Podcast
Questions and Answers
What is the primary purpose of barrel tumbling?
What is the primary purpose of barrel tumbling?
- To create uniform shapes in the workpiece
- To remove fins, flashes, and scales from parts (correct)
- To cut down surfaces using abrasives
- To apply paint or plating
What is the effect of adding water or dilute acid solutions during barrel rolling?
What is the effect of adding water or dilute acid solutions during barrel rolling?
- It slows down the tumbling process
- It prevents rust formation
- It reduces the amount of abrasive needed
- It enhances the cutting action of the abrasives (correct)
Which materials are commonly used as abrasives in barrel rolling?
Which materials are commonly used as abrasives in barrel rolling?
- Synthetic powders and polymers
- Steel shavings and rubber granules
- Organic materials and cornstarch
- Sand, granite chips, and glass fragments (correct)
How is the barrel filled for effective barrel rolling?
How is the barrel filled for effective barrel rolling?
Which final step is essential after tumbling the parts?
Which final step is essential after tumbling the parts?
What characteristic of abrasives is emphasized to ensure effective cutting during barrel rolling?
What characteristic of abrasives is emphasized to ensure effective cutting during barrel rolling?
Which operation is NOT typically associated with barrel tumbling?
Which operation is NOT typically associated with barrel tumbling?
What is the recommended cutting speed for P20 material when used in machining?
What is the recommended cutting speed for P20 material when used in machining?
Which machining operation is suitable for P30 material?
Which machining operation is suitable for P30 material?
What is the typical feed rate when machining P40 material?
What is the typical feed rate when machining P40 material?
For machining P50 material, what cutting speed range is recommended?
For machining P50 material, what cutting speed range is recommended?
What characteristic should the rake angle be for machining P30 under favorable conditions?
What characteristic should the rake angle be for machining P30 under favorable conditions?
Which material is specifically noted for having shrinkage cavities that affects machining recommendations?
Which material is specifically noted for having shrinkage cavities that affects machining recommendations?
What is a common challenge when machining steel castings with P40 materials?
What is a common challenge when machining steel castings with P40 materials?
What type of chips are formed at low feed rates when machining P20 material?
What type of chips are formed at low feed rates when machining P20 material?
Which of the following materials is NOT specified for machining within the P40 category?
Which of the following materials is NOT specified for machining within the P40 category?
In what scenario is a large rake angle used when machining P50 materials?
In what scenario is a large rake angle used when machining P50 materials?
Which materials are suitable for cutting with high toughness?
Which materials are suitable for cutting with high toughness?
What is the maximum hardness of grey cast iron that can be efficiently machined using turning, milling, and planing?
What is the maximum hardness of grey cast iron that can be efficiently machined using turning, milling, and planing?
Which of the following materials is most suitable for machining with high cutting speeds?
Which of the following materials is most suitable for machining with high cutting speeds?
Which type of iron is characterized by forming short chips during machining?
Which type of iron is characterized by forming short chips during machining?
Which of the following is not considered an abrasive type material for machining?
Which of the following is not considered an abrasive type material for machining?
Which machining process can be applied to soft grey cast iron?
Which machining process can be applied to soft grey cast iron?
Which of these materials is best suited for machining under unfavorable conditions?
Which of these materials is best suited for machining under unfavorable conditions?
For which materials would reaming be an inappropriate machining process?
For which materials would reaming be an inappropriate machining process?
Which materials are known for their resistance to wear while being machined?
Which materials are known for their resistance to wear while being machined?
Which of the following is not a characteristic of materials suitable for high feed rates?
Which of the following is not a characteristic of materials suitable for high feed rates?
What temperature range can super-alloys withstand without losing strength?
What temperature range can super-alloys withstand without losing strength?
Which type of super-alloy is commonly used in manufacturing turbine disks for turbo-jet engines?
Which type of super-alloy is commonly used in manufacturing turbine disks for turbo-jet engines?
