Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133559897
Author: KALPAKJIAN
Publisher: PEARSON
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Chapter 24, Problem 50SDP
Would you prefer to machine the part in Fig. 24. If from a preformed blank (near-net shape) rather than a rectangular blank? If so, how would you prepare such a blank? How would the number of parts required influence your answer?
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A 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?
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 = 0.72mm
Discuss 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.
Chapter 24 Solutions
Manufacturing Engineering & Technology
Ch. 24 - Explain why milling is such a versatile machining...Ch. 24 - Describe a milling machine. How is it different...Ch. 24 - Describe the different types of cutters used in...Ch. 24 - Define the following: face milling, peripheral...Ch. 24 - Can threads be machined on a mill? Explain.Ch. 24 - What is the difference between feed and feed per...Ch. 24 - Explain the relative characteristics of climb...Ch. 24 - Describe the geometric features of a broach and...Ch. 24 - What is a pull broach? A push broach?Ch. 24 - Why is sawing a commonly used process? Why do some...
Ch. 24 - What advantages do bed-type milling machines have...Ch. 24 - Explain why the axis of a hob is tilted with...Ch. 24 - What is a shell mill? Why is it used?Ch. 24 - Why is it difficult to saw thin sheet metals?Ch. 24 - Of the processes depicted in Fig. 24.2, which is...Ch. 24 - Describe the tool motion during gear shaping.Ch. 24 - When is filing necessary?Ch. 24 - Would you consider the machining processes...Ch. 24 - Why is end milling such an important versatile...Ch. 24 - List and explain factors that contribute to poor...Ch. 24 - Explain why broaching crankshaft bearings is an...Ch. 24 - Several guidelines are presented in this chapter...Ch. 24 - What are the advantages of helical teeth over...Ch. 24 - Explain why hacksaws are not as productive as band...Ch. 24 - What similarities and differences are there in...Ch. 24 - Why do machined gears have to be subjected to...Ch. 24 - How would you reduce the surface roughness shown...Ch. 24 - Why are machines such as the one shown in Fig....Ch. 24 - Comment on your observations concerning the...Ch. 24 - Explain how contour cutting could be started in a...Ch. 24 - Prob. 32QLPCh. 24 - Describe the parts and conditions under which...Ch. 24 - Explain the reason that it is difficult to use...Ch. 24 - Would you recommend broaching a keyway on a gear...Ch. 24 - Prob. 37QTPCh. 24 - A slab-milling operation is being performed at a...Ch. 24 - Show that the distance lc in slab milling is...Ch. 24 - Prob. 40QTPCh. 24 - Calculate the chip depth of cut, tc, and the...Ch. 24 - Estimate the time required to face mill a...Ch. 24 - A 12-in.-long, 1-in.-thick plate is being cut on a...Ch. 24 - A single-thread hob is used to cut 40 teeth on a...Ch. 24 - Assume that m the face-milling operation shown in...Ch. 24 - A slab-milling operation will take place on a part...Ch. 24 - Prob. 47QTPCh. 24 - In describing the broaching operations and the...Ch. 24 - The parts shown in Fig. 24.1 are to be machined...Ch. 24 - Would you prefer to machine the part in Fig. 24....Ch. 24 - Prob. 51SDPCh. 24 - Suggest methods whereby milling cutters of various...Ch. 24 - Prepare a comprehensive table of the process...Ch. 24 - Prob. 55SDPCh. 24 - Make a list of all the processes that can be used...
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- A student is using a lathe with 80-hp and 80% efficiency to fabricate a copper alloy with Sy = 1200ksi If the width of cut is 0.30 inand the student set a rake angle of 0and a cutting speed of 200fl / min while she assumed a coefficient of friction to be 0.5. What is the maximum depth of cut the student can achieve?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_forwardWhat is difference in turning and boring processes? Explain the difference if any in the equations for cutting speed, material removal rate, and machining timearrow_forward
- 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).arrow_forwardA 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. Indicate with a sketch the recommend size and location of the following tool angles: back rake, side rake, end relief, side relief and side and end cutting edge. Calculate the cutting time for the machining process.Calculate the required cutting force.arrow_forward7. What is the manufacturing process of lathe bed? Which material will be suitable for the product? Justify your answer.arrow_forward
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