Course detail

Experimental Methods

FSI-HE1 Acad. year: 2026/2027 Winter semester

This course covers the fundamental methods for measuring and evaluating the phenomena accompanying forming and machining processes. This encompasses mechanical testing, qualitative and quantitative wear assessment, and the measurement of forming forces, flow stress, strain rates, temperatures and heat, and vibration. These topics are considered in the context of specific forming and machining methods and tool working conditions (including the use of dynamometers, calorimeters, various sensors, and signal processing equipment).

The course also incorporates tribological testing of forming technologies, with an emphasis on the environmental sustainability of lubricants. This includes the assessment of friction, wear, and lubrication mechanisms under various forming conditions, the analysis of environmentally friendly lubricants, and their impact on energy consumption and tool longevity.

Furthermore, the course addresses the application of light (optical) and electron microscopy methods for evaluating the surface morphology of tools and workpieces.

Language of instruction

Czech

Number of ECTS credits

5

Supervisor

Ing. Miroslav Jopek, Ph.D.

Department

Institute of Manufacturing Technology

Entry knowledge

Students are expected to have the knowledge of the theory and technology of machining and forming, fundamentals of metrology (with orientation to measuring of the geometry) and measuring of temperature and mechanical quantities (tensometry).

Rules for evaluation and completion of the course

Conditions for awarding of the course-unit credit: participation in exercises, fulfilling the assignments, and submitting written reports of required content and graphic forms. If these conditions are not satisfied, the tutor may define alternative conditions, in justified cases. In the examination, which is written and oral, the theoretical knowledge of lectured problems of machining and metal-forming is checked. It is classificated to the ECTS grading scale.When awarding the mark, the evaluation of the student by the tutor can be taken into account.
- Attendance in lectures is recommended. Attendance in exercises is compulsory. Attendance at lessons is required and checked by the tutor. One absence can be compensated by attending a seminar with another group, or by elaboration of substitute tasks. Longer absence is may be compensated for via special tasks by the agreement with the tutor.
The attendance to the seminar is regularly checked and the participation in the lesson is recorded.

Aims

The goal of the subject is to acquaint the students with special experimental methods, which are necessary when evaluating the functional properties of cutting and forming tools, machinability and formability of materials, in the area of manufacture and research. The significance and application of technical measuring and testing in the development of the machining and metal-forming technologies are emphasized.
Students will be able to creatively participate in performing and evaluating of required experiments in the technological processes of machining and metal-forming. They will be able to recognize proper measuring methods and equipment with automated outputs and evaluation by the help of computer technique.

Study aids

 http://ust.fme.vutbr.cz/tvareni/studium/index.php?stranka=opory and E-learning

The study programmes with the given course

Programme N-STG-P: Manufacturing Technology, Master's
specialization STG: Manufacturing Technology, compulsory

Type of course unit

 

Lecture

26 hours, optionally

Syllabus


  1. Vibrations (principles, experimental equipment, sensors, signal processing instruments)

  2. Cutting Forces and Resistance (dynamometers, data acquisition and evaluation, data processing)

  3. Tool Wear (criteria, measurement methods and equipment, processing of measured values), comprehensive evaluation of cutting tool properties

  4. Microscopic Methods (surface morphology analysis of tools and workpieces using Scanning Electron Microscopy – SEM)

  5. Heat and Temperature, Measurement of High-Speed Phenomena (measurement methods, sensors, processing of measured values)

  6. Demonstration of the practical application of experimental methods in industrial practice

  7. Experimental testing of bulk formability

  8. Tribological testing of forming technologies with an emphasis on the environmental sustainability of lubricants

  9. Experimental determination of material mechanical properties under dynamic loading conditions

  10. Demonstration of the practical application of experimental methods in industrial practice

  11. Measurement of forming forces, determination of stress states at higher strain rates

  12. Determination of flow stress at higher strain rates

  13. Experimental verification of dynamic phenomena using numerical simulation

Laboratory exercise

26 hours, compulsory

Syllabus


  1. In-process measurement of tool wear and evaluation of results

  2. Processing of tool life-cutting speed relationships based on wear data

  3. Analysis of the cutting performance of drills

  4. Analysis of the cutting performance of milling cutters

  5. Torque measurement during thread cutting using a nut tap

  6. Analysis of energy and thermal phenomena in grinding

  7. Analysis of cutting fluid properties

  8. Comprehensive upsetting test and evaluation of flow stress, work of deformation, and strain rates

  9. Tribological testing of forming technologies with an emphasis on the environmental sustainability of lubricants

  10. Strain evaluation using the grid analysis method (macro-grids)

  11. Determination of impact forces and stress in the Taylor test

  12. Performing the Taylor test using a pneumatic gas gun and its evaluation

  13. Determination of dynamic mechanical properties of materials using the Hopkinson test method