• Semester 5, position 3

The main goal of this course is to emphasize the importance of production technologies in everyday life and to study the basic manufacturing processes, especially role of machine tools, tools and tooling in machining as well as bulk metal shaping and sheet metalworking processes. The course begins with an introduction to manufacturing and machining systems. Through lectures, demonstrations and practical applications, the student gets acquainted with various manufacturing processes. Students get acquainted with the basic metal removal processes: turning, drilling, planing, milling and grinding. Also, the basics of metal shaping processes (bulk metal shaping and sheet-metal) are considered. The most common non-traditional machining methods and thermal cutting processes (ultrasonic machining - USM, electric discharge machining - EDM, electro-chemical machining - ECM, etc.) are studied in detail. Special attention is paid to Computer Numerical Control (CNC) machine tools and industrial robotics technologies.

On successful completion of the course, students should be able to: • Identify different machining systems as well as relative movements between the tool and the work-piece to apply them in defining the machining process of the selected manufacturing technology. • Select the appropriate base elements for metalworking by cutting (especially turning, drilling, planing and milling). • Determine the principle (key) factors of metalworking by plastic deformation for the processes of forging, extruding and drawing. • Describe in brief the possibilities of using several manufacturing technologies for a specified product realization based on machining processes of the work-pieces with conceptual assembly procedure.

AT-1: Introduction to manufacturing technology - Fundamentals of machining. What is manufacturing? Materials in manufacturing - classification of metals, non-metals in general and especially i.e. polymers. Production, Manufacturing and Machining Systems. Manufacturing processes. Trends in 21st Century of Manufacturing Technologies - micro & nanotechnologies. AT-2: Systems and processes in manufacturing technology. AT-3: Quality system and accuracy of manufacturing. Dimensions, tolerances, and related surface attributes. Surfaces - Measurement of surfaces. Product quality - Effects of manufacturing processes. Quality programs in manufacturing. AT-4: Machining by chip removal - Theory of chip formation in metal machining. Overview of machining technologies and realization of work-piece geometry: turning, drilling and related operations, milling, shaping and planing, grinding and related abrasive processes, broaching, sawing, filing, and gear manufacturing (machining operations for special geometries). Determination of the principle (key) factors of the machining process. AT-5: Non-traditional machining methods: mechanical energy processes - ultrasonic machining (USM), thermal energy processes - electro-discharge machining (EDM) as well as electro-chemical machining (ECM) processes and combined methods. AT-6: Metal forming processes. Determination of the principle (key) factors of the metal forming processes. Bending deformation of a straight member. AT-7: Bulk deformation processes and sheet metalworking processes: Forging, Extrusion, Drawing, Bending, Rolling, etc. AT-8: Automation and robotized technologies in modern production. Computer Numerical Control (CNC) and Industrial Robotics. Flexible Manufacturing Systems (FMS) and Cells.

PA-1: Historical overview of the manufacturing processes (ppt); PA-2: Overview of machining systems and processes (ppt); PA-3: Overview of the quality system (ppt); AR-1 Selection of the starting material for cutting and deformation processes; AR-2: Selection of machining operations; AR-3: Selection of speeds and feeds for cutting processes; PZ-1: A task in machining process - metal cutting; PA-4: Non-traditional machining methods: ultrasonic machining (USM) processes, electric discharge machining (EDM) processes as well as electro-chemical machining (ECM) processes and combined methods (ppt); PZ-2: A task in metal forging; PZ-3: A task in drawing; PL-1: Metalworking machine tools for chip removal (lathe, milling machine tools, radial drilling machine tool, and planer). Cutting tool materials, tool geometry, and tool life; PL-2: Metalworking machine tools for chip removal (machining centers: Horizontal Machining Centers (HMC), special milling machine tools - Pfauter milling machine, Fellows planer, grinding machines for flat surface and round grinding, machine tools for abrasive machining - Water Jet Machining, and machine tools for finishing operations - honing, lapping, superfinishing, polishing and buffing); PL-3: Metalworking machine tools for deformation processes + Finite-element method by using the appropriate work-piece example for MEKELBA software package application and simulation of metal forming processes – OSA. Dies and Presses for Sheet-Metal Processes; PL-4: Technology design for Computer Numerical Control (CNC) machine tools, and industrial robots application in production - Automation of manufacturing processes and operations; Hardware components for automation.

Defined by the Study Program Curriculum.

Laboratory machine tools-machining systems and industrial robots, tools and tooling within the Laboratory for machining systems, the Laboratory for Flexible Manufacturing Systems, machining processes and tools (FMS), the Laboratory for production metrology and quality assurance (CAQ), the Laboratory for production automation (AUTOMATION) as well as the Laboratory for industrial robotics and artificial intelligence (ROBOTICS & AI) which all belong to the Center for New Technologies (CeNT): • universal and CNC lathes, • radial drilling machine tool, • milling machine tools - universal and vertical, • milling machine tool with parallel kinematics, • Pfauter-milling and Fellows-planer machine tools, • planer, • grinding machine tools, • CNC machining centers - Horizontal Machining Centers (HMC), • presses, • industrial robots, • EDM machine, etc.

Total assigned hours: 75

New material: 20
Elaboration and examples (recapitulation): 10

Auditory exercises: 5
Laboratory exercises: 12
Calculation tasks: 13
Seminar paper: 0
Project: 0
Consultations: 0
Discussion/workshop: 0
Research study work: 0

Review and grading of calculation tasks: 2
Review and grading of lab reports: 4
Review and grading of seminar papers: 0
Review and grading of the project: 0
Test: 0
Test: 4
Final exam: 5

Activity during lectures: 10
Test/test: 20
Laboratory practice: 20
Calculation tasks: 20
Seminar paper: 0
Project: 0
Final exam: 30
Requirement for taking the exam (required number of points): 30

Kalajdžić,M., (2023) MANUFACTURING TECHNOLOGY, Textbook (In Serbian), XIV edition, 407 pp. (ISBN 978-86-6060-010-5), University of Belgrade - Faculty of Mechanical Engineering.; Kalajdžić,M. (editor),Tanović,Lj.,Babić,B.,Glavonjić,M.,Miljković,Z., et al., (2021) CUTTING TECHNOLOGY, Handbook (In Serbian), IX Ed., LXXIX+453 pp. (ISBN 978-86-6060-097-6), UB-Faculty of Mech. Eng.; Tanović,Lj., Юpiй Петраков, (2007) Theory and Simulation of Machining Processes, Additional Textbook (In Serbian), 196 pp. (ISBN 978-86-7083-610-5), University of Belgrade - Faculty of Mechanical Eng.; Serope Kalpakjian, Stephen R. Schmid, (2013) MANUFACTURING ENGINEERING AND TECHNOLOGY, 7th SI Edition, 1224 pp. (ISBN 978-9810-694067), Pearson.; Groover Mikell P., (2019) FUNDAMENTALS OF MODERN MANUFACTURING - Materials, Processes, and Systems, 7th Edition, 816 pp. (ISBN 978-1-119-47521-7), WILEY.