EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 8220100793431
Author: KALPAKJIAN
Publisher: PEARSON
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Textbook Question
Chapter 23, Problem 8RQ
Explain why operations such as boring on a lathe and tapping are difficult.
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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.
In a production turning operation, the workpart is 60 mm in diameter and 500 mm long. A feed of 0.75 mm/rev is used in the operation. If cutting speed=9 m/s, the tool must be changed every 4 workparts; But if cutting speed=5 m/s, the tool can be used to produce 50 pieces between tool changes. Determine the Taylor tool life equation for this job. (use the equations given below for solution)
A cylindrical work part 200
mm in diameter and 700mm
long is to be turned in an
engine lathe. cutting
conditions are as follows: -
cutting speed 2.3 m/s. feed
is 0.32 mm/rev. depth of cut
is 1.8 mm. calculate cutting
time.
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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- A slab-milling operation is carried out on a 200 mm long, 80-mm-wide annealed mild-steel workpiece having a feedrate of 0.1 mm/tooth and a depth of cut of 4.0 mm. The cutter of 50 mm diameter has 18 straight teeth and rotates at 135 rpm. The given specific energy for this material is 3.5 W s/mm3 and the slab mill is wider than the workpiece to be machined. Calculate:‧ the material-removal rate;‧ the power and torque required for this operation;‧ the cutting time. (243 mm/min, 77760 mm3/min, 4.5 kW, 52.8 s)arrow_forwardA motorised metal guillotine machine is required to cut 45 mm diameter hole in a plate of 20 mm thickness at rate of 35 holes per minute. It requires a torque of 7 Nm for an area of hole in mm². If the cutting takes 1/10 of a second and the speed of it's flywheel varies from 165 rpm to 145 rpm, calculate 4.1)Energy required to cut a hole 4.2)Energy required for cutting work per second. 4.3)Maximum fluctuation of energy of the flywheel 4.4)Mass of the flywheel having radius of gyrations of 1,5 marrow_forwardIn a production turning operation, the workpart is 60 mm in diameter and 500 mm long. A feed of 0.75 mm/rev is used in the operation. If cutting speed=9 m/s, the tool must be changed every 4 workparts; But if cutting speed=5 m/s, the tool can be used to produce 50 pieces between tool changes. Determine the Taylor tool life equation for this job. (use the equations given below for solution)arrow_forward
- In a production turning operation, the workpart is 60 mm in diameter and 500 mm long. A feed of 0.75 mm/rev is used in the operation. If cutting speed-9 m/s, the tool must be changed every 4 workparts; But if cutting speed=5 m/s, the tool can be used to produce 50 pieces between tool changes. Determine the Taylor tool life equation for this job. (use the equations given below for solution) L Tm- 1,= Nf N AD, vT" = C %3| AD,L Tm fvarrow_forwardFor the operation of straight turning in a lathe machine, the diameter of the workpiece is 80 mm, the length is 0.12 m, the cutting speed is 80 m / min, the feed is 0.5 mm / rev and the depth of cut is 0.002 m . Find the material removing rate and the time of machining.arrow_forwardEstimate 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.arrow_forward
- (a) Explain the difference between roughing and finishing operations in machining.(b) What are the parameters of a machining operation that are included within the scope of cuttingconditions?(c) What is the difference between threading and tapping?(d) A cylindrical workpiece is to be turned in a lathe. Determine the material removal rate if thecutting speed = 2.30 m/s, feed = 0.32 mm/rev, and depth of cut = 1.8 mm.(e) In a turning operation using high-speed steel tooling, the cutting speed = 110 m/min. The Taylortool life equation has parameters n = 0.140 and C = 150 (m/min) when the operation is conducteddry. When a coolant is used in the operation, the value of C is increased by 15%. Determine thepercent increase in tool life that will result if the cutting speed is maintained at 110 m/min.arrow_forwardA flat milling operation will be carried out with a horizontal milling machine, in a piece of 250 mm in length and 50 mm in width, using a felicoidal bur with a diameter of 75 mm, with 10 teeth. If the feed per tooth is 0.2mm, and the cutting speed is 0.75 m / s, how would you determine the speed of metal removal to remove 6 mm from the surface of this piece?arrow_forwardCalculate the r/min required for finish turning of a 45mm diameter piece of machine steel (The cutting speed of the machine steel is 30m/min).arrow_forward
- A student is performing a turning operation with a workpiece with an initial diameter of 40 mm to produce a 30 mm diameter rod that is 100 mm long. The lathe power is 20 kW and is operating on 85% mechanical efficiency. If the student set the cutting speed to 0.5 m/min and the cutting tool is set to have a rake angle of 5 degrees: a.) What material can we choose for the rod is the coefficient of friction is 0.5? b.) If we select 4130 normalized heat-treated steel for the rod, and coefficient of friction is 0.5, what will the maximum depth of cut we can achieve?arrow_forwardIn a lathe machine, the maximum torque transmitted by a shaft exceeds the mean torque by 18 %. A power of 3 kW has to be transmitted to another shaft at a speed of 625 rpm. What should be the value of Maximum torque ? The maximum torque transmitted in N-m,arrow_forwardGiven that the length of a work-piece made from copper alloy to be face-milled is 250 mm and the width is 25 mm. The cutter diameter is 150 mm and the tooth number is 10. 1. If it takes 20 seconds to perform the cutting, suggest a cutting speed (in mm/s) and a feed (in mm/rev) to be used. 2. Give another set of values of cutting speed (in mm/s) and feed (in mm/rev) that can give the same cutting time as above.arrow_forward
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