Manufacturing Processes-i

Mode of Delivery

Face to Face

Prerequisites and Co-Requisites

None

Recommended Optional Programme Components

Not

Course Contents

Properties, principles and duty of machine technicians. Knowledge and skill of measurment and control devices, Basic knowledge and skill of universal lathe machine, Knowledge and skill of universal milling machine, Knowledge and skill of sharpening to cutting tools, Basic knowledge and skill of welding.

Weekly Schedule

1) The Metal Cutting (or Machining) Process, A Short History of Machining, Machining and the Global Economy
2) Metal Cutting Operations and Terminology; turning, boring operations, drilling, milling, broaching, shaping and planing
3) The Essential Features of Metal Cutting; The Chip, Techniques for Study of Chip Formation, Chip Shape, Chip Formation, The Chip/tool Interface, The Built-up Edge, Machined Surfaces,
4) Forces and Stresses in Metal Cutting; Stress on the shear plane, Forces in the Flow Zone, Forces in Metals and Alloys, Stresses in the Tool, Stress Distribution.
5) Heat in Metal Cutting; Heat In the Primary Shear Zone, Heat at the Tool/work Interface, Heat Flow at the Tool Clearance Face, Heat in Areas of Sliding, Methods of Tool Temperature Measurement, Measured Temperature Distribution in Tools, Relationship of Tool Temperature to Speed, Relationship of Tool Temperature to Tool Design.
6) Cutting Tool Materials, Steels; History, Carbon Steel Tools, High Speed Steels, Structure and Composition, Properties of High Speed Steels, Tool Life and Performance of High Speed Steel Tools,
7) Cemented Carbides: Structures and Properties, Tungsten Carbide-Cobalt Alloys (WC-Co), Tool Life and Performance of Tungsten Carbide-Cobalt Tools,, Tungsten-Titanium-Tantalum Carbide Bonded with Cobalt, Performance of (WC+TiC+TaC)-Co Tools.
8) Midterm examination/Assessment
9) Alumina (Ceramic) Tools, Alumina-Based Composites (Al2O3 + TiC), Sialon, Cubic Boron Nitride (CBN), Diamond, Synthetic Diamond and Diamond Coated Cutting Tools
10) Machinability; Magnesium, Aluminum and Aluminum Alloys, Copper, Brass and Other Copper Alloys, Commercially Pure Iron, Alloy Steels and Heat-Treatments, Free-Cutting Steels, Austenitic Stainless Steels, Cast Iron, Nickel and Nickel Alloys, Titanium and Titanium Alloys, Zirconium.
11) Coolants and Lubricants
12) Tolerances and Surface Finish
13) Grinding and Other Abrasive Processes
14) A technical excursion will be arranged to an industrial institution
15) The subjects about the whole semester will be summarized.
16) Final examination

Recommended or Required Reading

1- KOU Talaşlı Şekil Verme Ders Notları, Prof. Dr. Kutsal TÜLBENTÇİ, Prof. Dr. Erdinç KALUNÇ, Kocaeli, 2010
2- Modern Talaşlı İmalatın Esasları 1. Bölüm, Prof. Dr. M. Cemal Çakır, 2006
3- Metal Cutting Edward Trient, Paul Wright, Butterworth–Heinemann, 4 edition, Massachusetts, 2008
4- Machining Technology; machine tools and operations, Hassemi A. Youssef, Hassan El Hoffy, CRC Press, Berlin,
5- Öğretim elemanının ders notları
6- WEB siteleri
7- Lecturer's lecture notes
8- WEB sites
9- kütüphane ve internet araştırması
10- library and internet research

Planned Learning Activities and Teaching Methods

1) Lecture
2) Question-Answer
3) Discussion
4) Drill and Practice
5) Demonstration

Assessment Methods and Criteria

Contribution of Semester Studies to Course Grade	20%
Number Percentage Semester Studies Midterm Examination 1 30% Quiz 1 20% Workshop 1 50%
Contribution of Final Examination to Course Grade	80%
Total	100%

Language of Instruction

Turkish

Work Placement(s)

Not Required