EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 8220100793431
Author: KALPAKJIAN
Publisher: PEARSON
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Textbook Question
Chapter 27, Problem 32QTP
If the operation in Problem 27.31 were performed on an electrical-discharge machine, what would be the estimated machining time?
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Find the machining time required to turn a mild steel rod from 65mm to 58
mm over a length of 100 mm by using a carbide insert. If the approach length
and over run length is taken as 5 mm, Cutting speed as 20 m/min and feed is
=0.2 mm/rev, and the depth of cut is 0.5mm
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)
Q1. Calculate the time required to machine a workpiece 170 mm long, 60 mm diameter to 165 mm long
50 mm diameter. The workpiece rotates at 440 rpm, feed is 0.3 mm/rev and maximum depth of cut is 2
mm. Assume total approach and overtravel distance as 5 mm for turning operation.
Answer
Q2. A gray cast iron surface 280 wide and 540mm long may be machined either on a vertical milling
machine, using a 100mm - diameter face mill having eight inserted HSS teeth, or on a horizontal milling
machine using an HSS slab mill with eight teeth on a 200-mm. diameter. Which machine has the faster
cutting time? The values of feed per tooth and cutting speed for both processes are 0.4mm/tooth and
80m/min, respectively. The depth of cut = 3.0 mm and assume A and O equal to 5.
Answer
Chapter 27 Solutions
EBK MANUFACTURING ENGINEERING & TECHNOL
Ch. 27 - Describe the similarities and differences between...Ch. 27 - Name the processes involved in chemical machining....Ch. 27 - Explain the difference between chemical machining...Ch. 27 - What is the underlying principle of...Ch. 27 - Explain how the EDM process is capable of...Ch. 27 - What are the important features of the Blue Arc...Ch. 27 - What are the capabilities of wire EDM? Could this...Ch. 27 - Explain why laser Microjet has a large depth of...Ch. 27 - Describe the advantages of water-jet machining.Ch. 27 - What is the difference between photochemical...
Ch. 27 - What type of workpiece is not suitable for...Ch. 27 - What is an undercut? Why must it be considered in...Ch. 27 - Explain the principle of hybrid machining.Ch. 27 - Give technical and economic reasons that the...Ch. 27 - Why is the preshaping or premachining of parts...Ch. 27 - Explain why the mechanical properties of workpiece...Ch. 27 - Prob. 17QLPCh. 27 - Prob. 18QLPCh. 27 - Why has electrical-discharge machining become so...Ch. 27 - Prob. 20QLPCh. 27 - Which of the advanced machining processes would...Ch. 27 - Which of the processes described in require a...Ch. 27 - Describe your thoughts regarding the laser-beam...Ch. 27 - Are deburring operations still necessary for some...Ch. 27 - List and explain factors that contribute to a poor...Ch. 27 - What is the purpose of the abrasives in...Ch. 27 - Which of the processes described in this chapter...Ch. 27 - Is kerf width important in wire EDM? Explain.Ch. 27 - Comment on your observations regarding Fig. 27.4.Ch. 27 - Why may different advanced machining processes...Ch. 27 - A 200-mm-deep hole that is 30 mm in diameter is...Ch. 27 - If the operation in Problem 27.31 were performed...Ch. 27 - A cutting-off operation is being performed with a...Ch. 27 - A 0.80-in.-thick copper plate is being machined by...Ch. 27 - Explain why it is difficult to produce sharp...Ch. 27 - Make a list of the processes described in this...Ch. 27 - Would the processes described in this chapter be...Ch. 27 - Prob. 38SDPCh. 27 - Describe your thoughts as to whether the...Ch. 27 - Make a list of machining processes that may be...Ch. 27 - At what stage is the abrasive in abrasive...Ch. 27 - Describe the similarities and differences among...Ch. 27 - Describe the similarities and differences among...Ch. 27 - Describe any workpiece size limitations in...Ch. 27 - Suggest several design applications for the types...Ch. 27 - Based on the topics covered in Parts III and IV,...Ch. 27 - Review Example 27.1 and explain the relevant...Ch. 27 - Precision engineering is a term that is used to...Ch. 27 - With appropriate sketches, describe the principles...Ch. 27 - Make a table of the process capabilities of the...Ch. 27 - One of the general concerns regarding advanced...Ch. 27 - It can be seen that several of the processes...
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- 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_forwardA surface of 43 mm x 246 mm will be machined by using a shaper and 7 mm deep stock will be removed from the surface. The shaper is operating at 24 strokes/minute and feed is 0.7 mm/stroke. If the maximum stroke length is 827 mm and allowable depth of cut is 0.4 mm for both of rough and finish cuts, what is the total machining time, in minutes ?arrow_forwardIn orthogonal machining operation the chip thickness and the uncut chip thickness are equal to 0.45 mm. If the tool rake and is 0 deg. What is the shear plane angle?arrow_forward
- A 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_forwardI need the answer as soon as possiblearrow_forwardQuiz A piece of Low carbon steel has (85mm) length machined by a lathe with cutting tool made of HSS, depth of cut (2mm), feed (0.2mm/rev) and (4) number of cycles with (30m/min) cutting speed. If the final diameter is (44mm). calculate the machining time of this piece.arrow_forward
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