What is the primary role of Chromium (Cr) in super-alloys?
What is the primary role of Chromium (Cr) in super-alloys?
Which of the following is NOT a type of super-alloy mentioned?
Which of the following is NOT a type of super-alloy mentioned?
In which major application area are super-alloys primarily utilized?
In which major application area are super-alloys primarily utilized?
What is the primary purpose of the electrostatic fluidised bed process in powder coating?
What is the primary purpose of the electrostatic fluidised bed process in powder coating?
Which of the following operations would best describe the polishing process?
Which of the following operations would best describe the polishing process?
What type of materials are typically used for polishing wheels?
What type of materials are typically used for polishing wheels?
How is the polishing operation typically classified?
How is the polishing operation typically classified?
What is a common limitation of polishing operations?
What is a common limitation of polishing operations?
What level of surface roughness can typically be achieved after a polishing operation?
What level of surface roughness can typically be achieved after a polishing operation?
Does polishing improve machining accuracy?
Does polishing improve machining accuracy?
What is the characteristic color designation for carbide tips intended for precision turning?
What is the characteristic color designation for carbide tips intended for precision turning?
What machining condition is associated with carbide tip designation P10?
What machining condition is associated with carbide tip designation P10?
What is the appropriate cutting speed range for P30 material during machining?
What is the appropriate cutting speed range for P30 material during machining?
Which of the following materials is most suitable for turning, precision turning and boring?
Which of the following materials is most suitable for turning, precision turning and boring?
For which machining operation is P40 material most effectively utilized?
For which machining operation is P40 material most effectively utilized?
What defines the toughness characteristic in materials used with a P20 classification?
What defines the toughness characteristic in materials used with a P20 classification?
Which of the following abrasives is least likely to be used in barrel rolling?
Which of the following abrasives is least likely to be used in barrel rolling?
Which material would you typically expect to have the highest hardness rating at 60 HRC?
Which material would you typically expect to have the highest hardness rating at 60 HRC?
In barrel rolling, what is the typical fill percentage of the barrel for optimal operation?
In barrel rolling, what is the typical fill percentage of the barrel for optimal operation?
Which statement about the tumbling process is incorrect?
Which statement about the tumbling process is incorrect?
What distinguishes barrel rolling from barrel tumbling?
What distinguishes barrel rolling from barrel tumbling?
Why is wet rolling generally preferred in barrel rolling processes?
Why is wet rolling generally preferred in barrel rolling processes?
After completing the tumbling process, what is an essential step for the treated parts?
After completing the tumbling process, what is an essential step for the treated parts?
Which abrasive paste is typically used for achieving a high-quality finish in polishing operations?
Which abrasive paste is typically used for achieving a high-quality finish in polishing operations?
During which polishing operation is a fine grain size of abrasive typically used?
During which polishing operation is a fine grain size of abrasive typically used?
What is the typical surface roughness range achievable through polishing?
What is the typical surface roughness range achievable through polishing?
Which of the following is NOT a typical material used for polishing wheels?
Which of the following is NOT a typical material used for polishing wheels?
What material is often used in the polishing pastes alongside abrasives to enhance the finish?
What material is often used in the polishing pastes alongside abrasives to enhance the finish?
Which polishing operation is primarily characterized by the use of dry wheels?
Which polishing operation is primarily characterized by the use of dry wheels?
What type of parts poses challenges during the polishing process due to their geometry?
What type of parts poses challenges during the polishing process due to their geometry?
What grain size range is associated with dry fining polishing operations?
What grain size range is associated with dry fining polishing operations?
What distinguishes polishing from lapping in terms of machining accuracy?
What distinguishes polishing from lapping in terms of machining accuracy?
What is a key aspect of the mechanism involved in the polishing process?
What is a key aspect of the mechanism involved in the polishing process?
What is the primary benefit of the burnishing process on a surface?
What is the primary benefit of the burnishing process on a surface?
