EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 8220100793431
Author: KALPAKJIAN
Publisher: PEARSON
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Textbook Question
Chapter 24, Problem 22QLP
Explain why broaching crankshaft bearings is an attractive alternative to other machining processes.
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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)
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.
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
fv
Chapter 24 Solutions
EBK MANUFACTURING ENGINEERING & TECHNOL
Ch. 24 - Explain why milling is such a versatile machining...Ch. 24 - Describe a milling machine. How is it different...Ch. 24 - Describe the different types of cutters used in...Ch. 24 - Define the following: face milling, peripheral...Ch. 24 - Can threads be machined on a mill? Explain.Ch. 24 - What is the difference between feed and feed per...Ch. 24 - Explain the relative characteristics of climb...Ch. 24 - Describe the geometric features of a broach and...Ch. 24 - What is a pull broach? A push broach?Ch. 24 - Why is sawing a commonly used process? Why do some...
Ch. 24 - What advantages do bed-type milling machines have...Ch. 24 - Explain why the axis of a hob is tilted with...Ch. 24 - What is a shell mill? Why is it used?Ch. 24 - Why is it difficult to saw thin sheet metals?Ch. 24 - Of the processes depicted in Fig. 24.2, which is...Ch. 24 - Describe the tool motion during gear shaping.Ch. 24 - When is filing necessary?Ch. 24 - Would you consider the machining processes...Ch. 24 - Why is end milling such an important versatile...Ch. 24 - List and explain factors that contribute to poor...Ch. 24 - Explain why broaching crankshaft bearings is an...Ch. 24 - Several guidelines are presented in this chapter...Ch. 24 - What are the advantages of helical teeth over...Ch. 24 - Explain why hacksaws are not as productive as band...Ch. 24 - What similarities and differences are there in...Ch. 24 - Why do machined gears have to be subjected to...Ch. 24 - How would you reduce the surface roughness shown...Ch. 24 - Why are machines such as the one shown in Fig....Ch. 24 - Comment on your observations concerning the...Ch. 24 - Explain how contour cutting could be started in a...Ch. 24 - Prob. 32QLPCh. 24 - Describe the parts and conditions under which...Ch. 24 - Explain the reason that it is difficult to use...Ch. 24 - Would you recommend broaching a keyway on a gear...Ch. 24 - Prob. 37QTPCh. 24 - A slab-milling operation is being performed at a...Ch. 24 - Show that the distance lc in slab milling is...Ch. 24 - Prob. 40QTPCh. 24 - Calculate the chip depth of cut, tc, and the...Ch. 24 - Estimate the time required to face mill a...Ch. 24 - A 12-in.-long, 1-in.-thick plate is being cut on a...Ch. 24 - A single-thread hob is used to cut 40 teeth on a...Ch. 24 - Assume that m the face-milling operation shown in...Ch. 24 - A slab-milling operation will take place on a part...Ch. 24 - Prob. 47QTPCh. 24 - In describing the broaching operations and the...Ch. 24 - The parts shown in Fig. 24.1 are to be machined...Ch. 24 - Would you prefer to machine the part in Fig. 24....Ch. 24 - Prob. 51SDPCh. 24 - Suggest methods whereby milling cutters of various...Ch. 24 - Prepare a comprehensive table of the process...Ch. 24 - Prob. 55SDPCh. 24 - Make a list of all the processes that can be used...
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- Explain the difference between gear hobbing and gear shaping with referenceto various relative motions and applicationsarrow_forward1. 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?arrow_forwardA selection between advanced machining operation and conventional machine operation is to be made for mass production of 1000 parts. The part is a 20mm thick stainless steel plate and a hole of 10mm must be drilled. Calculate time required, material removal rate and feed rate for both processes to make a known decision to save production cost. The ECM process require 1000amp current with an expected efficiency of 90% whereas the conventional drilling is to be done with 8mm drill through hole. The point angle is 118°. The cutting speed is 15m/min and the feed is 0.30 mm/rev. The part handling time for ECM is 1min whereas for conventional process is 1.5min with the use of jig.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)arrow_forwardProblem 2. (Determining Cutting Speeds in Machining Economics) A turning operation is performed with HSS tooling on mild steel, with Taylor tool life parameters n = 0.12, C = 60 m/min. Work part length = 450 mm and diameter = 80 mm. Feed = 0.20 mm/rev. Handling time per piece = 4.0 min, and tool change time = 1.5 min. Cost of machine and operator = $27/hr, and tooling cost = $2 per cutting edge. Find the a. cutting speed for maximum production rate = 44.997m/min. b. cutting speed for minimum cost = 38.143m/min. Problem 3. (Production Rate and Cost in Machining Economics) For the two cutting speeds computed in problem 2, determine: a. the hourly production rate and b. the cost per piece. Need help with problem 3 already done problem 2arrow_forwardProblem 2. (Determining Cutting Speeds in Machining Economics) A turning operation is performed with HSS tooling on mild steel, with Taylor tool life parameters n = 0.12, C = 60 m/min. Work part length = 450 mm and diameter = 80 mm. Feed = 0.20 mm/rev. Handling time per piece = 4.0 min, and tool change time = 1.5 min. Cost of machine and operator = $27/hr, and tooling cost = $2 per cutting edge. Find the a. cutting speed for maximum production rate and b. cutting speed for minimum cost Problem 3. (Production Rate and Cost in Machining Economics) For the two cutting speeds computed in problem 2, determine: the hourly production rate and a. b. the cost per piece.arrow_forward
- A 16mm Solid carbide tool with two teeth is used to machine Aluminium using the cutting speed of 275.00 m/min. The feed per tooth is 0.28 mm. What is the right feed rate to use to program the CNC machine? Your Answer: Answerarrow_forward1. A 7.5 -mm-diameter drill is used on a drill press operating at 300 rpm. If the feed is 0.125 mm/rev, what is the MRR? What is the MRR if the drill diameter is doubled? 2. Assume that the work piece material is high-strength aluminum alloy and the spindle is running at N = 500 rpm. Estimate the torque required for this operation.arrow_forwardA turning operation is performed with HSS tooling on mild steel, with Taylor tool life parameters n = 0.12, C = 60 m/min. Work part length = 450 mm and diameter = 80 mm. Feed = 0.20 mm/rev. Handling time per piece = 4.0 min, and tool change time = 1.5 min. Cost of machine and operator = $27/hr, and tooling cost = $2 per cutting edge. Find the a. cutting speed for maximum production rate and b. cutting speed for minimum cost Equations used n *-=c(")* Vmax = C 1-n Tt Vmin = C =c(₁" n 1 n Co n CoTt + Ct narrow_forward
- Site an example of eccentrics and describe its function. NOTE: An eccentric is a shaft that may have two or more turned diameters parallel to each other, but not concentric with the normal axis of work. Eccentrics are used in locking devices, in the feed mechanism on some shapers, and in the crankshaft of an automobile, etc., where it is necessary to convert rotary motion into reciprocating motion, or vice versa.arrow_forwardExplain any one of the turning operations in terms of tool shape,tool path, final and generated geometry, possible tolerances. Then list possible applications or products that are made using that operation.arrow_forwardI need the answer at 20 minutearrow_forward
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