Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133559897
Author: KALPAKJIAN
Publisher: PEARSON
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Chapter 24, Problem 51SDP
To determine
In the mode of milling, if expanded honeycomb panels were to be machined, explain the protection would be taken to keep the sheet metal distorting due to various forces. Give as many solutions as you can.
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A 78 mm thick plate is to be milled down to a thickness of 60 mm using an 80 mm face milling cutter. Calculate the processing time if the cutting depth is 6 mm, the feed/rev is 1.1 mm and the cutting speed is 15 m/min, and if the over run for a 620 mm long plate is 10 mm.
In face milling, assume that the Diameter of the cutter is 200 mm, the width of the block is 60 mm, and the length of the block is 344 mm, if the depth of cut is 3 mm, = 0.6 mm/min, and N = 100 rpm. The cutter has 12 inserts, and the workpiece material is bronze. Calculate the estimated power required, the cutting force, and the torque.
A mild steel block of width 40 mm is being milled using a straight slab cutter 70 mm diameter with 30 teeth. If the cutter rotates at 40 rpm, and depth of cut is 2 mm, what is the value of maximum uncut chip thickness when the table feed is 20 mm/min?
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 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_forwardCalculate the spindle speed for a Lathe Machine, if the cutting speed for a mild steel material workpiece is 34 m/min and the diameter of the cylindrical workpiece is 46 mm.arrow_forwardExplain why the mechanical properties of workpiece materials are not significant in most of the processes described in Nontraditional Machining Processes.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_forwardExplain the differences between the up milling and down milling?arrow_forwardA slab-milling operation is carried out on a 200 mm long, 80-mm-wide annealed mild-steel workpiece having a feedrate of 0.1 mm/tooth and a depth of cut of 4.0 mm. The cutter of 50 mm diameter has 18 straight teeth and rotates at 135 rpm. The given specific energy for this material is 3.5 W s/mm3 and the slab mill is wider than the workpiece to be machined. Calculate:‧ the material-removal rate;‧ the power and torque required for this operation;‧ the cutting time. (243 mm/min, 77760 mm3/min, 4.5 kW, 52.8 s)arrow_forward
- What is difference in turning and boring processes? Explain the difference if any in the equations for cutting speed, material removal rate, and machining timearrow_forwardIn orthogonal turning of a bar 100 mm diameter with a feed of 0.25 mm/rev., depth of cut = 4 mm, cutting velocity = 90 m/min. it is observed that the main cutting force is perpendicular to friction force acting at the chip tool interface and cutting force is 1500 N. find (i) rake angle (ii) normal force.arrow_forward44. In Orthogonal Cutting Model, why chip thickness after cut is greater than chip thickness before cut? explain.arrow_forward
- A 6.5 inch long, 0.5 inch diameter stainless steel rod is being reduced to 0.480 inches by turning on a lathe. The spindle rotates at 400 RPM and the tool is travelling at an axial speed of 8 inches/min. Calculate the cutting speed, feed, time, and material removal rate required.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 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_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 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).arrow_forward
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