24 Questions
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
What types of part shapes and features can be created through machining?
screw threads, accurate round holes, very straight edges and surfaces
What are the benefits of machining in terms of accuracy and finish?
good dimensional accuracy and surface finish
What is the characteristic of a single-point tool?
A single dominant cutting edge, with a rounded point forming a nose radius.
What are some examples of abrasive processes?
grinding
What is one of the disadvantages of machining?
Wasteful of material
What are nontraditional processes?
various energy forms other than sharp cutting tool to remove material
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.
What are the three dimensions of a machining process?
Cutting speed (v), feed (f), and depth of cut (d).
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.
What are the most important machining operations?
Turning, Drilling, and Milling
How is the material removal rate (RMR) computed in certain operations like turning?
RMR = v f d
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.
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
What are the characteristics of roughing cuts?
High feeds and depths, and low speeds.
What is drilling used to create?
A round hole
What is the purpose of finishing cuts in a production process?
To complete part geometry, achieving final dimensions, tolerances, and finish.
What is the main difference between peripheral milling and face milling?
The direction of the cutting tool movement
Why is machining time-consuming?
A machining operation generally takes longer to shape a given part than alternative shaping processes
What are the characteristics of finishing cuts?
Low feeds and depths, and high cutting speeds.
What is an example of an alternative machining operation to turning, drilling, and milling?
Shaping and planing, Broaching, Sawing
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
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.
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