transformations 1/3
Dependence on axial position
M 03/20 (26) 4.2 The End Milling Process, Dependence on axial position (recap) 1/3
contd (238245) Axial integration details 1/3
Miscellaneous runout and ball end milling 1/3

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 Course Schedule
Day (#) Topic (Slide #) Description # Lec. Assignments
W 03/22 (27) Quiz 4 1/3
4.3 The Drilling Process (246 Basic drill geometry specifications 1/3
252) The radial coordinate 1/3
F 03/24 (28) 4.3 The Drilling Process, Cutting process angles 1/3
contd (253267) Similarity to and difference from boring force 1/3
transformations and integration along the edge
The oblique equivalent and summary 1/3
M 03/27 (29) Overview of remainder of course 1/3 HW6 Due (3.5, 4.1, bonus)
5.1 Overview of Machined Functional performance issues 2/3 Assign HW7 (4.2, 4.3, bonus
Surface Characterization for one image each of (a) an
(270273) inserted drill and (b) a split-
point drill)
Assign Final Project
W 03/29 (30) 5.1 Overview of Machined Production and product costs 1/3
Surface Characterization, Surface integrity and quantifying surface error 1/3
contd (274278)
5.2 Surface Error Components Effects of process inputs 1/3
(279281)
F 03/31 (31) 5.2 Surface Error Form error 1/3
Components, contd (282 Waviness 1/3
290) Roughness 1/3
M 04/03 (32) 5.2 Surface Error Lay; discrete vs. continuous characterization 1/3 HW7 Due (4.2, 4.3, bonus)
Components, contd (291292) Assign HW8 (5.1, 5.2, bonus
5.3 Surface Characterization Characterization parameters 1/3 for one image each of (a)
Parameters (293302) Roughness parameter quantification 1/3 wiper insert and (b) any
GD&T surface finish callout
with your brief explanation)
W 04/05 (33) Quiz 5 1/3
Final Project Questions, guidance, etc. 1/3
5.4 Turning, Boring, Drilling Zero and Non-zero corner radius 1/3
and Face Milling (303308)
F 04/07 (34) Final Project Questions, guidance, etc. 1/3
7.1 Tool Wear in Cutting (332 Wear zones 1/3
338) Tool failure and wear mechanisms 1/3
M 04/10 (35) Final Project Questions, guidance, etc. 1/3 HW8 Due (5.1, 5.2, bonus)
7.2 Tool Life Models for Wear curves 1/3 Assign HW9 (7.1, 7.2)
Cutting (339346) Tool life modeling 1/3

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 Course Schedule
Day (#) Topic (Slide #) Description # Lec. Assignments
W 04/12 (36) Final Project Questions, guidance, etc. 1/3
7.3 A Time, Cost and Profit Machining and engagement times 1/3
Model (347355) Unit time, cost and profit rate 1/3
F 04/14 (37) 7.3 A Time, Cost and Profit Dealing with intermittent processes 1/3
Model, contd (356362) 1/3
7.4 Economics-Based Minimizing and maximizing 1/3
Optimization (363372)
M 04/17 (38) Final Project Questions, guidance, etc. 1/3 HW9 Due (7.1, 7.2)
7.4 Economics-Based Maximizing profit rate and summary 1/3 Assign HW10 (7.6)
Optimization, contd (373
378) 1/3
8.1 Chip Control (381385) Chip breaker styles and breaking chips
W 04/19 (39) Quiz 6 1/3
Final Project Questions, guidance, etc. 2/3
F 04/21 (40) 8.3 Vibration and Chatter The dynamic model 1/3 HW10 Due (7.6)
(398418) Self-excited response 1/3 Read slides 404-409
Chatter 1/3
Final Ex. Day Exam 2 Covers Chapters 3.37.5 (HW610; Q 46)
Review session (TBD)
W 04/26 All Done! Final Project Due by 5:00
p.m.

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