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EME50 > Machining > Flashcards

Machining Flashcards

1
Q

Manufacturing goal

A

Convert raw materials to usable products

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2
Q

Machining

A

Various material removal processes

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3
Q

3 main machining types

A

Cutting
Abrasive
Advanced

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4
Q

Cutting processes

A

Turning
Drilling
Milling
Planing
Sawing

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5
Q

Abrasive processes

A

Grinding
Horning
Lapping

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6
Q

Advanced processes

A

Electrical
Chemical
Thermal

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7
Q

Pros of cutting

A

Dimensional accuracy
Preserve internal geometry
Good finish
Cheap

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8
Q

Cons of cutting

A

Wasted material
Slow material removal rate
Poor part integrity

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9
Q

Turning usage

A

Symmetric, helical, circular features

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10
Q

Drilling usage

A

Round holes, high production rate

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11
Q

Milling usage

A

All shapes, low to med prod rate

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12
Q

Planing usage

A

Large flat surfaces, piece moves under stationary tool

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13
Q

Sawing usage

A

Straight & contoured cuts

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14
Q

Lapping

A

Chemical sanding

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15
Q

Turning processes

A

Turing
Facing
Boring
Drilling
Reaming
Parting
Threading
Knurling

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16
Q

Turning

A

Remove exterior material, reduce part diameter

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17
Q

Facing

A

Reduce length, clear face

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18
Q

Boring

A

Remove interior material, internally reduce diameter

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19
Q

Drilling

A

Create fractional hole

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20
Q

Reaming

A

Create toleranced hole

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21
Q

Parting

A

Plunge into work diameter

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22
Q

Threading

A

Create exterior threads on cylindrical work

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23
Q

Knurling

A

Create external textured surface

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24
Q

Lathe types

A

Engine
Turret
Tracer
CNC

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25
Q

Collet chuck

A

Hold cylindrical work

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26
Q

Live center

A

Frictionless tailstock for high speeds

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27
Q

Dead center

A

Fixed tailstock for low speeds

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28
Q

Rest

A

Support long workpieces

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29
Q

Mandrel

A

Cylindrical holder supports from center

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30
Q

High speed steel (HSS) characteristics

A

Cheap
Can be repaired

31
Q

Carbide brazing characteristics

A

Better tool life
High temperature resistance
Better finish
Expensive

32
Q

Material removal rate (MRR)

A

Volume of material removed per unit time

33
Q

Independent variables in chip formation

A

Cutting tool conditions
Workpiece material
Cutting conditions (RPM, feed, depth)
Cutting fluid
Tool & work holding

34
Q

Dependent variables in chip formation

A

Chips produced
Temp (workpiece, tool)
Tool wear
Surface finish

35
Q

Continuous chips

A

High cutting speeds/rake angles
Good surface finish
BUE risk

36
Q

Built-up edge (BUE) chips

A

Chips pressure welded into tool/workpiece surface

37
Q

Reduced risk of BUE

A

Reduce cut depth
Increase RPM
Increase rake angle
More cutting fluid
Sharper tool

38
Q

Serrated chips

A

Hard materials like titanium
Saw teeth, segmented

39
Q

Discontinuous chips

A

Brittle workpiece w/impurities
Too deep cut
Low rake angle
Wrong speed

40
Q

Relationship between feed rate and roughness

A

Higher feed rate = higher roughness

41
Q

Leaded steel properties

A

Lead sheared on tool/chips
Lead = lubricant
Less shear stress = easier to machine

42
Q

Rephosphorized steel properties

A

Phosphorus = easier to machine b/c strengthens ferrite
E.g. cut paper vs cut yarn

43
Q

Calcium-deoxidized steel properties

A

Reduced tool wear

44
Q

Nickel and chromium properties

A

Reduced machinability

45
Q

Aluminum properties

A

Easy to machine
BUE risk b/c soft, use high RPM
Dimensional problems b/c thermal expansion

46
Q

Cast iron properties

A

Cheap, easy to machine
Very abrasive = easy for tool to chip & fracture

47
Q

Cobalt alloy properties

A

Abrasive & $$$
Low speeds and feeds

48
Q

Copper properties

A

Hard to machine b/c soft = BUE risk
Leaded brass is easier

49
Q

Magnesium properties

A

Easy to machine
MUST use argon or inert gas
Flammable = ignite w/ air

50
Q

Tungsten properties

A

Brittle, abrasive
Low machinability @ room temp

51
Q

Chatter fixes

A

Increase tool stiffness & machine tool damping

52
Q

Effects of chatter

A

Poor surface finish
Poor dimensional accuracy
Tool wear/damage
Noise

53
Q

Tool wear mechanisms

A

Abrasion
Adhesion
Oxidation
Diffusion
Thermal

54
Q

Tool wear monitoring

A

Temp
Torque sensors
Visually inspect

55
Q

Tool wear types

A

Nose wear
Flank wear
Crater wear
Plastic wear/breakage

56
Q

Flank wear causes

A

Adhesive & abrasive wear
High temps
Medium cutting speed

57
Q

Crater wear causes

A

High temps
High speeds
Deep cuts

58
Q

Nose wear causes

A

Low cutting speeds

59
Q

Plastic wear/breakage causes

A

Very high speeds
Interrupted cutting

60
Q

Drill bits are ___.
Endmills are ___.

A

pointed; flat

61
Q

Counterbores are ___.
Countersinks are ___.

A

flat; slanted

62
Q

Center drilling

A

Used before drilling
Hole location dimensional accuracy

63
Q

Reaming

A

Enlarges drilled hole to accurate dimension

64
Q

Tapping

A

Creates internal threads

65
Q

Dies (as in tapping and dyeing)

A

Create external threads

66
Q

Sawing is a ___ movement.
Broaching is a ___ movement.

A

rotational; translational

67
Q

Conventional milling characteristics

A

(Up milling)
Cutter rotates against feed
Max chip thickness @ end
Doesn’t depend on work geometry, does not affect tool life
Chatter risk
Workpiece might get pulled away from holding

68
Q

Climb milling characteristics

A

(Down milling)
Cutter rotates with feed
Max chip thickness @ start
Very good surface
Backlash risk, bounce out of pocket
Decreases tool life

69
Q

With turning, the ___ rotates, and the ___ moves linearly.
With milling, the ___ rotates, and the ___ moves linearly.

A

piece; tool
tool; piece

70
Q

High speed machining characteristics

A

High spindle speed, low cut depth
High MRR
Expensive

71
Q

High-efficiency machining range

A

Optimal cutting speed for time and cost

72
Q

Cutting fluid purposes

A

Reduce friction & temp
Improve tool life
Reduce cutting force
Wash away chips

73
Q

How much material should be left for a finishing pass?

A

.005 - .010 in

EME50 (9 decks)

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