Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 22, Problem 47SDP
One of the principal concerns with coolants is degradation due to biological attack by bacteria. To prolong the life of a coolant, chemical biocides often are added, but these biocides greatly complicate the disposal of the coolant. Conduct a literature search concerning the latest developments in the use of environmentally benign biocides in cutting fluids.
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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?
The frontal working area of the electrode in an Electrochemical Machining (ECM)
operation is 1000 mm. The applied current is 900 amps and the voltage is 12 volts.
The resistivity of the electi olyte is 140 Q-mm. The material being cut has a valency
of 4 and specific removal rate of 0.0342 mm /A-s. If the process efficiency is 90%,
determine the material remova! rate (MRR) and inter-electrode gap after 30 minutes
of machining when the resistivity of the electrolyte has dropped to 75% of its
original value.
What form of energy is used in electrosugical cutting? 2. What are the modes of electrosurgery?
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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- What two ingredients are often used as additives to improve lubrication qualities of cutting oils?arrow_forwardThe frontal working area of the electrode in an ECM operation is 2000 mm?. The applied current is 2000 amps and the voltage is 12 volts. The material being cut is nickel (valence = 2, CN; =3.42x10-2mm2/A-s). (a) If the process is 90% efficient, determine the cutting rate into the workpart. (b) If the resistivity of the electrolyte is 160 ohm – mm, determine the working gap. Tool feed Tool holder and feed mechanism Formed tool (cathode). Electrolyte flow -Insulation Electrolyte Work (anode) feed mm/min gap micrometersarrow_forwardWhich of the following processes resulted in metallurgical damage to the cut surface: a. Ultrasonic machining b. Water jet cutting C. Plasma arc cutting d. Electrochemical machining e. None of themarrow_forward
- Calculate the material removal rate and electrode feed rate in the electrochemical machining of an iron surface that is 25 mm × 25 mm in cross-section, using NaCl in water as electrolyte. The gap between the tool and the work-piece is 0.25 mm. The supply voltage is 12 volt D.C. The specific resistance of electrolyte is 3 2 cm. Take for iron: Valency = 2, Atomic weight = 55.85,Density = 7860 kg/m³.arrow_forwardExplain the differences between active and passive recovery methods.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
- Please I want answer for this question. Thanksarrow_forward1) Identify what are the step by step machining and grinding processes to produce that part from a blank material. Assume that both part made from cast iron. 2) Then, taking into consideration of green manufacturing/ sustainability, you need to suggest what kind of improvement that you could do to the list of machining processes that you have identified (e.g. change of machining operation, use of dry machining instead of using cutting fluid or etc.) to reduce power consumption during machining, reduce waste and even pollution. Please give justification on your suggestions. 3). You need to include the figure of your chosen part and label the processes involve.arrow_forwardSelect TWO (2) types of cutting processes that are cleanly cut for preparing edge connection of Coupling of stainless steel.arrow_forward
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