Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 21, Problem 18QLP
List reasons that machining operations may be required, and provide an example for each reason.
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Investigate the non-traditional machining methods. Describe each in your own words and sketch
out the process and appropriate scale (inches/microns etc). Then tabulate the material removal
mechanism, workpiece materials, applications, costs/speed, advantages and
limitations/disadvantages of each. The slides are for your starting point. List references, articles,
videos, etc...
Mechanical Methods
1. Water Jet Machining (WJM)
2. Abrasive Water Jet Machining (AWJM)
3. Ultrasonic Machining (USM)
Non-Mechanical Methods
1. Electrochemical Machining (ECM)
2. Electro-Discharge Machining (EDM)
3. Wire EDM
4. Laser Drilling
5.
Electron beam machining (EBM)
For the following application, identify one or more nontraditional machining processes that might be used, and present arguments to support your selection. Assume that either the part geometry or the work material (or both) preclude the use of conventional machining. The application is a matrix of 0.1 mm (0.004 in) diameter holes in a plate of 3.2 mm (0.125 in) thick hardened tool steel. The matrix is rectangular, 75 by 125 mm (3.0 by 5.0 in) with the separation between holes in each direction = 1.6 mm ( 0.0625 in).
Broadly define what machining processes are.
Chapter 21 Solutions
Manufacturing Engineering & Technology
Ch. 21 - Explain why continuous chips are not necessarily...Ch. 21 - Name the factors that contribute to the formation...Ch. 21 - What is the cutting ratio? Is it always less than...Ch. 21 - Explain the difference between positive and...Ch. 21 - Explain how a dull tool can lead to negative rake...Ch. 21 - Comment on the role and importance relief angle.Ch. 21 - Explain the difference between discontinuous chips...Ch. 21 - Why should we be interested in the magnitude of...Ch. 21 - What are the differences between orthogonal and...Ch. 21 - What is a BUE? Why does it form?
Ch. 21 - Is there any advantage to having a built-up edge...Ch. 21 - What is the function of chip breakers? How do they...Ch. 21 - Identify the forces involved in a cutting...Ch. 21 - Explain the characteristics of different types of...Ch. 21 - List the factors that contribute to poor surface...Ch. 21 - Explain what is meant by the term machinability...Ch. 21 - What is shaving in machining? When would it be...Ch. 21 - List reasons that machining operations may be...Ch. 21 - Are the locations of maximum temperature and...Ch. 21 - Is material ductility important for machinability?...Ch. 21 - Explain why studying the types of chips produced...Ch. 21 - Prob. 22QLPCh. 21 - Tool life can be almost infinite at low cutting...Ch. 21 - Explain the consequences of allowing temperatures...Ch. 21 - The cutting force increases with the depth of cut...Ch. 21 - Why is it not always advisable to increase the...Ch. 21 - What are the consequences if a cutting tool chips?Ch. 21 - What are the effects of performing a cutting...Ch. 21 - Prob. 29QLPCh. 21 - Prob. 30QLPCh. 21 - Prob. 31QLPCh. 21 - Prob. 32QLPCh. 21 - Comment on your observations regarding Figs. 21.1...Ch. 21 - Prob. 34QLPCh. 21 - Comment on your observations regarding the...Ch. 21 - Why does the temperature in cutting depend on the...Ch. 21 - You will note that the values of a and b in Eq....Ch. 21 - Prob. 38QLPCh. 21 - Prob. 39QLPCh. 21 - Explain whether it is desirable to have a high or...Ch. 21 - The Taylor tool-life equation is directly...Ch. 21 - Prob. 42QLPCh. 21 - Why are tool temperatures low at low cutting...Ch. 21 - Can high-speed machining be performed without the...Ch. 21 - Prob. 45QLPCh. 21 - Prob. 46QLPCh. 21 - State whether or not the following statements are...Ch. 21 - Let n = 0.5 and C = 400 in the Taylor equation for...Ch. 21 - Assume that, in orthogonal cutting, the rake angle...Ch. 21 - Prob. 50QTPCh. 21 - Prob. 51QTPCh. 21 - Using trigonometric relationships, derive an...Ch. 21 - An orthogonal cutting operation is being carried...Ch. 21 - Prob. 54QTPCh. 21 - Prob. 55QTPCh. 21 - Prob. 56QTPCh. 