(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)

(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)

Elements Of Electromagnetics

7th Edition

ISBN:9780190698614

Author:Sadiku, Matthew N. O.

Publisher:Sadiku, Matthew N. O.

ChapterMA: Math Assessment

Section: Chapter Questions

Problem 1.1MA

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Can you show me how each of these values were achieved through interpolation method, thank you.
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.
Figure 9 shows the effect of rotary speed on the material removal rate by using conventional EDM and ultrasonic-assisted EDM. Discuss on the effect of rotary speed on the material removal rate for both EDM processes.
(USCS units) A turning operation is performed using a rake angle of 15°. Cutting speed = 200 ft/min, feed= 0.012 in/rev, and depth of cut = 0.100 in. The chip thickness ratio measured after the cut = 0.48. Determine (a) chip thickness after the cut, (b) shear angle, (c) friction angle, (d) coefficient of friction, and (e) shear strain (USCS units) The turning operation in the previous problem involves a work material whose shear strength = 52,000 lb/in2. Based on your answers to the previous problem, compute (a) shear force, (b) cutting force, (c) thrust force, and (d) friction force.
A HSS tool is used to turn a steel workpart that is 300 mm long and 80 mm in diameter. The parameters in the Taylor equation are: n = 0.13 and C = 75 (m/min) for a feed of 0.4 mm/rev. The operator and machine tool rate = $30.00/hr, and the tooling cost per cutting edge = $4.00. It takes 2.0 min to load and unload the workpart and 3.50 min to change tools. Determine: Tutting speed for maximum production rate, Tool life in min of cutting, and Cycle time and cost per unit of product. determine cutting speed for minimum cost.
In 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 done
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).
What are the problems that may occur during TBM (tunnel boring machine) cutting disc production and what are the breakages arising from these problems?
What are the significance of tolerance and allowance in production process? Diagram?
In a turning operation, cutting speed =200 m/min; feed = 0.25mm mm/rev, and depth of cut = 4.00mm Thermal diffusivity of the work material = 20m mm^2/s and volumetric specific heat =3.5(10^ -3 )J/mm^ 3 -C If the temperature increase above ambient temperature (20degreesC) is the angle measured by a tool-chip thermocouple to be 700degreesC, determine the specific energy for the work material in this operation.
The following data were obtained in a study taken on a horizontal milling machine:Parts produced per cycle: 8.Average measured cycle time: 8.36 minutes.Average measured stress time per cycle: 4.62 minutes.Average fast traverse time: 0.08 minutes.Average cutting time with electrical power: 3.66 minutes.Performance rating: 115%.Clearance (machine time): 10%.Slack (effort time): 15%.The operator works on the task 8 hours a day and produces 380 parts. How many standard hours does the operator work? What is the operator's efficiency for the 8-hour day?
The following data were obtained in a study taken on a horizontal milling machine:Parts produced per cycle: 8.Average measured cycle time: 8.36 minutes. Average measured stress time per cycle: 4.62 minutes. Average fast traverse time: 0.08 minutes. Average cutting time with electrical power: 3.66 minutes. Performance rating: 115%. Clearance (machine time): 10%. Slack (effort time): 15%. The operator works on the task 8 hours a day and produces 380 parts. How many standard hours does the operator work? What is the operator's efficiency for the 8-hour day?