Machining and Grinding Processes Flashcards

DMM1: manufacturing Deck 4

1
Q

What is the difference between Machining and Grinding processes?

A

Machining: cutting a desired shape out of a billet
Grinding: using abbrasion to wear away the surface of a billet into a desired shape

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2
Q

What are the three main types of machining processes

A

Single Point Cutting
Multiple point cutting
Abrasive cutting

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3
Q

What is turning

A

the workpiece is rotated and a stationary cutting tool is put in contact with it to create rounded shapes.

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4
Q

What are the 12 functions of a lathe?

A

Facing
straight turning
external grooving
drilling
boring and internal grooving
cutting(parting) off
taper turning
profiling
face grooving
tool forming
threading
kurling

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5
Q

what requirement are needed for turned parts?

A

all internal corners need a radius >0.4mm
externa corners must be deburred and chamfered

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6
Q

What is center drilling

A

drilling a hole that will act as a centre of rotation for following
drilling operation

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7
Q

What is reaming?

A

A process of finishing holes or slightly removing material from the hole to align it with tolerances

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8
Q

What is tapping?

A

a process used to crease small female threads

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9
Q

What is Milling?

A

A rotating tool i used to cut away matterial from a billet at a set depth to create complex shapes

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10
Q

What are the three types of vertical milling?

A

Face Milling
End Milling
T-slot milling

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11
Q

What are the 5 types of horizontal milling?

A

Slab/ Peripheral milling
Slotting
Slitting
Form milling
straddle milling

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12
Q

What are the requirements for end milling?

A

All internal corners have the radius of the end mill
all external edges must be deburred and chamfered

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13
Q

Describe the structure of abrasive machining surfaces

A

A porous network of abrasive grits embedding into a tough matrix that holds them together

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14
Q

What is Swarf?

A

waste chips of material cut away during machining

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15
Q

What is the purpose of a chip breaker?

A

a tool which splits chip into smaller parts so they are not long enough to be dangerous or damage equitment

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16
Q

What is machineability?

A

a materials ability to fracture under a small amount of strain as well as lower shear strength

17
Q

what rake angle should be used for soft materials?

A

large rake angles as they increase the length of the shear zone

17
Q

What is rake angle?

A

the angle of the cutting tools face normal to the surface of the material

18
Q

What rake angle should be used for brittle materials?

A

small if not zero angle as this improves the surface finish on a material prone to splintering

19
Q

how is the power needed for a cutting process determined?

A

P = (Specific energy x material removal rate)/ drive efficiency

20
Q

what causes a tool to fracture or chip?

A

Excessive stresses from high cutting forces often due to too deep cuts or too fast feed rates

21
Q

What causes tools to blunt or deform premeturely

A

Hard workpiece material causing high
cutting forces to be generated. Softening of tool due to lack of cooling

22
Q

What causes gradual wear and erosion in tools

A

Friction on flank causing gradual abrasive wear. Crater
wear on tool rake face due to abrasive wear from chip.

23
Q

Where is the highest temperature on the tool?

A

at the point of maxium friction and wear

24
How is tool life determined ?
VT^n = C T -> tool life V -> cutting speed n,C are constants from the specific cutting conditions
25
What order should turning processes follow?
Facing -> turining -> Chamfering -> parting off
26
What is a handling cost?
the cost of time loading and unloading machines
27
What is machining costs
the cost associated wth the time taken to machine each part
28
What is tooling cost?
the cost of all the components of the machinery and tools as well as their replacements
29