Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133559897
Author: KALPAKJIAN
Publisher: PEARSON
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Chapter 23, Problem 22QLP
Why would machining operations be necessary even on net-shape or near-net-shape parts made by precision casting, forming, or powder metallurgy products, as described in preceding chapters? Explain.
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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 through-hole in the shape of the letter L in a 12.5 mm (0.5 in) thick plate of glass. The size of the "L" is 25 by 15 mm (1.0 by 0.6 in) and the width of the hole is 3 mm (1/8 in).
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).
Identify some of the reasons why machining is commercially and technologically important.
Chapter 23 Solutions
Manufacturing Engineering & Technology
Ch. 23 - Describe the types of machining operations that...Ch. 23 - What is turning? What kind of chips are produced...Ch. 23 - What is the thrust force in turning? What is the...Ch. 23 - What are the components of a lathe?Ch. 23 - (a) What is a tracer lathe? (b) What is an...Ch. 23 - Describe the operations that can be performed on a...Ch. 23 - Why were power chucks developed?Ch. 23 - Explain why operations such as boring on a lathe...Ch. 23 - Why are turret lathes typically equipped with more...Ch. 23 - Describe the differences between boring a...
Ch. 23 - How is drill life determined?Ch. 23 - What is the difference between a conventional...Ch. 23 - Why are reaming operations performed?Ch. 23 - Explain the functions of the saddle on a lathe.Ch. 23 - Describe the relative advantages of (a)...Ch. 23 - Explain how external threads are cut on a lathe.Ch. 23 - Prob. 17RQCh. 23 - Explain the reasoning behind the various design...Ch. 23 - Note that both the terms tool strength and...Ch. 23 - (a) List and explain the factors that contribute...Ch. 23 - Explain why the sequence of drilling, boring, and...Ch. 23 - Why would machining operations be necessary even...Ch. 23 - A highly oxidized and uneven round bar is being...Ch. 23 - Describe the difficulties that may be encountered...Ch. 23 - (a) Does the force or torque in drilling change as...Ch. 23 - Explain the similarities and differences in the...Ch. 23 - Describe the advantages and applications of having...Ch. 23 - Assume that you are asked to perform a boring...Ch. 23 - Explain the reasons for the major trend that has...Ch. 23 - Describe your observations concerning the contents...Ch. 23 - The footnote to Table 23.12 states that as the...Ch. 23 - In modern manufacturing, which types of metal...Ch. 23 - Sketch the tooling marks you would expect if a...Ch. 23 - What concerns would you have in turning a powder...Ch. 23 - The operational severity for reaming is much lower...Ch. 23 - Review Fig. 23.6, and comment on the factors...Ch. 23 - Explain how gun drills remain centered during...Ch. 23 - Comment on the magnitude of the wedge angle on the...Ch. 23 - If inserts are used in a drill bit (see Fig....Ch. 23 - Refer to Fig. 23.11b, and in addition to the tools...Ch. 23 - Calculate the same quantities as in Example 23.1...Ch. 23 - Estimate the machining time required to rough turn...Ch. 23 - A high-strength cast-iron bar 8 in. in diameter is...Ch. 23 - A 0.30-in.-diameter drill is used on a drill press...Ch. 23 - In Example 23.4, assume that the workpiece...Ch. 23 - For the data in Problem 23.45, calculate the power...Ch. 23 - A 6-in.-diameter aluminum cylinder 10 in. in...Ch. 23 - A lathe is set up to machine a taper on a bar...Ch. 23 - Assuming that the coefficient of friction is 0.25,...Ch. 23 - A 3-in.-diameter, gray cast iron cylindrical part...Ch. 23 - Would you consider the machining processes...Ch. 23 - Would it be difficult to use the machining...Ch. 23 - If a bolt breaks in a hole, it typically is...Ch. 23 - An important trend in machining operations is the...Ch. 23 - Review Fig. 23.8d, and explain if it would be...Ch. 23 - Boring bars can be designed with internal damping...Ch. 23 - A large bolt is to be produced from extruded...Ch. 23 - Make a comprehensive table of the process...
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- What is dielectric? Discuss the impact of dielectric properties on machining characteristics in EDM.arrow_forwardA flat milling operation will be carried out with a horizontal milling machine, in a piece of 250 mm in length and 50 mm in width, using a felicoidal bur with a diameter of 75 mm, with 10 teeth. If the feed per tooth is 0.2mm, and the cutting speed is 0.75 m / s, how would you determine the speed of metal removal to remove 6 mm from the surface of this piece?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_forward
- Draw the forces and angles involved in the cutting process and calculate shear angle (0), friction coefficient and tangential force if ,cutting force = 80 kN, resultant of forces =100kN, friction force=75kN, rake angle =20° undeformed chip thickness = 0.65mm and deformed chip thickness = 0.72mmarrow_forwardDiscuss the effects of cutting speed, feed rate, and depth of cut on the tool wear rate during a turning operation. How does each parameter influence the surface finish of the workpiece? Provide a detailed explanation based on the principles of metal cutting mechanics.arrow_forwardExplain the differences between the up milling and down milling?arrow_forward
- What is the mechanism material removal in EDM? Explain in detail.arrow_forwardDuring a certain machining experiment at the UCSI workshop, it is observedthat temperature at the tool workpiece interface is 1200 oC at a cutting speed of300 mm/min with a feed rate of 0.002 mm/rev. (i) Analyse how the temperature will be affected if the cutting speed isincreased by 100 %.(ii) Determine the cutting speed necessary to achieve a maximum cuttingtemperature of 900 oCarrow_forwardA slab milling operation is performed on the top surface of a tool-steel workpiece 450 mm long by 7.5 cm wide. The helical milling cutter, which has an 80 mm diameter and seven teeth, is set up to overhang the width of the part on both sides. Cutting speed is 4000 mm/min, feed is 0.015 cm/tooth, and depth of cut = 0.60 cm. Determine (a) the actual machining time to make one pass across the surface and (b) the maximum metal removal rate during the cut. (c) If an additional approach distance of 0.05 m is added at the beginning of the pass, and an overtravel distance at the end of the pass equal to the cutter radius plus 0.0115 cm, what is the duration of the feed motionarrow_forward
- 1. Why are nontraditional machining methods (NTM) required as compared to conventional machining methods? 2. What industries have benefitted from the development of NTM operations? 3. Select an industry and describe how the industry you have chosen uses nontraditional machining in its manufacturing.arrow_forwardExplain how machineries equipment sustain and stabilize thermal effects.arrow_forwardA motorised metal guillotine machine is required to cut 45 mm diameter hole in a plate of 20 mm thickness at rate of 35 holes per minute. It requires a torque of 7 Nm for an area of hole in mm2. If the cutting takes 1/10 of a second and the speed of its flywheel varies from 165 rpm to 145 rpm, calculate:arrow_forward
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