EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 8220100793431
Author: KALPAKJIAN
Publisher: PEARSON
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Textbook Question
Chapter 23, Problem 33QLP
Sketch the tooling marks you would expect if a part was (a) turned; (b) reduced in diameter with a straight form tool; and (c) extruded.
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A 200 mm long magnesium alloy bar, 63 mm in diameter is turned on a lathe using a high speed steel cutter travelling at 180 mm/min. The spindle rotates at 450 rpm and lathe is equipped with a 10 kW motor, operating at a mechanical efficiency of 92%. The final diameter of the magnesium alloy bar is 59,5 mm.
Indicate with a sketch the recommend size and location of the following tool angles: back rake, side rake, end relief, side relief and side and end cutting edge.
Calculate the cutting time for the machining process.Calculate the required cutting force.
1. A milling operation is to be performed on a ductile cast iron shaft to make slots for assembly. The operation will be done at high speeds for good surface finish. For each of the following tool materials, indicate whether it is a reasonable candidate to use in the operation with a detailed description of why or why not including required alloying element/grade/group etc. where applicable:
(i) plain carbon steel,
(ii) high-speed steel,
(iii) cemented carbide,
(iv) ceramic, and
(v) Sintered polycrystalline diamond.
After selection of material/materials discuss about
(i) recommended angles and tool signature
(ii) how to held cutting edge, and type of cutting fluids
With reasons for each recommended material.
2. Make a figure and explain how shear plane angle effect the power requirements in the machining. How can you reduce the power requirements during machining in orthogonal cutting?
1. A milling operation is to be performed on a ductile cast iron shaft
to make slots for assembly. The operation will be done at high
speeds for good surface finish. For each of the following tool
materials, indicate whether it is a reasonable candidate to use in
the operation with a detailed description of why or why not
including required alloying element/grade/group etc. where
applicable:
) plain carbon steel,
(i) high-speed steel,
(ii)cemented carbide,
(iv) ceramic, and
(v) Sintered polycrystalline diamond.
After selection of material/materials discuss about
) recommended angles and tool signature
(ii) how to held cutting edge, and type of cutting fluids
With reasons for each recommended material.
Chapter 23 Solutions
EBK MANUFACTURING ENGINEERING & TECHNOL
Ch. 23 - Describe the types of machining operations that...Ch. 23 - What is turning? What kind of chips are produced...Ch. 23 - What is the thrust force in turning? What is the...Ch. 23 - What are the components of a lathe?Ch. 23 - (a) What is a tracer lathe? (b) What is an...Ch. 23 - Describe the operations that can be performed on a...Ch. 23 - Why were power chucks developed?Ch. 23 - Explain why operations such as boring on a lathe...Ch. 23 - Why are turret lathes typically equipped with more...Ch. 23 - Describe the differences between boring a...
Ch. 23 - How is drill life determined?Ch. 23 - What is the difference between a conventional...Ch. 23 - Why are reaming operations performed?Ch. 23 - Explain the functions of the saddle on a lathe.Ch. 23 - Describe the relative advantages of (a)...Ch. 23 - Explain how external threads are cut on a lathe.Ch. 23 - Prob. 17RQCh. 23 - Explain the reasoning behind the various design...Ch. 23 - Note that both the terms tool strength and...Ch. 23 - (a) List and explain the factors that contribute...Ch. 23 - Explain why the sequence of drilling, boring, and...Ch. 23 - Why would machining operations be necessary even...Ch. 23 - A highly oxidized and uneven round bar is being...Ch. 23 - Describe the difficulties that may be encountered...Ch. 23 - (a) Does the force or torque in drilling change as...Ch. 23 - Explain the similarities and differences in the...Ch. 23 - Describe the advantages and applications of having...Ch. 23 - Assume that you are asked to perform a boring...Ch. 23 - Explain the reasons for the major trend that has...Ch. 23 - Describe your observations concerning the contents...Ch. 23 - The footnote to Table 23.12 states that as the...Ch. 23 - In modern manufacturing, which types of metal...Ch. 23 - Sketch the tooling marks you would expect if a...Ch. 23 - What concerns would you have in turning a powder...Ch. 23 - The operational severity for reaming is much lower...Ch. 23 - Review Fig. 23.6, and comment on the factors...Ch. 23 - Explain how gun drills remain centered during...Ch. 23 - Comment on the magnitude of the wedge angle on the...Ch. 23 - If inserts are used in a drill bit (see Fig....Ch. 23 - Refer to Fig. 23.11b, and in addition to the tools...Ch. 23 - Calculate the same quantities as in Example 23.1...Ch. 23 - Estimate the machining time required to rough turn...Ch. 23 - A high-strength cast-iron bar 8 in. in diameter is...Ch. 23 - A 0.30-in.-diameter drill is used on a drill press...Ch. 23 - In Example 23.4, assume that the workpiece...Ch. 23 - For the data in Problem 23.45, calculate the power...Ch. 23 - A 6-in.-diameter aluminum cylinder 10 in. in...Ch. 23 - A lathe is set up to machine a taper on a bar...Ch. 23 - Assuming that the coefficient of friction is 0.25,...Ch. 23 - A 3-in.-diameter, gray cast iron cylindrical part...Ch. 23 - Would you consider the machining processes...Ch. 23 - Would it be difficult to use the machining...Ch. 23 - If a bolt breaks in a hole, it typically is...Ch. 23 - An important trend in machining operations is the...Ch. 23 - Review Fig. 23.8d, and explain if it would be...Ch. 23 - Boring bars can be designed with internal damping...Ch. 23 - A large bolt is to be produced from extruded...Ch. 23 - Make a comprehensive table of the process...
