DeGarmo's Materials and Processes in Manufacturing
12th Edition
ISBN: 9781118987674
Author: J. T. Black, Ronald A. Kohser
Publisher: WILEY
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Chapter 21, Problem 17P
Using Figure 21.4 for input data, determine the maximum and minimum MRR values for rough machining (turning) a 1020 carbon steel with a BHN value of 200. Repeat for finish machining assuming a DOC value equal to 10% of the roughing DOC.
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A 200 mm long magnesium alloy bar, 63 mm in diameter is turned on a lathe using a high speed steel cutter travelling at 180 mm/min. The spindle rotates at 450 rpm and lathe is equipped with a 10 kW motor, operating at a mechanical efficiency of 92%. The final diameter of the magnesium alloy bar is 59,5 mm.
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Chapter 21 Solutions
DeGarmo's Materials and Processes in Manufacturing
Ch. 21 - Why has the metal-cutting process resisted...Ch. 21 - What variables must be considered in understanding...Ch. 21 - Which of the seven basic chip formation processes...Ch. 21 - How is feed related to speed in the machining...Ch. 21 - Before you select speed and feed for a machining...Ch. 21 - Milling has two feeds. What are they, and which...Ch. 21 - What is the fundamental mechanism of chip...Ch. 21 - What is the difference between oblique machining...Ch. 21 - What are the implications of Figure 21.13, given...Ch. 21 - Note that the units for the approximate equation...
Ch. 21 - For orthogonal machining, the cutting edge radius...Ch. 21 - How do the magnitude of the strain and strain rate...Ch. 21 - Why is titanium such a difficult metal to machine?...Ch. 21 - Explain why you get segmented or discontinuous...Ch. 21 - Why is metal cutting shear stress such an...Ch. 21 - Which of the three cutting forces in oblique...Ch. 21 - How is the energy in a machining process typically...Ch. 21 - Where does the energy consumed in metal cutting...Ch. 21 - What are two ways of estimating the primary...Ch. 21 - What are the three different ways to perform...Ch. 21 - Why does the cutting force Fc increase with...Ch. 21 - Why doesnt the cutting force Fc increase with...Ch. 21 - Prob. 23RQCh. 21 - How does the selection of the machining parameters...Ch. 21 - Suppose you had a machining operation (boring)...Ch. 21 - Make a sketch like that shown in Figure 21.1 with...Ch. 21 - Show how you would do near orthogonal machining in...Ch. 21 - Can you do orthogonal machining on a shaper or...Ch. 21 - What process and material combination would yield...Ch. 21 - What is meant by the statement that machining...Ch. 21 - Prob. 31RQCh. 21 - Figure 21.4 provides suggested cutting speeds and...Ch. 21 - For problem 1, suppose you selected a speed of 145...Ch. 21 - If the cutting forces is 1000 lb calculate the...Ch. 21 - Explain how you would estimate the cutting force...Ch. 21 - For a turning operation, you have selected a...Ch. 21 - For a slab milling operation using a...Ch. 21 - The power required to machine metal is related to...Ch. 21 - In order to drill a hole in the material described...Ch. 21 - Suppose you have the data in Table 21.A obtained...Ch. 21 - Calculate the horsepower that a process is going...Ch. 21 - Explain how you would estimate the cutting force...Ch. 21 - Derive equations for F and N using the circular...Ch. 21 - Prob. 14PCh. 21 - Prob. 15PCh. 21 - A manufacturing engineer needs an estimate of the...Ch. 21 - Using Figure 21.4 for input data, determine the...Ch. 21 - Estimate the horsepower needed to remove metal at...Ch. 21 - For a turning process, the horsepower required was...
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- Find the machining time required to turn a mild steel rod from 65mm to 58 mm over a length of 100 mm by using a carbide insert. If the approach length and over run length is taken as 5 mm, Cutting speed as 20 m/min and feed is =0.2 mm/rev, and the depth of cut is 0.5mmarrow_forwardA job has to be machined in shaping and the process parameters are given below: Length of the job=120 mm Speed of the motor=640 rpm Cutting speed=248 m/min Tool allowance before cutting =31.5 mm Tool allowance after cutting=10 mm Determine the cutting to return stroke ratio for the above operation and draw the arrangement of machining with tool head and allowances.arrow_forwardPlease give the correct solution A cylinder of 25 mm diameter and 100 mm length is turned with a tool, for which the relation VT0.25 = 55 is applicable. The cutting velocity is 22 m/min. For a tool feed of 0.046 mm/rev, the number of tool regrinds required to produce 425 cylinders is?arrow_forward
- In machining a mild steel work piece with carbide tool, the life of the tool was found to be 1 hour and 40 minutes, at a spindle speed of 25 m/min. Calculate the tool life if it has to be operated at a speed of 30% higher than the initial cutting speed. Also calculate the cutting speed if the tool is required to have a life of 2 hours and 45 minutes. Assume Taylor’s exponent value n is 0.28.arrow_forwardFor 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 blind-hole in the shape of the letter G in a 50 mm (2.0 in) cube of steel. The overall size of the "G" is 25 by 19 mm (1.0 by 0.75 in), the depth of the hole is 3.8 mm (0.15 in), and its width is 3 mm (1/8 in).arrow_forwardExplain the following terms and situations in metal cutting. Give enough explanation with figures if it is necessary. A)Force and chatter vibrations. How can you detect the vibration during the machining? How can you decide which type of the vibration you have? B) Mode shapes. C)Mode coupling. D)Process damping. Which parameters can affect the process damping? i)Mode coupling. j) Regenerative chatter vibrations. k) Stability lobes.arrow_forward
- 8 A job has to be machined in shaping and the process parameters are given below: a. Length of the job=120 mm b. Speed of the motor=640 rpm c. Cutting speed=264 m/min d. Tool allowance before cutting =30 mm e. Tool allowance after cutting=15mm Determine the cutting to return stroke ratio for the above operation and draw the arrangement of machining with tool head and allowances.arrow_forwardAssuming that the coefficient of friction is 0.25, calculate the maximum depth of cut forturning a hard aluminium alloy on a 15-kW lathe (with a mechanical efficieny of 80%) at awidth of cut of 6 mm, rake angle of 0˚, and a cutting speed of 90 m/min, shear strength of 150 MPa.arrow_forward21.62 Using Eq. (21.30), select an appropriate feed for R =1 mm and a desired roughness of 0.5 μ m. How would you adjust this feed to allow for nose wear of the tool during extended cuts? Explain your reasoning.arrow_forward
- 21.18 List reasons that machining operations may be required, and provide an example for each reason.arrow_forwardIn an orthogonal machining with a tool of 9 degree orthogonal rake angle, the uncut chip thickness is 0.2mm. The chip thickness fluctuates between 0.25 mm and 0.4 mm. The ratio of the maximum shear angle to the minimum shear angle during machining isarrow_forward22.37 Which of the properties listed in Table 22.1 is, in your opinion, the least im portant in cutting tools? Explain.arrow_forward
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