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FINAL EXAM 322 > Machining Operations > Flashcards

Machining Operations Flashcards

week 9 - 10

1
Q

is machining good for mass production

A

no

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2
Q

Rotational Vs. Nonrotational (prismatic)

A

rotational: cylindrical or disk-like shape

nonrotational: block-like or plate-like shape

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3
Q

Further machine operation and part geometry classification

A
  1. Generating - part geometry determined by feed trajectory of cutting tool
  2. Forming - part geometry is created by the shape of the cutting tool
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4
Q

In generating Shape the __________ of the cutting tool determines the shape

A

moment

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5
Q

In forming the __________________ determines the shape

A

shape of the cutting tool

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6
Q

what machine is used for the turning operation

A

a lathe

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7
Q

flat turning /turning is

A

reducing the diameter (single-point cutting tool)

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8
Q

Lathe specification

A

1.size designation
- length of bed
- max distance b/t centers
- swing (max diameter that can be rotated on lathe)
2. max RPM
3. horse powe

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9
Q

bed of a basic lathe

A

– Foundation of the
lathe
– Supports all other
major components
– Top part has two
ways

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10
Q

head stock of a basic Lathe

A
  1. fixed
  2. mounted on the ways
  3. consists of
    - hollow spindle
    - bearings
    -motors, pulley and belts or transmition gears to drive spindle
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11
Q

Carriage of basic lathe

A

Along with the apron—
provides the base for
mounting and moving
cutting tools

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12
Q

cross slide of basic lathe

A

Mounted to the carriage
and provides movement
for facing and cut-off
operations

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13
Q

Compound rest of basic lathe

A
  • Mounted to the cross
    slide. Can rotate for angle
    cuts.
    – the component that holds
    the tool post for cutting
    tools.
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14
Q

tail stock of basic lathe

A
  • Supports the other end
    of the workpiece
  • Lower portion of casting
    fits inner ways
  • Can slide along the
    ways
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15
Q

feed rod of basic lathe

A

provides forward and reverse motion for carriage and cross slide

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16
Q

lead screw for basic lathe

A

– Used for threading
purposes.
– Engages with the
half-nut to provide
correct feed for
specific lead of
thread.

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17
Q

4 methods of holding the work peice in lathe

A
  1. holding the work between center
  2. chuck
  3. collet
  4. face plate
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18
Q

holding the work between two centers

A
  • one in head stock called dog
  • stock-cone shaped point (live center turns and doesnt have heat, dead center does not turn and produces heat
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19
Q

when is holding the work between centers used

A

when part has large length to diameter ratio

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20
Q

holding work peice using chuck

A
  • quick and easy to hold work peice
  • 3 jaws for circle, 4 for square or multi for other shapes
  • dont need a tail stock to use
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21
Q

when are chucks used

A

for parts with low length to diameter ratio - no tail stock

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22
Q

work holding collets

A
  • holding device has to match size (custom design)
  • better than chucks bc more accuracy and holding power
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23
Q

work holding face plate

A
  • hold parts with irregular shapes
  • custom designed
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24
Q

Types of Lathes (turning machines)

A
  • Engine
  • Toolroom (small, more acurate)
  • Turret ~ cutting tool moved quickly manually
  • Automatic (chucking) ~ same as turret
  • Automatic bar machines ~instead of chuck a cullet is used
  • screw machine - make screws
  • multiple screws - makes multiple tools
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25
Q

basic hole making processes acount for approx _________

A

50- 60 % of all metal removal processes

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26
Q

what does the flute of a drill do

A
  • allow coolant to flow to the cutting-edge
  • move chips from cut zone
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27
Q

3 main components of a drill bit

A
  • Shank
    – Body
    – Point
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28
Q

what are the 3 standard pint drill geometry angles

A
  1. conventional (118* for soft metals)
  2. long angle point (60-90* for non-ferrous materials)
  3. flat angle point (135* for harder metals)
29
Q

Work holding for drill presses can be claimed in any of the following:

A

– Vise - general purpose work holder with two jaws
– Fixture - work holding device that is usually custom-designed for the particular work part
– Drill jig – similar to fixture but also provides a means of guiding the tool during drilling

30
Q

reaming (type of drilling)

A

enlarges hole its not boring because it gives a good surface finish

31
Q

tapping (type of drilling)

A

Used to provide internal screw
threads on an existing hole
(its rpm is same as feed)

32
Q

Countersinking

A

tapered feature at the end of a hole
- used for flat head screws

33
Q

Counterboring

A

Enlarging of an existing hole at one end.
- used for head screws

34
Q

Spot facing

A

Smoothing, squaring, and/or flattening a surface (lets it touch end of hole if the shape is rounded)

