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Manufacturing Technology: Metal Cutting > Cutting Types And Rake Angles > Flashcards

Cutting Types And Rake Angles Flashcards

1
Q

What characteristics will a positive rake angle produce?

A
  • Sharper cutting edge
  • lower cutting force required -> less power consumption.
  • higher surface quality and cutting speed.
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2
Q

What characteristics will a negative rake angle produce?

A
  • longer tool life
  • higher cutting force needed
  • larger cutting depth
  • lower surface quality.
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3
Q

What is orthogonal cutting?

A

When the tool is perpendicular to the direction of primary motion.

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4
Q

What is oblique cutting?

A

The tool is at an angle to the direction of primary motion.

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5
Q

What does single cutting point mean, and what are some examples of this?

A

Only one major cutting edge.
Turning, shaping, boring.

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6
Q

What is multipoint cutting and what are some examples of this?

A

More than one cutting edge.
Drilling, milling, broaching, reaming.

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7
Q

What is feed?

A

Relative movement of the tool in order to process the entire surface of the workpiece.

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8
Q

Under what conditions would continuous chips be formed?

A

-ductile material
-positive rake angle
- high cutting speeds

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9
Q

Under what conditions would discontinuous chips be formed?

A
  • brittle material
  • negative rake
  • low cutting speeds
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10
Q

What does continuous with built up edge chip mean?

A
  • long ribbon of material
  • a work hardened edge
  • leaves rough machined surface
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11
Q

Where would an external chip breaker be mounted?

A

Clamped to the tool face.

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12
Q

Where would an integral chip breaker be located?

A

Bulge formed into tool face. (Part of tool)

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13
Q

Under what conditions would chatter marks be formed?

A
  • part vibrating causing tool to bounce
  • vibration of the machine
  • inconsistent material.
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14
Q

What are the results of chatter marks?

A
  • low quality surface finish
  • low accuracy
  • damage to the tool and machine
  • added noise.
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15
Q

What are the solutions to avoid chatter marks?

A
  • more stable machine.
  • change cutting conditions:
    Speed, depth, add fluid, change feed rate.
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16
Q

What is the equation for turning cutting speed?

A

Cutting speed = Revolution speed * pi * average diameter

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17
Q

What application would a square thread be used for?

A

High axial force

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18
Q

What is the main strength of a general purpose thread?

A

It self centres

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19
Q

What application would a National buttress thread be used for?

A

One directional force

20
Q

What application would a NPT pipe thread be used for?

A

Self tightening, self sealing

21
Q

What is the equation for material removal rate for turning?

A

Material removal rate = cutting speed * feed * depth of cut

22
Q

What is the equation for cutting time for turning?

A

Cutting time = length / feed rate

23
Q

What is the difference between slab and face milling

A

Slab milling - parallel plane to axis of cutter

Face milling - right angle to rotation of cutter

24
Q

What is slot milling?

A

Creating a narrow ridge in the part

25
Q

What are the characteristics of conventional milling

A

Smoother cutting

Firmer fixture of part required

26
Q

What are the characteristics of climb milling?

A
  • backlash eliminator required
  • less power required
  • not for parts with hard surfaces
    -longer tool life
27
Q

What is the equation to calculate cutting speed of milling machine?

A

Cutting speed = pi * cutter diameter * speed of cutter

28
Q

What could cause a drill bit to break?

A

Dull drill bit, feed too high

29
Q

What could cause excessive drill bit wear?

A
  • cutting speed to high
  • more fluid required
  • rake angle too high
30
Q

What could cause a tapered or oversized hole?

A

Drill bit miss aligned or bent

31
Q

What factors would produce a poor surface finish on a drilled hole?

A
  • dull drill
  • lack of coolant
    -improper alignment
    -vibration
    -high fees rate
  • low cutting speed
32
Q

What are the 3 types of abrasive cutting?

A

Bonded abrasive
Coated abrasive
Free abrasive

33
Q

What are some examples of bonded abrasives?

A

Grinding, superfinishing

34
Q

What are some examples of coated abrasives?

A

Belt grinding, wire cutting

35
Q

What are examples of free abrasives?

A

Jet machining
Buffing ( with fluid)

36
Q

What is a work envelope ?

A

Max prt dimensions Cnc machine can take

37
Q

Why are multi tool magazine cnc’s good

A

Reduces set up time
Allows for multiple operations in same machine

38
Q

What does a pallet do in a Cnc machine

A

Base part is fixed to, can move

39
Q

What are robotic machining characteristics

A

Not as accurate or stiff
For softer material
Accesses difficult to reach areas

40
Q

How do Cnc machines extend tool life

A

Adjust based on vibration and force

41
Q

What properties will a cutting tool have?

A
  • high hardness
  • resistance to abrasion
  • high toughness
  • hot hardness
42
Q

Which tools are cheaper, Solid or too with inserts

A

Solid

43
Q

Where are cutting oils used?

A

Heavy cutting on tough steel

44
Q

Where are soluble oils used

A

Aluminium and copper

45
Q

Where are chemical fluids used?

A

Good flushing and cooling abilities

Manufacturing Technology: Metal Cutting (1 decks)

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