ME 6224: Machine Tool Analysis and Control

Offered Spring, Even Years


Credit Hours: 3-0-3
Prerequisites: ME 6222 or equivalent, or with the consent of the instructor
Catalog Description: Mechanics and dynamics of machining, machine tool components and structures, sensors and controls of machine tools, machine process planning and optimization.
Textbooks: George Tlusty and Jiri Tlusty, Manufacturing Processes and Equipment, 1st Edition, Addison-Wesley, 1999.
Instructors: Steven Liang
References: Metal Cutting Principles, M. C. Shaw, Clarendon Press, 1984
Analysis of Material Removal Processes, W. R. DeVries, Springer-Verlag, 1992.
Fundamentals of Machining and Machine Tools, G. Boothroyd and W. A. Knight, Marcel Dekker, 2nd ed., 1989.
Machining Science and Application, Theory and Practice for Operation and Development of Machining Processes, M. Kronenbeg, Pergamon Press, 1966.
Machine Tool Dynamics, D. B. Welcourn and J. D. Smith, Cambridge University Press, 1970.
International Journal of Machine Tools and Manufacture
ASME Transactions, Journal of Engineering for Industry
ASME Transactions, Journal of Dynamic Systems, Measurement, and Control
Goals: To develop an advanced understanding of machining processes in the context of machinery, mechanics, dynamics, monitoring techniques, and control strategies.
Prerequisites by topics: Basic knowledge of typical manufacturing processes such as machining, casting, bulk deformation, etc
Topics:
  • Introduction of machining processes and machine tool structure;
  • Analysis of chip formation and morphology; kinematic and mechanistic models for single-point and multi-point machining;
  • CNC and feature-based programming for multi-axis machine tool control;
  • Shear plane solutions; chip load convolution integration analysis; cutting Temperatures and thermal models; machinability assessment;
  • Classifications of tool vibrations based on energy sources; time and frequency domain analysis of tool motion and governing equation;
  • Dynamic measurement; theory of chatter and stability lobes;
  • Damping and vibration absorbers;
  • Modifying factors to chatter stability;
  • In-process assessment of the condition of tools, workpieces, cutting processes, and machine tools; sensors and signal processing for machining monitoring;
  • Levels of optimization and automation; constraints and controllable parameters;
  • CNC systems for machine tools; closed-loop control with in-process sensors;
  • Case study of monitoring and control in other manufacturing processes.
Delivery mode (%):

Lecture

80

Demonstration

20

Grading Scheme (%):

Homework

20

Group Projects

20

Exams

60