35
Q

Upright Drill Press

A
  • good service finish
  • motion is limited
36
Q

Radial Drill Press

A
  • allows for more motion (rotates in and out)
  • not good accuracy in tolerance
37
Q

Drill Tapping Machines

A

makes threads

38
Q

Drill Multi spindle

A

allows for multiple workpieces at once

39
Q

Turret Drill Press

A

multiple cutting tools but u can only operate on one work piece

40
Q

explain rotation in milling

A
  • TOOL is rotating
  • axis of rotation is perpendicular to feed
  • multiple cutting edges
41
Q

What are the two types of milling

A
  1. Peripheral milling (aka plain milling)
  2. Face Milling
42
Q

What is peripheral milling

A

cutter axis parallel to the surface and cutting edges on the outside periphery of the cutter

43
Q

what is face milling

A

cutter axis is perpendicular to the surface being milled and cutting edges on both the end and outside periphery of the cutter

44
Q

What is peripheral - slab milling -

A

cutter width extends beyond the workpiece on both sides

45
Q

What is peripheral - slotting -

A

width of cutter is less than workpiece
width, creating a slot in the work

46
Q

variations of peripheral milling

A
  • teeth to the side - slide milling
  • two cutting teeth- straddle milling
  • more than two teeth - gang milling
  • cutting through entire thing- slitting
  • form or shape milling
47
Q

explain face milling

A
  • axis of rotation perpendicular to work piece surface
  • milled surface is flat and has no relation ship to the cutter
48
Q

Face milling variations

A
  • partial facing
  • end milling
  • surface contouring
49
Q

what is face milling - end milling -

A

it’s to the side (not side milling that’s for peripheral)

50
Q

what is face milling - profile milling -

A

outside periphery (boundary) of a
flat part is cut

51
Q

what is face milling - Surface Contouring -

A

Ball-nose cutter fed back and forth across work along a curvilinear path at close intervals to create a three dimensional surface form

51
Q

what is face milling - pocket milling -

A

used to mill shallow pockets into flat parts

52
Q

Conventional milling feed direction
(spins clockwise, fed left to right)

A
  • ship is thinnest at the start
  • less “shock” to cutter
  • less vibration and chatter
  • lifts the workpiece up (not efficient for thin samples)
53
Q

Climb milling feed direction
(spins clockwise, fed right to left)

A
  • chip is thick at the start
  • results in more shock to cutter
  • more vibration and chatter
  • holds work against table (can machine thin parts )
  • better surface finish
54
Q

knee and column milling machine

A

moves parallel in z axis and if head is rotated x axes
(looks like a human)

55
Q

Bed mill - horizontal spindle

A

used for heavier and larger materials

56
Q

milling operations - 4th axis

A

usually rotary - the tool or the work (on x or 2 axis) this expands the possibilities

57
Q

Mill-turn centers

A

one or both of the work piece or tool has to be rotatating

58
Q

Shaping and planing

A

LINEAR MOTION (NO ROTATION)
SINGLE POINT CUTTING TOOL
Shaping (feed provides work, speed is by tool)
Planning (feed provides speed, speed is by work)

59
Q

Broaching

A

in a single stroke, u get the final finish BUT u have to custom-make the broaching tool
- good surface finish and tolerance
- expensive, good for high volume

60
Q

Circular saws

A

used for linear shapes

61
Q

Band saw

A

– Irregular shapes
– Very versatile
– Profile cuts
– Internal cuts
– external configurations

62
Q

Hack saw

A

linear reciprocating motion of hack saw blade

63
Q

High speed machining (surface speed is faster)

A
  1. faster production rates
  2. shorter lead times
  3. reduce costs
  4. better finish
64
Q

what is DN ratio

A

(bearing bore diameter{mm})(max spindle speed - RPM {rev/min})
Between 500,000 and 1,000,000

65
Q

What is HP/RPM Ratio

A

hp/rpm ratio = horspower/max spindle speed (RPM)

66
Q

how to define High speed Machining (HSM)

A
  • DN ratio
  • HP/RPM Ratio
    – Higher production rates
    – Shorter lead times
    – Rather than functions of spindle speed
67
Q

requirement for high speed machining

A
  • “look ahead”, helps avoid “undershooting” and “Overshooting” tool path
  • Balanced cutting tools, toolholders, and
    spindles to minimize vibration
  • Coolant delivery systems that provide
    higher pressures than conventional
    machining
  • Chip control and removal systems to cope
    with much larger metal removal rates

FINAL EXAM 322 (5 decks)

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