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- Illustrate the basic operations of sheet metal working, indicating on the side of each illustration the name, type of load applied and type of tools used.arrow_forward4- A round sheet metal slug produced in a hole punching operation will have the same diameter as which of the following? (a) die opening, or (b) punch. 5- proof ( el+ ɛ2+ ɛ3=D0) at constant volume 6- List three of the products produced on a rolling mill. 7- Identify the three basic types of sheet metal working operations. 8- Which of the following is typical of the work geometry in sheet metal processes? (a) high volume-to-area ratio, or (b) low volume-to-area ratioarrow_forwardAsaparrow_forward
- The figure below shows a symmetric plane-strain upsetting process. The process may also be thought of as a form of side extrusion. Observations show that the deformation is confined to two shear planes, each one being analogous to that seen in plane-strain cutting. You may assume that there is no friction between the work material and the tool/die walls; the uniaxial yield strength of the material is σy and is independent of strain rate and temperature, and the material behaves as a rigid plastic solid. a) Calculate the pressure (p) required for the upsetting process in terms of σy. b) If friction existed at the die walls and the frictional work (energy) dissipation was 30% of the energy required for shape change alone (part (a) above), then what would be the pressure (p)?arrow_forwardThis Question is from Metal and Machine Tools. Due Today Please Answer !!arrow_forwardPlease carefully solvearrow_forward
- Define specific energy for plane strain machining (cutting). In plane-strain machỉning, the two main sources of energy dissipation are deformation along the shear plane (~70%) and friction at the tool-chip contact along the rake face (~30%). Consider machining of a rigid perfectly-plastic work material whose uniaxial yield stress is 700 MPa, and is independent of strain rate and temperature. A tool of zero-degree rake angle is employed. Measurements showed the (deformed) chip thickness to be twice that of the undeformed chip thickness. Based on the aforementioned distribution of energy, estimate the specific energy for this process.arrow_forward(34 10l ll SHEET 4 Lathes and... -> SHEET 4 Lathes and Milling operations 1- Define lath Process, why the tool should have Red Hardness Property? 2- What are the kinds of Cutting operations carried out using Lathes? 3- What are the Cutting Tools used in Shaping operation? 4- Explain some of common operation associated with drilling? 5- Define Milling Operations and what are differences between lathes and milling machines? 6- Explain with Drawings different types of Milling operations? 7- What are the different types of Milling machines?arrow_forwardThis problem from Degarmo's textbook is our report.arrow_forward
- In orthogonal turning of a cylindrical tube of wall thickness 5 mm, the axial and the tangential cutting forces were measured as 1259 N and 1601 N, respectively. The measured chip thickness after machining was found to be 0.3 mm. The rake angle was 10° and the axial feed was 100 mm/min. the rotational speed of the spindle was 1000 rpm. Assuming the material to be perfectly and Merchant's first solution, the shear strength of the material is closest toarrow_forward2. Calculate the blank size for the following sheet metal bending operation when the thickness of the sheet is 4mm, R-1.5t, A-60mm, B-250mm and C-80mm.arrow_forwardQuestion 3. A cemented carbide tool is used to turn a part with length = 18.0 in and diameter = 3.0 in. The parameters in the Taylor equation are: n= 0.27 and C = 1200. The rate for the operator and machine tool = $33.00/hr, and the tooling cost per cutting edge = $2.00. It takes 3.0 min to load and unload the workpart and 1.50 min to change tools. The feed = 0.013 in/rev. Determine: a) Cutting speed for maximum production rate, b) Tool life in min of cutting, and c) Cycle time and cost per unit of product.arrow_forward
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