Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 33, Problem 51SDP
Describe your thoughts on the desirability of integrating surface-roughness measuring instruments into the machine tools described in Parts III and IV? How would you go about doing so, giving special consideration to the factory environment in which they are to be used? Make some preliminary sketches of such a system.
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(a)
Figure 1 shows surface roughness and tolerances obtained in Chemical
Machining (CM) and Electrochemical Machining (ECM) process for different
types of electronic products.
Comment on the differences between chemical and electrochemical machining
process in terms of surface roughness and tolerance of the machined product as
illustrated in Figure 1.
0.9
CM
0.8
0.7
Z ECM
0.6
0.5
0.4
0.3
0.2
0.1
Product A
Product B
Product C
Product D
Products
25
E ČM
20
Z ECM
15
10
Product A
Product B
Product C
Product D
Products
Figure 1: Surface roughness and tolerances of various electronic products
Surface roughness, Ra
Tolerance, (t mm x 10)
Estimate the manufacturing cost for a simple machined component: a. Compare the costs for manufacturing volumes of 1, 10, 100, 1000, and 10,000 pieces with an intermediate tolerance and surface finish. Explain why there is a great change between 1 and 10 and a small change between 1000 and 10,000 pieces. b. Compare the costs for fit, intermediate, and rough tolerances with a volume of 100 pieces. c. Compare the costs of manufacturing the component out of various materials.
A turning machining experiment was performed at the UCSI University's
Mechanical Engineering workshop using a lathe machine with palm oil as
lubricant. It was observed that during the entire machining, the technician set
cutting tool perpendicular to the direction of tool motion. A further investigation
revealed that the tool rake angle was 25° while the dynamometer results'
analysis showed that the frictional force and the normal force to the friction was
5 kN and 25 kN respectively. Analyze how the chip thickness will be affected
if the machining is performed without any lubricant and the frictional force is
increased by 100 %. Assume that, all other parameters were kept constant during
the entire operation for both machining with lubricant and the dry machining
process.
Chapter 33 Solutions
Manufacturing Engineering & Technology
Ch. 33 - What is tribology?Ch. 33 - Explain what is meant by (a) surface texture and...Ch. 33 - List and explain the types of defects typically...Ch. 33 - Define the terms (a) roughness, and (b) waviness.Ch. 33 - Explain why the results from a profilometer are...Ch. 33 - Prob. 6RQCh. 33 - List the types of wear generally observed in...Ch. 33 - Define the terms wear, friction, and lubricant.Ch. 33 - How can adhesive wear be reduced? Abrasive wear?Ch. 33 - Prob. 10RQ
Ch. 33 - Explain the functions of a lubricant in...Ch. 33 - Prob. 12RQCh. 33 - Prob. 13RQCh. 33 - Describe the factors involved in lubricant...Ch. 33 - Prob. 15RQCh. 33 - Prob. 16QLPCh. 33 - Explain the significance of the fact that the...Ch. 33 - Prob. 18QLPCh. 33 - Explain why identical surface-roughness values do...Ch. 33 - Prob. 20QLPCh. 33 - Prob. 21QLPCh. 33 - Prob. 22QLPCh. 33 - Prob. 23QLPCh. 33 - Comment on the surface roughness of various parts...Ch. 33 - Prob. 25QLPCh. 33 - Do the same as for Problem 33.25, but for surface...Ch. 33 - Describe your observations regarding Fig. 33.7.Ch. 33 - Give the reasons that an originally round specimen...Ch. 33 - Prob. 29QLPCh. 33 - Explain the reason that the abrasive-wear...Ch. 33 - Prob. 31QLPCh. 33 - List the similarities and differences between...Ch. 33 - Explain why the types of wear shown in Fig. 33.11...Ch. 33 - List the requirements of a lubricant.Ch. 33 - List manufacturing operations in which high...Ch. 33 - List manufacturing operations in which high wear...Ch. 33 - Prob. 37QLPCh. 33 - Prob. 38QTPCh. 33 - A surface with a triangular sawtooth roughness...Ch. 33 - List the steps you would follow if you wished to...Ch. 33 - Discuss the tribological differences between...Ch. 33 - Section 33.2 listed major surface defects. How...Ch. 33 - Describe your own thoughts regarding biological...Ch. 33 - Prob. 48SDPCh. 33 - Prob. 49SDPCh. 33 - Prob. 50SDPCh. 33 - Describe your thoughts on the desirability of...
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- manufacturing technology please answer as soon as possiblearrow_forwardDear Tutor please help me pleasearrow_forwardDefine specific energy for plane strain machining (cutting). In plane-strain machỉning, the two main sources of energy dissipation are deformation along the shear plane (~70%) and friction at the tool-chip contact along the rake face (~30%). Consider machining of a rigid perfectly-plastic work material whose uniaxial yield stress is 700 MPa, and is independent of strain rate and temperature. A tool of zero-degree rake angle is employed. Measurements showed the (deformed) chip thickness to be twice that of the undeformed chip thickness. Based on the aforementioned distribution of energy, estimate the specific energy for this process.arrow_forward
- Please solve no 4 (engineering tribology)arrow_forward2 2 . 11 Describe the advantages and limitations of (a) single crystal and (b) polycrystalline diamond tools.arrow_forwardWhat are assessments that measure strength, speed, agility, or high-speed strength? What are the protocols and norms for each?arrow_forward
- A machine part must be inserted in a proper orientation, what modification you should do with part A?arrow_forwardIn plane-strain orthogonal machining, the two main sources of energy dissipation are deformation along the shear plane (~70%) and friction at the tool-chip contact along the rake face (~30%). Consider plane-strain machining of a rigid perfectly-plastic work material whose uniaxial yield stress is 700 MPa, and is independent of strain rate and temperature. A tool of zero-degree rake angle is employed. Measurements showed the (deformed) chip thickness to be twice that of the undeformed chip thickness. Based on the aforementioned distribution of energy, estimate the specific energy for this process.arrow_forwardIn an orthogonal cutting test with a bar of 75 mm diameter is reduced to 73 mm by using a HSS tool with arake angle = 10o, following observations were made: length of the chip, lc = 69.44 mm, cutting ratio r =0.3, the horizontal component of the cutting force, FH = 1450 N, and the vertical component of the cuttingforce, FV = 850 N. The various parameters recorded in this cutting operation are: depth of cut, d = 2 mm;feed rate, f = 0.3 mm/rev, cutting speed, V = 60 m/min. Using Merchant’s theory calculate the following:1) Friction force along rake face2) Normal force acting on rake face3) Shear force along the shear plane4) Normal force acting on shear plane5) The percentage error in shear angle predicted by Merchant’s theory6) Shear velocity7) Chip velocity8) Total work done9) The shear work proportion out of the total work done10) The friction work proportion out of the total work donearrow_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_forwardThe tool signature of a single point cutting tool in ORS system is 10° – 15° – 20° – 15° – 30° – 60° – 0 mm. Assume reasonable length of the tool, cross-sectional area, shank length and other dimensions if required. (a) Draw an isometric view (in scale) of the single point cutting tool. (b) Show all the angles clearly in sectional views.arrow_forward(a) Describe three basic categories of material removal process. (b) What is the different between machining with another manufacturing process. (c) Explain the advantages and disadvantages machining process. (d) Briefly explain the difference between roughing and finishing operation in machining.arrow_forward
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