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FINAL EXAM 322 > Machining Fundamentals > Flashcards

Machining Fundamentals Flashcards

week 8 (61 cards)

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1
Q

In machining is there a wastage of material?

A

Yes

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2
Q

Machining

A

material removal by a sharp
cutting tool, e.g., turning, milling, drilling

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3
Q

Abrasive processes

A

material removal by hard, abrasive particles, e.g., grinding

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3
Q

Nontraditional processes

A

various energy forms other than sharp cutting tools to remove material

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4
Q

What is a chip

A

whatever material removed is called a chip

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5
Q

cutting action involves sheer deformation of material to form a _____.

A

chip

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6
Q

why is machining important?

A
  1. good dimensional accuracy and surface finish
  2. variety of work materials
  3. variety of part shapes and special; geometric features
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7
Q

disadvatage with machining

A
  1. wastage of material (chip)
  2. Time consuming (removed layer by layer)
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8
Q

where is machining in the manufacturing sequence?

A

generally performed after other manufacturing processes (casting, forging, bat drawing)

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9
Q

what are the types of machining operations

A

Common machining types:
*Turning
*Drilling
*Milling

Other machining types:
*Sawing
*Shaping and planing
*Broaching
*Grinding

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10
Q

What is turning operation

A

work peice is rotating and cutting tool provides feed (single point cutting)

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11
Q

Flat turning feed:

A

tool is fed parallel to the work axis

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12
Q

what is drilling

A

tool is rotating and speed depends on tool diameter

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13
Q

drilling feed

A

parallel to tool axis

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14
Q

depth of cut is the

A

depth of the hole

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15
Q

drilling is a

A

multi point cutting

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16
Q

what is milling

A

tool is turniing (defining surface speed)

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17
Q

in milling surface velocity depends on

A

diameter of the tool

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18
Q

depth of cut in milling

A

tool penetrates beneath original work surface (multi point cutting )

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19
Q

feed of milling

A

work feeds in the direction perpendicular to tool surface

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20
Q

which operations are single point cutting

A

turning

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21
Q

which operations are multi point cutting

A

drilling and milling

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22
Q

what is rake face

A

directs flow of new chips - at an angle called rake angle

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23
Q

what does flank of the tool provide

A

provides the clearence berween the tool and the new work surface - at an angle called relief/clearance angle

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24
what is cutting speed (m/sec or ft/min) - v
relative motion between tool and work piece (primary motion)
25
what is feed (mm or inch) - f
tool is moved laterally across the work (secondary motion)
26
depth of cut (mm or inch) - d
penetration of cutting tool below original work surface
27
Roughing vs. Finishing
Roughing - removes large amounts of material (gets close to wanted geometry) Finishing- completes part dimensions (final dimension, tolerances and finishes)
28
what are the required settings for roughing
high feeds and depth, low speeds
29
what are the required settings for finishing
low feeds and depths, high speeds
30
what is cutting fluid used for
applied to cool and lubricate the tool (depends on work material and tooling)
31
define sheer strian
deflection of the element over orthogonal distance over which deformation occurs
32
primary shear zone
where deformation of material takes place
33
secondary shear zone
due to friction between the chip and the tool (tool chip interface)
34
4 types of chips
* Discontinuous chip * Continuous chip * Continuous chip with buildup edge * Serrated chips
35
continuoes chip
good finish - ductile material - high cutting speed or high rake angle - small feed and depth of cut
36
problem of continuoes chip
chip disposal and tangling about the tool (chip breakers are usually used)
37
when does a build up edge happen
when heat is being accumalted and the melts onto the cutting tool
38
continuous chip with build up edge (BUE)
- ductile material - low to medium cutting dpprf - local high temp and extreme pressure in the cut zone cause parts of material to stick to rake face of the tool near the cutting edge (BUE)
39
problems of continuous chip with build up edge (BUE)
- reduces toool life time - rough surface finish (BUE on work surface)
40
advantages of continuous chip with build up edge (BUE)
thin stable bue protects the tool surface
41
reduce built up edge chips
1. increase cutting speed 2. decrease the depth of cut 3. increase rake angle 4. use a sharp tool 5. reduce friction with a cutting fluid
42
serrated chip
material difficult to machine (titanium alloy, nickel-based superalloys) - high cutting speed - have a saw tooth appearance (alternate high and low shear strain surface; irregular texture)
43
Discontinuous chip
- brittle material (cant undergo higher shear strain) - low cutting speed, large feed and depth of particles, low rake angle, lack of good cutting fluid, low stiffness of machine tool, high tool chip friction irregular texture
44
problems of discontinuous chip
machine tool vibrates and chatter causing 1. bad surface finish and accuracy 2. wear on cutting tool
45
solution for discontinuous chip
high cutting speed, high temperature and a more ductile material
46
what are the forces in cutting metal
friction force (F), Normal force to friction (N), shear force (Fs), Normal force to shear (Fn)
47
what forces can be measured
cutting force and thrust force
48
Friction force F
friction force between tool and chip resisting the flow of chip along the rake face
49
Normal force to friction N,-
force normal to the friction force
50
Shear force, Fs -
force that cause shear deformation in the shear plane
51
Normal force to shear, Fn
normal to shear force
52
Cutting force Fc
- direction of cutting
53
Thrust force, Ft
- perpendiculat to cutting force
54
resultant force consists of...
thrust force and cutting force OR frictional force and normal force perpendicular to friction force
55
thrust force, Ft is positive or negative depending on the _______
rake angle
56
what is the merchant's assumption
the shear angle will form to minimize energy
57
when the shear angle increases
shear length decreases and less energy is needed and vice versa
58
heat is difused to
chip (ideal) work peice cutting tool
59
what does is the surface roughness defined by
1. radius of cutting tool 2. feed rate
60

FINAL EXAM 322 (5 decks)

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