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EME50 > Machining > Flashcards

Machining Flashcards

1
Q

Manufacturing goal

A

Convert raw materials to usable products

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2
Q

Machining

A

Various material removal processes

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3
Q

3 main machining types

A

Cutting
Abrasive
Advanced

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4
Q

Cutting processes

A

Turning
Drilling
Milling
Planing
Sawing

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5
Q

Abrasive processes

A

Grinding
Horning
Lapping

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6
Q

Advanced processes

A

Electrical
Chemical
Thermal

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7
Q

Pros of cutting

A

Dimensional accuracy
Preserve internal geometry
Good finish
Cheap

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8
Q

Cons of cutting

A

Wasted material
Slow material removal rate
Poor part integrity

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9
Q

Turning usage

A

Symmetric, helical, circular features

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10
Q

Drilling usage

A

Round holes, high production rate

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11
Q

Milling usage

A

All shapes, low to med prod rate

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12
Q

Planing usage

A

Large flat surfaces, piece moves under stationary tool

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13
Q

Sawing usage

A

Straight & contoured cuts

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14
Q

Lapping

A

Chemical sanding

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15
Q

Turning processes

A

Turing
Facing
Boring
Drilling
Reaming
Parting
Threading
Knurling

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16
Q

Turning

A

Remove exterior material, reduce part diameter

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17
Q

Facing

A

Reduce length, clear face

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18
Q

Boring

A

Remove interior material, internally reduce diameter

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19
Q

Drilling

A

Create fractional hole

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20
Q

Reaming

A

Create toleranced hole

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21
Q

Parting

A

Plunge into work diameter

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22
Q

Threading

A

Create exterior threads on cylindrical work

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23
Q

Knurling

A

Create external textured surface

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24
Q

Lathe types

A

Engine
Turret
Tracer
CNC

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25
Collet chuck
Hold cylindrical work
26
Live center
Frictionless tailstock for high speeds
27
Dead center
Fixed tailstock for low speeds
28
Rest
Support long workpieces
29
Mandrel
Cylindrical holder supports from center
30
High speed steel (HSS) characteristics
Cheap Can be repaired
31
Carbide brazing characteristics
Better tool life High temperature resistance Better finish Expensive
32
Material removal rate (MRR)
Volume of material removed per unit time
33
Independent variables in chip formation
Cutting tool conditions Workpiece material Cutting conditions (RPM, feed, depth) Cutting fluid Tool & work holding
34
Dependent variables in chip formation
Chips produced Temp (workpiece, tool) Tool wear Surface finish
35
Continuous chips
High cutting speeds/rake angles Good surface finish BUE risk
36
Built-up edge (BUE) chips
Chips pressure welded into tool/workpiece surface
37
Reduced risk of BUE
Reduce cut depth Increase RPM Increase rake angle More cutting fluid Sharper tool
38
Serrated chips
Hard materials like titanium Saw teeth, segmented
39
Discontinuous chips
Brittle workpiece w/impurities Too deep cut Low rake angle Wrong speed
40
Relationship between feed rate and roughness
Higher feed rate = higher roughness
41
Leaded steel properties
Lead sheared on tool/chips Lead = lubricant Less shear stress = easier to machine
42
Rephosphorized steel properties
Phosphorus = easier to machine b/c strengthens ferrite E.g. cut paper vs cut yarn
43
Calcium-deoxidized steel properties
Reduced tool wear
44
Nickel and chromium properties
Reduced machinability
45
Aluminum properties
Easy to machine BUE risk b/c soft, use high RPM Dimensional problems b/c thermal expansion
46
Cast iron properties
Cheap, easy to machine Very abrasive = easy for tool to chip & fracture
47
Cobalt alloy properties
Abrasive & $$$ Low speeds and feeds
48
Copper properties
Hard to machine b/c soft = BUE risk Leaded brass is easier
49
Magnesium properties
Easy to machine MUST use argon or inert gas Flammable = ignite w/ air
50
Tungsten properties
Brittle, abrasive Low machinability @ room temp
51
Chatter fixes
Increase tool stiffness & machine tool damping
52
Effects of chatter
Poor surface finish Poor dimensional accuracy Tool wear/damage Noise
53
Tool wear mechanisms
Abrasion Adhesion Oxidation Diffusion Thermal
54
Tool wear monitoring
Temp Torque sensors Visually inspect
55
Tool wear types
Nose wear Flank wear Crater wear Plastic wear/breakage
56
Flank wear causes
Adhesive & abrasive wear High temps Medium cutting speed
57
Crater wear causes
High temps High speeds Deep cuts
58
Nose wear causes
Low cutting speeds
59
Plastic wear/breakage causes
Very high speeds Interrupted cutting
60
Drill bits are ___. Endmills are ___.
pointed; flat
61
Counterbores are ___. Countersinks are ___.
flat; slanted
62
Center drilling
Used before drilling Hole location dimensional accuracy
63
Reaming
Enlarges drilled hole to accurate dimension
64
Tapping
Creates internal threads
65
Dies (as in tapping and dyeing)
Create external threads
66
Sawing is a ___ movement. Broaching is a ___ movement.
rotational; translational
67
Conventional milling characteristics
(Up milling) Cutter rotates against feed Max chip thickness @ end Doesn’t depend on work geometry, does not affect tool life Chatter risk Workpiece might get pulled away from holding
68
Climb milling characteristics
(Down milling) Cutter rotates with feed Max chip thickness @ start Very good surface Backlash risk, bounce out of pocket Decreases tool life
69
With turning, the ___ rotates, and the ___ moves linearly. With milling, the ___ rotates, and the ___ moves linearly.
piece; tool tool; piece
70
High speed machining characteristics
High spindle speed, low cut depth High MRR Expensive
71
High-efficiency machining range
Optimal cutting speed for time and cost
72
Cutting fluid purposes
Reduce friction & temp Improve tool life Reduce cutting force Wash away chips
73
How much material should be left for a finishing pass?
.005 - .010 in

EME50 (9 decks)

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