EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 9780100793439
Author: KALPAKJIAN
Publisher: YUZU
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Chapter 22, Problem 33QLP
In Table 22.1, the last two properties listed important to the life of a cutting tool. Why?
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Question 1: Explain the following terms and situations in metal cutting. Give enough explanation with figures if it is necessary.
a) Up and down milling operations. What are the effects on the workpiece surface finish and machine tool? b) Orthogonal and oblique cutting. c) Cutting force diagram in orthogonal cutting. d) Theoretical prediction of shear angle in orthogonal cutting. e) Machinability. f) Force and chatter vibrations. How can you detect the vibration during the machining? How can you decide which type of the vibration you have? g) Mode shapes. Mode coupling. h) Process damping. Which parameters can affect the process damping? i) j) Regenerative chatter vibrations. k) Stability lobes.
Question 2: How will the cutting force be affected by the following situations during the machining operation? Why?
a) Large rake angle b) Small relief angle c) Large nose radius d) Sharp cutting edge e) Smooth rake face f) Hard workpiece material g) High cutting speed h) Large feed rate i)…
Explain 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.
Choose TWO (2) types of cutting processes that are suitable for cutting thick materials (>20mm thick plate).
Chapter 22 Solutions
EBK MANUFACTURING ENGINEERING & TECHNOL
Ch. 22 - What are the major properties required of...Ch. 22 - What is the composition of a typical carbide tool?Ch. 22 - Why were cutting-tool inserts developed?Ch. 22 - Why are some tools coated? What are the common...Ch. 22 - Explain the applications and limitations of...Ch. 22 - List the major functions of cutting fluids.Ch. 22 - Why is toughness important for cutting-tool...Ch. 22 - Is the elastic modulus important for cutting-tool...Ch. 22 - Explain how cutting fluids penetrate the toolchip...Ch. 22 - List the methods by which cutting fluids are...
Ch. 22 - Describe the advantages and limitations of (a)...Ch. 22 - What is a cermet? What are its advantages?Ch. 22 - Explain the difference between M-series and...Ch. 22 - Why is cBN generally preferred over diamond for...Ch. 22 - What are the advantages to dry machining?Ch. 22 - Explain why so many different types of...Ch. 22 - Which tool-material properties are suitable for...Ch. 22 - Describe the reasons for and advantages of coating...Ch. 22 - Make a list of the alloying elements used in...Ch. 22 - As stated in Section 22.1, tool materials can have...Ch. 22 - Explain the economic impact of the trend shown in...Ch. 22 - Why does temperature have such an important effect...Ch. 22 - Ceramic and cermet cutting tools have certain...Ch. 22 - What precautions would you take in machining with...Ch. 22 - Can cutting fluids have any adverse effects in...Ch. 22 - Describe the trends you observe in Table 22.2.Ch. 22 - Why are chemical stability and inertness important...Ch. 22 - Titanium-nitride coatings on tools reduce the...Ch. 22 - Describe the necessary conditions for optimal...Ch. 22 - Negative rake angles generally are preferred for...Ch. 22 - Do you think that there is a relationship between...Ch. 22 - Make a survey of the technical literature, and...Ch. 22 - In Table 22.1, the last two properties listed...Ch. 22 - It has been stated that titanium-nitride coatings...Ch. 22 - Note in Fig. 22.1 that all tool materials,...Ch. 22 - Referring to Table 22.1, state which tool...Ch. 22 - Which of the properties listed in Table 22.1 is,...Ch. 22 - If a drill bit is intended only for woodworking...Ch. 22 - What are the consequences of a coating on a tool...Ch. 22 - Discuss the relative advantages and limitations of...Ch. 22 - Emulsion cutting fluids typically consist of 95%...Ch. 22 - List and explain the considerations involved in...Ch. 22 - Review the contents of Table 22.1. Plot several...Ch. 22 - Obtain data on the thermal properties of various...Ch. 22 - The first column in Table 22.2 shows 10 properties...Ch. 22 - Describe in detail your thoughts regarding the...Ch. 22 - One of the principal concerns with coolants is...Ch. 22 - How would you go about measuring the effectiveness...Ch. 22 - There are several types of cutting-tool materials...Ch. 22 - Assume that you are in charge of a laboratory for...Ch. 22 - Tool life could be greatly increased if an...Ch. 22 - List the concerns you would have if you needed to...
