MMT LabWork

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Experimental and simulative investigations of turning a C45 material

Within the scope of the MMT (Master of Science in Manufacturing Technology) LabWork the machining of a C45 material is investigated experimentally on the basis of turning tests with different cutting parameters on one hand and on 2D-FE-simulations on the other hand. The focus is on the resulting process forces, which are measured with the help of suitable measuring technology, and on the surface quality of the generated workpiece surfaces. Furthermore, the chip formation, which varies depending on the set cutting parameters, is also at the forefront of the investigations. The entire laboratory is run in groups of maximum three participants each.

Prior to the execution of the experiment, an examination of the knowledge necessary for the experiments is carried out in the form of an attestation. The relevant information will be provided prior as a script. The grade obtained in the attestation is included in the final grade. Insufficient performance in the attestation leads to direct exclusion from the laboratory. The attestation will probably take place on the first week of summer semester. The groups will be formed randomly afterwards.

The practical part of the laboratory is divided into three sections. First, experimental investigations on the processing of C45 materials are carried out using a CNC turning center. During the turning tests a variation of the cutting parameters is carried out according to a given experimental plan. In addition to the mechanical tool load, the focus of the turning tests is on chip formation and the surface quality achieved.

The second part includes the digital execution and analysis of tests with different types of inserts to specifically influence chip formation. For this purpose, videos of the tests under variation of the inserts will be made available in moodle. In addition, the results of the force measurement, the results of the roughness measurement and recordings of the chips produced will be provided.

In the third section of the practical part, the groups perform 2D-FE-simulations of the orthogonal cut using a suitable software. For this purpose, on the one hand, a corresponding tutorial video for setting up the simulations and handling the simulation program and, on the other hand, literature references on chip formation simulation are provided. The objective of the simulative investigations is to represent the cutting process as realistically as possible by selecting a suitable material model or material parameter set.

A written report shall be drawn up after completion of the investigations (maximum of 15 pages, excluding the cover sheet, table of contents and appendix). The deadline for submitting the report is eight weeks and begins with the start of the specialist laboratory. Furthermore, the results obtained are to be presented in a 15-20-minute presentation.


Registration

The lab is 5-credit-hour and it is offered in summer semester. For participating in the Lab., please use self-enroll in the lab moodle webpage during March:

https://moodle.tu-dortmund.de/enrol/index.php?id=15859


Contact

If you have any questions regarding the organisation of the MMT laboratory, please contact lab. coordinator (Youssef Alammari M. Sc., MB III, Room 2.027, phone: +49 231 755 5814, e-mail: youssef.alammari@tu-dortmund.de).