• Production Engineering, Semester 2, position 1

1. Understanding the structure of the modern machining systems, the functions of the basic subsystems and their interactions. 2. Application of methodological frameworks of developed design theories. 3. Study of static and dynamic properties of the machining system and optimization methodology of its mechanical structures 4. Application of modern CAD/CAM/CAE systems for simulating static and dynamic behavior of mechanical structures of machining systems 5. Gaining practical experience in experimental identification of static and dynamic properties of supporting structures 6. Application of modern software environments in the creation of a virtual prototype of a machine system 7. Practical experience in drafting technical reports.

Upon successful completion of this course, students should be able to: 1. Within the methodological framework of the design theory formulates functional requirements, design parameters and the design matrix at all levels of the design process of one product and implements the necessary corrections that lead to the optimization of the design solution. 2. Set up the concept of a static model of the concrete supporting structure of the machining system, with the necessary simplifications of the real model, define the model of the support system and external load, generate a discretized model using the finite element method (FEM), perform simulation in the selected program environment for FEM analysis and explain the obtained results: displacements, stresses and reactions of supports; 3. Set up the concept of a dynamic model of the concrete supporting structure of the processing system, define a model of the support system, define a simplified model, mass characteristics and generate a discretized model using the finite element method (FEM), calculate the natural frequencies and forms of oscillation using a computer and explain the results obtained; 4. Creating a setup for experimental identification of parameters of static and dynamic behavior of a mechanical structure; 5. Possesses the necessary knowledge for designing a machine system (transmission for spindle system, transmissions for feed drives, main spindles of machine tools), in the form of analytical models, standards, market of specialized components, and already realized design solutions. 6. Uses modern software environments in creating a virtual prototype of a machine system or its subsystem; 7. Conceptualizes a technical elaboration, which refers to the considered design solution or performed tests, in the field of processing systems.

Theoretical teaching is organized through the following teaching units: АТ-1 Developed design theories and methodologies for developing and constructing technical systems and products АТ-2 Processing system - statics АТ-3 Dynamics of processing systems (models of supporting structures with concentrated masses, regenerative effect, position coupling, damping and dampers) АТ-4 Bearing structures of machine tools (morphology, materials, topology, optimization) АТ-5 Finite element method in the analysis of the static behavior of the supporting structure АТ-6 Finite element method in the analysis of the dynamic behavior of the supporting structure АТ-7 Experimental identification of parameters of static and dynamic behavior of supporting structures of machine tools АТ-8 Main spindle transmission subsystem of machine tools; functional requirements and models for project solution synthesis АТ-9 Feed drives of machine tools (mechanical structure); functional requirements and models for project solution synthesis Elaboration of the material includes: АR-1 FEM : Computational example of analysis of the static behavior of a supporting structure АR-2 FEM : Computational example of analysis of the dynamic behavior of a supporting structure АR-3 Guidelines for the synthesis of the project solution: Main spindle system (main spindle and transmission) of the machine tool АR-4 Guidelines for the synthesis of the project solution: Transmission of the linear / rotary feed movement of the machine tool

Practical work consists of work in the laboratory and the creation of the design solution according to the given project assignment. 1. Laboratory exercises: (1) Transmissions of the machine tools spindle system of (2) Identification of static and dynamic properties of the mechanical substructures of the machine tool using finite element method. (3) Example of experimental modal analysis for a system with two degrees of freedom. 2. The project of configuring the given machining system, that is, one of its subsystems. Students use modern CAD/CAM/CAE environments in their work, through teamwork and verification with available resources. Final report on the acquired knowledge in this course is formed according to the instructions and model given at the beginning of the course. The report consists of reports from laboratory exercises and a project.

Study curriculum and student motivation for learning about machine tools and machining systems according to the goals set and outcomes offered.

1. Lectures in electronic form, 2. Instructions for writing laboratory reports, 3. Instructions for creating a project, 4. Machining systems in the Department of Machine Tools, Department of Production Mechanical Engineering: conventional machines - lathes, milling machine and numerically controlled machine tools - CNC lathes (PH42-CNC and TCN410) and machining centers (LOLA HMC500 and LOLA HBG80), 5. Sensor and acquisition system for experimental modal analysis. 6. CAD/CAM/CAE systems for simulation of static and dynamic behavior of mechanical structures.

Total assigned hours: 75

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

Auditory exercises: 6
Laboratory exercises: 6
Calculation tasks: 0
Seminar paper: 0
Project: 18
Consultations: 0
Discussion/workshop: 0
Research study work: 0

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

Activity during lectures: 0
Test/test: 20
Laboratory practice: 15
Calculation tasks: 10
Seminar paper: 0
Project: 25
Final exam: 30
Requirement for taking the exam (required number of points): 35

Yusuf Altintas, Manufacturing Automation (2nd ed.) Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design, Cambridge University Press, ISBN 978-1-107-00148-0, 2012.; M. Weck, C. Brecher, Werkzeugmaschinen 2 - Konstruktion und Berechnung, Springer, ISBN 10 3-540-22502-1 Springer Berlin Heidelberg New York, 2005. ; M. Weck, C. Brecher, Werkzeugmaschinen 5, Messtechnische Untersuchung und Beurteilung, dynamische Stabilität, Springer, ISBN 10 3-540-22505-6, 2006.; Suh, N.P., The principles of design, Oxford univerity press, 1990.