Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 22, Problem 37QLP
Which of the properties listed in Table 22.1 is, in your opinion, the least important in cutting tools? Explain.
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Estimate the machining time required in rough turning a 2.0-m-long, annealed aluminum-alloy round bar that is 75 mm in diameter, using (a) a high-speed steel tool; and (b) a carbine tool. Use a feed of 2 mm/rev. Assume max cutting speed for high-speed tools is moving 4 m/s and for carbide tools is moving 7 m/s.
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.
Determine ratio of friction energy to total energy
Chapter 22 Solutions
Manufacturing Engineering & Technology
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 at 20 minutearrow_forwardWhat are the functions served by cutting fluid? Give broad classification of cutting fluid and explain each in detail .arrow_forwardQuestion 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)…arrow_forward
- 2 2 . 16 Explain why so many different types of cutting-tool materials have been developed over the years. Why are they still being developed further?arrow_forward(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, Fc = 500 N, and Thrust force, F1= 200 N. Calculate the percentage of the total energy that is dissipated in the shear plane of cutting process.arrow_forward(b) During a certain machining experiment at the UCSI workshop, it is observed that temperature at the tool workpiece interface is 1200 °C at a cutting speed of 300 mm/min with a feed rate of 0.002 mm/rev. (1) Analyse how the temperature will be affected if the cutting speed is increased by 100 %. (ii) Detemine the cutting speed necessary to achieve a maximum cutting temperature of 900 °C.arrow_forward
- In conventional metal cutting process,tool wear is inevitable.Explain why cutting tool failure due to tool wear is difficult to predict.(Write it broadly in your own words)arrow_forwardDuring orthogonal cutting operation of material has shear strength 95.5 Mpa. The cutting force is more than thrust force by 10%. The rake angle = 5°, the width of the cut = 5.0 mm, the chip thickness before the cut = 0.6, and the chip thickness ratio = 0.38. Determine (a) both cutting force and thrust force and (b) the coefficient of friction in the operation.arrow_forward2 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_forward
- Draw the geometry of single point cutting tool (3 views) and explain the importance of each angle in metal cutting.arrow_forwardDiscuss the effects of cutting speed, feed rate, and depth of cut on the tool wear rate during a turning operation. How does each parameter influence the surface finish of the workpiece? Provide a detailed explanation based on the principles of metal cutting mechanics.arrow_forwardA turning operation is carried out on aluminum. Based on the specific energy values in the table in your text, determine material removal rate and cutting power in the operation under the following sets of conditions: (a) Cutting speed = 5.6 m/s, feed = 0.25 mm/rev, and depth of cut = 2.0 mm; and (b) cutting speed = 1.3 m/s, feed = 0.75 mm/rev, and depth of cut = 4.0 mm.arrow_forward
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