The teaching unit is mandatory.
The teaching unit is taught in French
The teaching unit is taught in  English

Outline

3 ECTS / 30 h
 Lectures : 16h
 Tutorials : 8h
 Practical works : 8h

Team
Coord. Gerard POULACHON (gerard.poulachon@ensam.eu, ENSAM Cluny)

Pedagical team :

Gérard POULACHON, Professeur des Universités, Arts et Métiers, Cluny, gerard.poulachon@ensam.eu

Frédéric ROSSI, Maître de Conférences, ENSAM, Cluny, frederic.rossi@ensam.eu

   Hélène BIREMBAUX, Maître de Conférences, ENSAM, Cluny, helene.birembaux@ensam.eu

Procedure and organisation:

Course 1 – Cutting, High Speed machining and Analytical Models: orthogonal cutting principles, description of tool geometry, description of the cutting zone, Albrecht’s & Merchant’s theories, analytical modeling of cutting forces.

Course 2 – Thermal aspects of cutting: instrumentation and modeling.

Course 3 – Machinability of difficult-to-cut materials & Interaction material-process: Physical phenomena around the cutting edge, built-up edge, tribological aspects during metal cutting.

Course 4 – Numerical modeling and simulation of subtractive machining: introduction; fundamental aspects of numerical simulation; constitutive laws, friction and contact laws; simulation of chip morphology (separation of material); boundaries conditions; validation; FEM software dedicated for cutting simulation, case study.

Course 5 – Surface Integrity (SI): Introduction and definitions; surface defaults; residual stresses; microstructure and phase transformations; experimental techniques to evaluate the surface integrity; modeling and simulation of SI.

Pedagogical objectives:

The objective is to analyze the thermomechanical phenomena in the vicinity of the tool tip and its consequences on the integrity of the machined surface. These phenomena will be observed at mesoscopic and microscopic scales, based on experiments and numerical simulations of the cutting operation.

Content:

• Fundamentals notions and theory of cutting by material removing.
• Machinability of difficult-to-cut materials, such as those encountered in the aeronautical, automotive and nuclear sectors.
• Determination of the validity fields of the cutting parameters for a given tool and material.
• Qualification of new generation cutting tools and validation of new metallurgies of work materials.
• Implementation of numerical simulation and experimental means dedicated for understanding the thermomechanical phenomena of cutting.
• Analysis of the surface integrity of machined parts, including evaluation of mechanical, metallurgical and topographic conditions.

 

Skills:

Notions of the machining process; Numerical methods ; Continuum mechanics ; Thermal theory.

Bibliography:

• Jan Eric Stahl, Metal cutting -Theory and models, Printed by Elanders, 2012.
• M.A. Davies, T. Ueda, R. M'Saoubi, B. Mullany, A.L. Cooke, On The Measurement of Temperature in Material Removal Processes, CIRP Annals, Volume 56, Issue 2, 2007, Pages 581-604.
• I.S. Jawahir, E. Brinksmeier, R. M’Saoubi, D.K. Aspinwall, J.C. Outeiro, D. Meyer, D. Umbrello, A.D. Jayal, “Surface Integrity in Material Removal Processes: Recent Advances”, CIRP Annals - Manufacturing Technology, keynote paper, Vol. 60/2, pp. 603-626, 2011.
• J. Outeiro “Residual Stresses in Machining”, in Book “Mechanics of Materials in Modern Manufacturing Methods and Processing Technique”, Edited by V. Silberschmidt, Elsevier, 2019.
• Viktor P. Astakhov, “Metal Cutting Mechanics” Edited by CRC Press, 1999. ISBN 0-8493-1895-5.
• David A. Stephenson, John S. Agapiou, “Metal cutting theory and pratice”, edited by Marcel Dekker 1999. ISBN 0-8247-9579-2.
• Graham T. Smith, “Cutting Tool Technology”, edited by Springer. ISBN 978-1-84800-205-0.