Machining Disadvantages in Manufacturing

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Questions and Answers

What is the common feature of shaping operations?

removal of material from a starting workpart so the remaining part has the desired geometry

What is machining?

material removal by a sharp cutting tool

What is the purpose of the cutting action in machining?

to form a chip, and as the chip is removed, a new surface is exposed

What type of materials can be machined?

a variety of work materials, most frequently metals Signup and view all the answers

What types of part shapes and features can be created through machining?

screw threads, accurate round holes, very straight edges and surfaces Signup and view all the answers

What are the benefits of machining in terms of accuracy and finish?

good dimensional accuracy and surface finish Signup and view all the answers

What is the characteristic of a single-point tool?

A single dominant cutting edge, with a rounded point forming a nose radius. Signup and view all the answers

What are some examples of abrasive processes?

grinding Signup and view all the answers

What is one of the disadvantages of machining?

Wasteful of material Signup and view all the answers

What are nontraditional processes?

various energy forms other than sharp cutting tool to remove material Signup and view all the answers

What is the difference between single-point tools and multiple cutting edge tools?

Single-point tools have one dominant cutting edge, while multiple cutting edge tools have more than one cutting edge. Signup and view all the answers

What are the three dimensions of a machining process?

Cutting speed (v), feed (f), and depth of cut (d). Signup and view all the answers

Why is machining generally performed after other manufacturing processes?

Other processes create the general shape of the starting workpart, and machining provides the final shape, dimensions, finish, and special geometric details. Signup and view all the answers

What are the most important machining operations?

Turning, Drilling, and Milling Signup and view all the answers

How is the material removal rate (RMR) computed in certain operations like turning?

RMR = v f d Signup and view all the answers

What is the purpose of roughing cuts in a production process?

To remove large amounts of material from the starting workpart, leaving some material for finish cutting. Signup and view all the answers

What is the purpose of turning in machining?

To form a cylindrical shape by removing material from a rotating workpiece with a single point cutting tool Signup and view all the answers

What are the characteristics of roughing cuts?

High feeds and depths, and low speeds. Signup and view all the answers

What is drilling used to create?

A round hole Signup and view all the answers

What is the purpose of finishing cuts in a production process?

To complete part geometry, achieving final dimensions, tolerances, and finish. Signup and view all the answers

What is the main difference between peripheral milling and face milling?

The direction of the cutting tool movement Signup and view all the answers

Why is machining time-consuming?

A machining operation generally takes longer to shape a given part than alternative shaping processes Signup and view all the answers

What are the characteristics of finishing cuts?

Low feeds and depths, and high cutting speeds. Signup and view all the answers

What is an example of an alternative machining operation to turning, drilling, and milling?

Shaping and planing, Broaching, Sawing Signup and view all the answers

Study Notes

Disadvantages of Machining

Wasteful of material: chips generated in machining are wasted material
Time-consuming: machining operations generally take longer to shape a part than alternative shaping processes

Machining in the Manufacturing Sequence

Performed after other manufacturing processes, such as casting, forging, and bar drawing
Machining provides the final shape, dimensions, finish, and special geometric details that other processes cannot create

Machining Operations

Most important machining operations: turning, drilling, and milling
Other machining operations: shaping and planing, broaching, and sawing

Turning

Single point cutting tool removes material from a rotating workpiece to form a cylindrical shape

Drilling

Used to create a round hole, usually by means of a rotating tool (drill bit) with two cutting edges

Milling

Rotating multiple-cutting-edge tool is moved across work to cut a plane or straight surface
Two forms: peripheral milling and face milling

Cutting Tool Classification

Single-point tools: one dominant cutting edge, used in turning
Multiple cutting edge tools: more than one cutting edge, used in drilling and milling

Cutting Conditions in Machining

Three dimensions of a machining process: cutting speed (v), feed (f), and depth of cut (d)
Material removal rate (RMR) can be computed as RMR = v f d

Cutting Conditions in Turning

Speed, feed, and depth of cut in a turning operation

Roughing vs. Finishing Cuts

Roughing cuts: remove large amounts of material from starting workpart, high feeds and depths, low speeds
Finishing cuts: complete part geometry, final dimensions, tolerances, and finish, low feeds and depths, high cutting speeds

Material Removal Processes

A family of shaping operations, including machining, abrasive processes, and nontraditional processes
Machining: material removal by a sharp cutting tool
Abrasive processes: material removal by hard, abrasive particles
Nontraditional processes: various energy forms other than sharp cutting tool to remove material

Why Machining is Important

Variety of work materials can be machined, most frequently used to cut metals
Variety of part shapes and special geometric features possible, such as screw threads, accurate round holes, and very straight edges and surfaces
Good dimensional accuracy and surface finish

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Description

This quiz covers the disadvantages of machining in manufacturing, including material waste and time consumption. It also discusses the time taken for machining operations compared to alternative shaping processes.