DeGarmo's Materials and Processes in Manufacturing
12th Edition
ISBN: 9781118987674
Author: J. T. Black, Ronald A. Kohser
Publisher: WILEY
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Chapter 21, Problem 25RQ
Suppose you had a machining operation (boring) running perfectly and you changed work materials. All of a sudden, you are getting lots of chatter. Why?
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In the machining operation with orthogonal cutting, the cutting plane angle is 9.5°, the cutting depth 0.4 mm, chip thickness 2.9 mm, cutting width 3.1 mm, shear strength 185 MPa in the process;
a) Find the rake angle (α).
b) Find the shear deformation (γ).
c) Find the shear force. (Note: The shear force is 1.4 times the thrust.)
2. Which of the following is the advantage of shaping process?
a) Large objects can be machined easily.
b) Thin or fragile workpiece can also be machined.
c) Lower machining time.
d) Higher tool life.
A cutting tool (0.250 in wide, rake angle 5°) is used to machine in orthogonal mode at 0.010 inch depth
of cut and the chip thickness is 0.027 inch when cutting in air.
a) Calculate the shear angle
b) Calculate the coefficient of friction at the tool and chip interface.
c) If oil is used during machining to reduce the coefficient of friction to 50% of the previous case,
calculate the chip thickness when cutting in oil
Chapter 21 Solutions
DeGarmo's Materials and Processes in Manufacturing
Ch. 21 - Why has the metal-cutting process resisted...Ch. 21 - What variables must be considered in understanding...Ch. 21 - Which of the seven basic chip formation processes...Ch. 21 - How is feed related to speed in the machining...Ch. 21 - Before you select speed and feed for a machining...Ch. 21 - Milling has two feeds. What are they, and which...Ch. 21 - What is the fundamental mechanism of chip...Ch. 21 - What is the difference between oblique machining...Ch. 21 - What are the implications of Figure 21.13, given...Ch. 21 - Note that the units for the approximate equation...
Ch. 21 - For orthogonal machining, the cutting edge radius...Ch. 21 - How do the magnitude of the strain and strain rate...Ch. 21 - Why is titanium such a difficult metal to machine?...Ch. 21 - Explain why you get segmented or discontinuous...Ch. 21 - Why is metal cutting shear stress such an...Ch. 21 - Which of the three cutting forces in oblique...Ch. 21 - How is the energy in a machining process typically...Ch. 21 - Where does the energy consumed in metal cutting...Ch. 21 - What are two ways of estimating the primary...Ch. 21 - What are the three different ways to perform...Ch. 21 - Why does the cutting force Fc increase with...Ch. 21 - Why doesnt the cutting force Fc increase with...Ch. 21 - Prob. 23RQCh. 21 - How does the selection of the machining parameters...Ch. 21 - Suppose you had a machining operation (boring)...Ch. 21 - Make a sketch like that shown in Figure 21.1 with...Ch. 21 - Show how you would do near orthogonal machining in...Ch. 21 - Can you do orthogonal machining on a shaper or...Ch. 21 - What process and material combination would yield...Ch. 21 - What is meant by the statement that machining...Ch. 21 - Prob. 31RQCh. 21 - Figure 21.4 provides suggested cutting speeds and...Ch. 21 - For problem 1, suppose you selected a speed of 145...Ch. 21 - If the cutting forces is 1000 lb calculate the...Ch. 21 - Explain how you would estimate the cutting force...Ch. 21 - For a turning operation, you have selected a...Ch. 21 - For a slab milling operation using a...Ch. 21 - The power required to machine metal is related to...Ch. 21 - In order to drill a hole in the material described...Ch. 21 - Suppose you have the data in Table 21.A obtained...Ch. 21 - Calculate the horsepower that a process is going...Ch. 21 - Explain how you would estimate the cutting force...Ch. 21 - Derive equations for F and N using the circular...Ch. 21 - Prob. 14PCh. 21 - Prob. 15PCh. 21 - A manufacturing engineer needs an estimate of the...Ch. 21 - Using Figure 21.4 for input data, determine the...Ch. 21 - Estimate the horsepower needed to remove metal at...Ch. 21 - For a turning process, the horsepower required was...
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- On a shaper, a workpiece with a tool machining stroke L = 4000 mm and a width B = 1000 mm will be processed in the pass. The cutting time of the tool is tc = 10 s, the rotation time is tr = 5 s. In this process; a) Machine power, b) Main machining time, c) Find the double stroke number of the tool. (f = 1,5 mm/çs, ap = 10 mm, kc = 2200 N/mm2 , ņM = 0,6) %3Darrow_forwardb) Is it possible to machine uneven surface with electromechanical machining process (ECM) ? Justify your answersb) Is it possible to machine uneven surface with electromechanical machining process (ECM) ? Justify your answersarrow_forward6) 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_forward
- 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)arrow_forwardSubject: manufacturing processarrow_forwardIn an orthogonal machining with a tool of 9 orthogonal rake angle, the uncut chip thickness is 0.2 mm. 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_forward
- a) A face milling operation is not yielding the required surface finish on the work. The cutter is a four-tooth insert type face milling cutter. The machine shop foreman thinks the problem is that the work material is too ductile for the job, but this property tests well within the ductility range for the material specified by the designer. Without knowing any more about the job, describe THREE (3) changes in i. cutting conditions ii. tooling would you suggest to improve the surface finish?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_forwardList four industries that depend on machining.arrow_forward
- Find the machining time, in seconds, and the rate of material removing in mmA3;sec for a turning operation having the following information: 1- Wp diameter is 80mm, 2- the length is 0.12m, 3- the cutting speed is 80m/min, 4- feed i50.5 mm/rev and 5- the depth of cut is 0.002m.arrow_forwardQ.1- Choose the correct answer of the following: 1. If the metals are ductile and the cutting speed is high, then are formed. Continuous chips. b) Discontinuous chips. c) Serrated chips. d) None of the mentioned. 2. In which operation, motion of cutting tool is rotary and motion of workpiece is translating? a) Turning. b) Drilling. Milling. d) All of the mentioned 3. In internal cylindrical grinding process, the grinding wheel is a) Reciprocates.Rotates. c) Rotates and reciprocates. d) None of the mentioned. C 4. In electric discharge wire cutting (EDWC) process, the wire is made of; a) Copper High speed steel. c) Cast iron. d) All of the Mentioned. 5. The built up edge in cutting tools can be eliminated by; a) Fast cutting speed. b) Higher rake angles Reducing depth of cut. d) All of the mentioned. 6. The rpm (N) of the shaft, diameter (d) = 25 mm, cutting speed (v) = 50 m/min is: a) (39.25), b) (392.5). c) (63.69). (636.9). Vs NT ⇒N= T 7. Which of the following abrasive materials is…arrow_forward1. Enumerate at least 3 items that we should check prior to machining. 2. Enumerate the 5 minimum personal protective equipment (PPE) required during machining. 3. In case of emergency, where can we locate the emergency stop of milling machine? 4. In milling machine, how many axis can we operate the worktable?arrow_forward
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