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- i need the answer quicklyarrow_forward2. The following data was obtained from an orthogonal cutting test: Rake angle = 20° Cutting speed = 100 m/min Chip length before cutting = 29.4 mm Chip length after cutting = 12.9 mm Vertical cutting force 1050 N Horizontal cutting force = 630 N Using Merchant's analysis, calculate (a) resultant force (c) friction force and friction angle (b) shear plane angle (d) total work donearrow_forward3. Draw the forces and angles involved in the cutting process and calculate shear angle (Ø), friction coefficient and tangential force if ,cutting force = 80 kN , resultant of forces =100kN , friction force=75KN, rake angle =20° undeformed chip thickness = 0.65mm and deformed chip thickness 0.72mm. %3Darrow_forward
- 22.28 Titanium-nitride coatings on tools reduce the coefficient of friction at the tool–chip interface. What is the significance of this property?arrow_forward22.7 Why is toughness im portant for cutting-tool materials?arrow_forward22.37 Which of the properties listed in Table 22.1 is, in your opinion, the least im portant in cutting tools? Explain.arrow_forward
- Question 1. Provide brief explanations to each one of the following questions: 1.a. Explain why studying the types of chips produced is important in understanding cutting operations. 1.b. Describe the reasons for and advantages of coating cutting tools with multiple layers of different materials. What are the possible effects of these coatings on the developed chip during cutting process 1.c. Describe the reasons for and advantages of coating cutting tools with multiple layers of different materials. 1.d. Emulsion cutting fluids typically consist of 95% water and 5% soluble oil and chemical additives. Why is the ratio so unbalanced? Is the oil needed at all? 1.e. What is the difference between a live center and a dead center, when these terms are used in the context of workholding in a lathe?arrow_forwardProblem 2. Turning Consider Step 2 (Turn Shoulder) in machining the flashlight handle (Figure 2). STEP 1: CUT TO LENGTH STEP 2: TURN SHOULDER 0.600 1.0" 3.000 -0.440 Figure 2. Turning step for Problem 2. i) Calculate the (1) cutting time (in s), (2) the material removal rate (in in3 /s or mm3/s) for this cut, assuming you remove all of the material with one pass (i.e., depth of cut d = (1"-0.6")/2 = 0.2"), and (3) the power (hp or W) required for this turning operation: Consider the following scenarios: Feed (f) in/rev Rotational Speed Cutting Time MRR Power (n) in RPM 0.02 1000 ? ? ? 0.025 900 ? ? ? 0.03 800 ? ? ? 1 j) What changes could you make to the process if you needed to decrease the power requirement?arrow_forward44. In Orthogonal Cutting Model, why chip thickness after cut is greater than chip thickness before cut? explain.arrow_forward
- 22.1 What are the major properties required of cutting-tool materials? Why?arrow_forward(a) Draw and label the basic orthogonal cutting process model. The diagram must include cutting direction, shear plane, chip formation and all relevant angles. (b) An orthogonal cutting operation is being carried out under the following conditions: depth of cut, to = 0.1 mm, chip thickness, to 0.2 mm, width of cut = 4 mm, cutting speed, v = 3 m/s, rake angle, a = 10°, Cutting force, Fo = 5000 N, and Thrust force, Fi= 200 N. Calculate the percentage of the total energy that is dissipated in the shear plane of cutting process. *)arrow_forwardIn a cutting test with 0.3 mm flank wear as tool failure criterion, a tool life of 10 min was obtained at a cutting velocity of 20 m/min. Taking tool life exponent as 0.25, the tool life in minutes at 40 m/min of cutting velocity will bearrow_forward
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