21 - Show that, for the same shear angle, there are two...Ch. 21 - With appropriate diagrams, show how the use of a...Ch. 21 - In a cutting operation using a 5 rake angle, the...Ch. 21 - For a turning operation using a ceramic cutting...Ch. 21 - In Example 21.3, if the cutting speed V is...Ch. 21 - Using Eq. (21.30), select an appropriate feed for...Ch. 21 - With a carbide tool, the temperature in a cutting...Ch. 21 - The following flank wear data were collected in a...Ch. 21 - The following data are available from orthogonal...Ch. 21 - Prob. 66QTPCh. 21 - Design an experimental setup whereby orthogonal...Ch. 21 - Describe your thoughts on whether chips produced...Ch. 21 - Recall that cutting tools can be designed so that...Ch. 21 - Recall that the chip-formation mechanism also can...Ch. 21 - Prob. 73SDPCh. 21 - Describe your thoughts regarding the recycling of...Ch. 21 - List products that can be directly produced from...Ch. 21 - Obtain a wood planer and some wood specimens. Show...Ch. 21 - It has been noted that the chips from certain...Ch. 21 - As we have seen, chips carry away the majority of...
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Need a deep-dive on the concept behind this application? Look no further. Learn more about this topic, mechanical-engineering and related others by exploring similar questions and additional content below.Similar questions
- Identify some of the reasons why machining is commercially and technologically important.arrow_forwardFor the following application, identify one or more nontraditional machining processes that might be used, and present arguments to support your selection. Assume that either the part geometry or the work material (or both) preclude the use of conventional machining. The application is a through-hole in the shape of the letter L in a 12.5 mm (0.5 in) thick plate of glass. The size of the "L" is 25 by 15 mm (1.0 by 0.6 in) and the width of the hole is 3 mm (1/8 in).arrow_forwardExplain the following terms and situations in metal cutting. Give enough explanation with figures if it is necessary. A)Force and chatter vibrations. How can you detect the vibration during the machining? How can you decide which type of the vibration you have? B) Mode shapes. C)Mode coupling. D)Process damping. Which parameters can affect the process damping? i)Mode coupling. j) Regenerative chatter vibrations. k) Stability lobes.arrow_forward
- 6) It has been stated that it is generally undesirable to allow temperatures to rise excessively in machining operations. Explain why. 7) Explain the possible disadvantages of a machining operation if a discontinuous chip is produced. 8) List and explain the factors that contribute to poor surface finish in machining operations 9) Given your understanding of the basic machining process, describe the important physical and chemical properties of a cutting tool.arrow_forwardIn an orthogonal machining with a tool of 9 degree orthogonal rake angle, the uncut chip thickness is 0.2mm. The chip thickness fluctuates between 0.25 mm and 0.4 mm. The ratio of the maximum shear angle to the minimum shear angle during machining isarrow_forwardSubject: manufacturing processarrow_forward
- What is surface roughness? Surface finish is one of the most important measures for determining the quality of products in machining. Explain in some details.arrow_forwardIn machining a mild steel work piece with carbide tool, the life of the tool was found to be 1 hour and 40 minutes, at a spindle speed of 30 m/min. Calculate the tool life if it has to be operated at a speed of 40% higher than the initial cutting speed. Also calculate the cutting speed if the tool is required to have a life of 2 hours and 45 minutes. Assume Taylor's exponent valuen is 0.28.arrow_forwardThis Question is from Metal and Machine Tools. Due Today Please Answer !!arrow_forward
- 2 1.23 Tool life can be almost infinite at low cutting speeds.Would you then recommend that all machining be done at low speeds? Explain.arrow_forwardIn an orthogonal cutting operation an 8 mm deep groove is to be turned on a 50 mm diameter steel bar. Spindle speed is 300 rpm and a feed rate of 0.25 mm/rev is given to the tool. Produced chips have a width of 2 mm. Calculate the material removal rate at the beginning and at the end of the cut. Can u help me please?arrow_forwardDiscuss three (3) advantages of using cutting fluids in machining operation.arrow_forward
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