EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 9780100793439
Author: KALPAKJIAN
Publisher: YUZU
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Textbook Question
Chapter 24, Problem 30QLP
Comment on your observations concerning the designs illustrated in Fig. 24.23b and on the usefulness of broaching operations.
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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.
In machining a mild steel work piece with carbide tool, the life of the tool was
found to be 1 hour and 40 minutes, at a spindle speed of 30 m/min. Calculate the
tool life if it has to be operated at a speed of 40% higher than the initial cutting
speed. Also calculate the cutting speed if the tool is required to have a life of
2 hours and 45 minutes. Assume Taylor's exponent valuen is 0.28.
(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.
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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- 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.arrow_forwardDetermine ratio of friction energy to total energyarrow_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
- An external turning operation is performed on a hollow workpiece of 200 mm external diameter and 100 mm inner diameter, at 40 m/min cutting speed, 2 mm depth of cut and 0.20 mm/rev feed. Calculate: The rotational speed for this workpiece. The machining time needed for a length of 250 mm. The material removal rate used. The parting-off time needed if the cross feed is 0.1 mm/rev. The expected tool life if the constants in Taylor Formula are n=0.23 and C= 240. The maximum number of work pieces that could be produced under the given cutting conditions, before the tool needs re-sharpening.arrow_forward11. Estimate the machining time required to rough turn a 0.5 m long annealed copper alloyRound bar from a 60 mm diameter to a 58 mm diameter, using a high-speed tool. Estimate the time required for an uncoated carbide tool.arrow_forwardAn orthogonal cutting operations is being carried out in which uncut thickness is 0.010 mm, cutting speed is 130 m/min, rake angle is 15° and width of cut is 6 mm. It is observed that the chip thickness is 0.015 mm, the cutting force is 60 N and the thrust force is 25 N. The ratio of friction energy to total energy is (correct to twoarrow_forward
- This Question is from Metal and Machine Tools. Due Today Please Answer !!arrow_forwardIn face milling, assume that the Diameter of the cutter is 200 mm, the width of the block is 60 mm, and the length of the block is 344 mm, if the depth of cut is 3 mm, = 0.6 mm/min, and N = 100 rpm. The cutter has 12 inserts, and the workpiece material is bronze. Calculate the estimated power required, the cutting force, and the torque.arrow_forwardThe outside diameter of a cylinder made of steel is to be turned. The starting diameter is 120 mm and the length is 1400 mm. The feed is 0.3 mm/rev and the depth of cut is 2.5mm. The cut will be made with a cemented carbide cutting tool whose Taylor tool life parameters are: n= 0.33 and C=500. Units for the Taylor equation are min for tool life and m/min for cutting speed. Compute the cutting speed that will allow the tool life to be just equal to the cutting time required to complete this turning operation.arrow_forward
- A 6.5 inch long, 0.5 inch diameter stainless steel rod is being reduced to 0.480 inches by turning on a lathe. The spindle rotates at 400 RPM and the tool is travelling at an axial speed of 8 inches/min. Calculate the cutting speed, feed, time, and material removal rate required.arrow_forwardOrthogonal turning is performed on a cylindrical workpiece with shear strength of 250 MPa. The following conditions are used: cutting velocity is 180 m/min, feed is 0.20 mm/rev, depth of cut is 3 mm, chip thickness 0.5. The orthogonal rake angle is 7°. Apply ratio Merchant's theory for analysis.arrow_forwardAssume that, in orthogonal cutting, the rake angle, oz,is 20° and the friction angle, B, is 35° at the chip-tool interface.Determine the percentage change in chip thickness when the friction angle is 50°. (Note: do not use Eq. (21.3)arrow_forward
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