Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 25, Problem 53SDP
To determine
Review the part in Fig. 25.1a and list the machining operations and machine tools you would recommend to produce this part.
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Investigate the non-traditional machining methods. Describe each in your own words and sketch
out the process and appropriate scale (inches/microns etc). Then tabulate the material removal
mechanism, workpiece materials, applications, costs/speed, advantages and
limitations/disadvantages of each. The slides are for your starting point. List references, articles,
videos, etc...
Mechanical Methods
1. Water Jet Machining (WJM)
2. Abrasive Water Jet Machining (AWJM)
3. Ultrasonic Machining (USM)
Non-Mechanical Methods
1. Electrochemical Machining (ECM)
2. Electro-Discharge Machining (EDM)
3. Wire EDM
4. Laser Drilling
5.
Electron beam machining (EBM)
6) It has been stated that it is generally undesirable to allow temperatures to rise
excessively in machining operations. Explain why.
7) Explain the possible disadvantages of a machining operation if a discontinuous
chip is produced.
8) List and explain the factors that contribute to poor surface finish in machining
operations
9) Given your understanding of the basic machining process, describe the important
physical and chemical properties of a cutting tool.
2 1.23 Tool life can be almost infinite at low cutting speeds.Would you then recommend that all machining be done at low speeds? Explain.
Chapter 25 Solutions
Manufacturing Engineering & Technology
Ch. 25 - Describe the distinctive features of machining...Ch. 25 - Explain how the tooling system in a machining...Ch. 25 - Explain the trends in materials used for...Ch. 25 - Is there any difference between chatter and...Ch. 25 - What are the differences between forced and...Ch. 25 - Explain the importance of foundations in...Ch. 25 - Explain why automated pallet changers and...Ch. 25 - What types of materials are machine-tool bases...Ch. 25 - What is meant by the modular construction of...Ch. 25 - What is a hexapod? What are its advantages?
Ch. 25 - What factors contribute to costs in machining...Ch. 25 - List the reasons that temperature is important in...Ch. 25 - Explain the technical and economic factors that...Ch. 25 - Spindle speeds in machining centers vary over a...Ch. 25 - Explain the importance of stiffness and damping of...Ch. 25 - Are there machining operations described in...Ch. 25 - How important is the control of cutting-fluid...Ch. 25 - Review Fig. 25.10 on modular machining centers,...Ch. 25 - Prob. 19QLPCh. 25 - Describe the adverse effects of vibration and...Ch. 25 - Describe some specific situations in which thermal...Ch. 25 - Prob. 22QLPCh. 25 - Prob. 23QLPCh. 25 - Prob. 24QLPCh. 25 - List the parameters that influence the temperature...Ch. 25 - List and explain factors that contribute to poor...Ch. 25 - Prob. 27QLPCh. 25 - Prob. 28QLPCh. 25 - Describe types and sizes of workpieces that would...Ch. 25 - Prob. 30QLPCh. 25 - Explain the advantages and disadvantages of...Ch. 25 - What are the advantages and disadvantages of (a)...Ch. 25 - What would be the advantages and limitations of...Ch. 25 - Explain how you would go about reducing each of...Ch. 25 - Describe workpieces that would not be suitable for...Ch. 25 - Give examples of forced vibration or self-excited...Ch. 25 - A machining-center spindle and tool extend 10 in....Ch. 25 - Using the data given in the example, estimate the...Ch. 25 - A machining-center spindle and tool extend 12 in....Ch. 25 - In the production of a machined valve, the labor...Ch. 25 - Estimate the optimum cutting speed in Problem...Ch. 25 - Prob. 42QTPCh. 25 - If you were the chief engineer in charge of the...Ch. 25 - Prob. 45SDPCh. 25 - Make a list of components of machine tools that...Ch. 25 - The cost of machining and turning centers is...Ch. 25 - Prob. 49SDPCh. 25 - Describe your thoughts on whether or not it is...Ch. 25 - Prob. 51SDPCh. 25 - Prob. 53SDP
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- hand write asap ( i'll give you multiple upvotearrow_forwardEstimate the machining time that will be required to finish a vertical flat surface of length 100 mm and depth 20 mm by an end mill cutter of 32 mm diameter and 60 mm length in a milling machine. Assume cutting speed of 30 m/min and feed of 0.12 mm/tooth. Let over run distance equal to approach distance.arrow_forwardIn 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.arrow_forward
- In an orthogonal cutting operation an 8 mm deep groove is to be turned on a 50 mm diameter steel bar. Spindle speed is 300 rpm and a feed rate of 0.25 mm/rev is given to the tool. Produced chips have a width of 2 mm. Calculate the material removal rate at the beginning and at the end of the cut. Can u help me please?arrow_forwardFor the following application, identify one or more nontraditional machining processes that might be used, and present arguments to support your selection. Assume that either the part geometry or the work material (or both) preclude the use of conventional machining. The application is a through-hole in the shape of the letter L in a 12.5 mm (0.5 in) thick plate of glass. The size of the "L" is 25 by 15 mm (1.0 by 0.6 in) and the width of the hole is 3 mm (1/8 in).arrow_forwardCalculate the machining time intervals for face milling a cutter 10 inches long, 2 inches wide, with a depth of cut of 0.1 inch for the following workpiece materials: (a) low-carbon steel ; (b) titanium alloys; (c) aluminum alloys, and (d) thermoplastics.arrow_forward
- Title It has been stated that it is generally undesirable to allow temperatures to rise excessively in... Description It has been stated that it is generally undesirable to allow temperatures to rise excessively in machining operations. Explain why. By the student. This is an open-ended problem with a large number of acceptable answers. The consequences of allowing temperatures to rise to high levels in cutting include: (a) Tool wear will be accelerated due to high temperatures. (b) High temperatures will cause dimensional changes in the workpiece, thus reducing dimensional accuracy. (c) Excessively high temperatures in the cutting zone may induce metallurgical changes and cause thermal damage to the machined surface, thus affecting surface integrity.arrow_forwardIn an orthogonal machining with a tool of 9 degree orthogonal rake angle, the uncut chip thickness is 0.2mm. The chip thickness fluctuates between 0.25 mm and 0.4 mm. The ratio of the maximum shear angle to the minimum shear angle during machining isarrow_forwardFor the following application, identify one or more nontraditional machining processes that might be used, and present arguments to support your selection. Assume that either the part geometry or the work material (or both) preclude the use of conventional machining. The application is a blind-hole in the shape of the letter G in a 50 mm (2.0 in) cube of steel. The overall size of the "G" is 25 by 19 mm (1.0 by 0.75 in), the depth of the hole is 3.8 mm (0.15 in), and its width is 3 mm (1/8 in).arrow_forward
- For the following application, identify one or more nontraditional machining processes that might be used, and present arguments to support your selection. Assume that either the part geometry or the work material (or both) preclude the use of conventional machining. The application is a matrix of 0.1 mm (0.004 in) diameter holes in a plate of 3.2 mm (0.125 in) thick hardened tool steel. The matrix is rectangular, 75 by 125 mm (3.0 by 5.0 in) with the separation between holes in each direction = 1.6 mm ( 0.0625 in).arrow_forwardi need the answer quicklyarrow_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_forward
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