Machining

Question 1

Machining starts with a __________ of material and __________ material __________ to achieve a desired shape or finish

Answer 1

solid block, removes, gradually

Question 2

Machining is Used extensively to:
1. Create parts from __________
2. Perform _________ operations on parts shaped by another principle
3. Make _______ or _______ to be used in other operations
4. Deliver a desired _________

Answer 2

Stock material, secondary, molds, dies, surface finish

Question 3

Machining allows virtually unlimited _______________ with a very ___________ range of
production volumes

Answer 3

form freedom, large

Question 4

What are the three machining methods we learned about?

Answer 4

Drilling, Turning, Milling

Question 5

In many mechanical machining methods, the ___________of tool moves with _______________ through a solid slab of material at a _______ depth

Answer 5

Leading edge, constant speed, fixed

Question 6

In machining, the tool is ______ shaped with an internal “____________” and Its position relative to material is defined by the _______ angle and the _______ angle

Answer 6

wedge, contour angle, relief, rake

Question 7

____________+_________________+_________________= 90 deg

Answer 7

Relief angle, Contour Angle, Rake Angle

Question 8

Machining is process of __________ deformation that is localized in a “shear zone” just ahead of cutting tool. The material is quickly sheared away by the tool while __________ heats the material rapidly

Answer 8

Plastic, friction

Question 9

For isotropic materials, shear yield stress is about _________of tensile yield stress

Answer 9

50-60%

Question 10

o
o The ________ angle prevents ________________in the
region behind the part
two directions
tangential force
vertical force
climbing
higher
elastically
springs back
relief excessive friction

Question 11

What two directions does the tool apply force in?

Answer 11

Tangential & Vertical

Question 12

In machining, a ______________ (Fh) allows the tool to cut in the horizontal
direction

Answer 12

Tangential Force

Question 13

In Machining, a ______________(Fv) helps keep the tool from “______________” out of the material. Under this force, the material deforms __________ and _________ behind the tool while the ________ angle prevents ________________in the region behind the part

Answer 13

vertical, climbing, elastically, springs back, relief, friction

Question 14

The ________ the rake angle, the higher the required Fv.

Answer 14

higher

Question 15

For typical rake angles, Fh ≈ 1.5kt, where k is the ____________ and t is _______________

Answer 15

shear yield stress, cutting depth

Question 16

What are the typical relief angles for:
Steel _____
Aluminum _________
Plastics _________

Answer 16

4, 6, 10

Question 17

Machining generates heat from the _________________ and the ________ between the cutting tool and the part

Answer 17

Plastic deformation and friction

Question 18

o About ______ of heat from machining ends up in chip

Answer 18

80%

Question 19

__________ is often used in machining to remove heat, ________ chips and__________ the tool and machining surfaces but can be hazardous in work environments and pose environmental issues associated with disposal

Answer 19

Cooling fluid, wash away, lubricate,

Question 20

Special alloys are sometimes used to __________ machining

Answer 20

Speed up

Question 21

In materials with added alloys, certain elements such as ________ or _________
promote the formation of _____________ which are somewhat detrimental to material properties but promote weakness in the _________ resulting in a reduction in required _________

Answer 21

lead, sulfur, inclusions, shear zone, cutting forces

Question 22

To produce ________________, try to avoid applying forces in ________ or __________
which produce much larger ___________ than forces in ___________ or __________ and consideration should be given to the clamping system used to
hold the part during machining

Answer 22

tighter tolerances, bending, torsion, deformation, compression, tension

Question 23

Deformation considerations may dictate the ________ in which
machining tasks are completed

Answer 23

order

Question 24

One way to reduce tool deformation is to __________ the required cutting force by making __________ cuts and reducing __________

Answer 24

reduce, shallower, tool size

Question 25

When reduced tools and cut depth are used, In order to maintain ____________ , the tool speed must be __________ which is known as ________________. This Increases friction, so __________ tools are often used and ___________ becomes a problem when operating at high speeds, especially with thin parts

Answer 25

Productivity, increased, high speed machining, ceramic, vibration

Question 26

When machining, __________ and __________ of cuts are __________ compared
to overall part, so cutting must be done in passes. Ideally, there would be no overlap between __________ , but inevitably there is which creates repeating surface pattern roughness

Answer 26

depth, width, small, passes

Question 27

__________ are created when the tool “runs out” across edge of material

Answer 27

Burrs

Question 28

__________ are created when the tool creates repetitive impressions on the part

Answer 28

Lay patterns

Question 29

__________ is ideal for parts that have rotational symmetry

Answer 29

Turning

Question 30

The __________ is the most common turning machine where the material is usually __________ on one side with a chuck and then fixed on the other with a __________

Answer 30

Lathe, clamped, center pin

Question 31

Typical lathes turn in a range between __________ rpm

Answer 31

1000-5000

Question 32

What type of Drilling is described here?
o Drilling a hole to act as a guide for drilling the final hole

Answer 32

Spot Drilling

Question 33

What type of Drilling is described here?
o A stepped hole in which a larger diameter follows a smaller diameter partially into the hole

Answer 33

Counterboring

Question 34

What type of Drilling is described here?
o Similar to counterboring, but the hole is cone-shaped

Answer 34

Countersinking

Question 35

What type of Drilling is described here?
o Precisely enlarges an existing hole

Answer 35

Boring

Question 36

What machining method is described here?
o In milling, material is moved below a spinning tool
o Material moves in multiple axis (at least two , but often
three)

Question 37

What variety of Mill is Described Below?
o Long narrow cylinder for making slots and fine details

Answer 37

End Mill

Question 38

What variety of Mill is Described Below?
o Short squat cylinder for removing a lot of material fast

Answer 38

Slab Mill

Question 39

What variety of Mill is Described Below?
o Has spherical head and can create double curved shapes