Which of the following describes the action of barrel burnishing?
Which of the following describes the action of barrel burnishing?
What is typically NOT a characteristic of surfaces that have undergone burnishing?
What is typically NOT a characteristic of surfaces that have undergone burnishing?
How should parts be prepared before barrel burnishing to ensure optimal results?
How should parts be prepared before barrel burnishing to ensure optimal results?
During the burnishing process, which of the following tools is commonly NOT used?
During the burnishing process, which of the following tools is commonly NOT used?
What is one major disadvantage of burnishing in relation to surface defects?
What is one major disadvantage of burnishing in relation to surface defects?
What is a key aspect of the operating conditions for effective barrel burnishing?
What is a key aspect of the operating conditions for effective barrel burnishing?
What type of deformation is primarily associated with burnishing?
What type of deformation is primarily associated with burnishing?
What is the relationship between barrel burnishing and surface porosity?
What is the relationship between barrel burnishing and surface porosity?
What is the primary mechanism for maintaining workpieces during barrel burnishing?
What is the primary mechanism for maintaining workpieces during barrel burnishing?
Which method increases the wear resistance of burnished surfaces by 1.5 to 2 times?
Which method increases the wear resistance of burnished surfaces by 1.5 to 2 times?
What is a common application of roller burnishing?
What is a common application of roller burnishing?
How does burnishing pressure typically affect machining accuracy?
How does burnishing pressure typically affect machining accuracy?
What materials can be effectively used in barrel burnishing processes?
What materials can be effectively used in barrel burnishing processes?
What is the effect of using smooth balls or mandrels in internal surface burnishing?
What is the effect of using smooth balls or mandrels in internal surface burnishing?
What is the process of powder coating primarily characterized by?
What is the process of powder coating primarily characterized by?
What challenges might arise from fastening parts in racks inside the barrel during burnishing?
What challenges might arise from fastening parts in racks inside the barrel during burnishing?
What role do rollers and balls play in the roller/ball burnishing process?
What role do rollers and balls play in the roller/ball burnishing process?
Which materials are commonly used for powder coating apart from thermo-plastic resins?
Which materials are commonly used for powder coating apart from thermo-plastic resins?
Flashcards
Barrel Tumbling
Barrel Tumbling
A surface finishing process that utilizes a rotating barrel filled with workpieces and abrasive media to clean, deburr, and improve surface finish.
Barrel Rolling
Barrel Rolling
Similar to barrel tumbling, but uses abrasive media to cut down surfaces, improving finish and removing material.
Broken Chips of Glass or Carborundum
Broken Chips of Glass or Carborundum
A type of abrasive media used in barrel rolling and tumbling, made from broken glass or carborundum.
Slag
Slag
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Wet Rolling
Wet Rolling
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Dry Rolling
Dry Rolling
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Deburring
Deburring
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Electrostatic Fluidised Bed Powder Coating
Electrostatic Fluidised Bed Powder Coating
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Electrostatic Spraying
Electrostatic Spraying
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Polishing
Polishing
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Materials for Polishing Wheels
Materials for Polishing Wheels
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Classification of Polishing
Classification of Polishing
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Limitations of Polishing
Limitations of Polishing
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Surface Roughness from Polishing
Surface Roughness from Polishing
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Polishing and Machining Accuracy
Polishing and Machining Accuracy
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What are super-alloys?
What are super-alloys?
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What is Chromium's role in super-alloys?
What is Chromium's role in super-alloys?
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Where are super-alloys used?
Where are super-alloys used?
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What is a common application of Ni-based super-alloys?
What is a common application of Ni-based super-alloys?
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What kind of equipment is used in foundries?
What kind of equipment is used in foundries?
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Turning
Turning
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Milling
Milling
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Boring
Boring
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Reaming
Reaming
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Broaching
Broaching
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Scraping
Scraping
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Shaping
Shaping
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Planing
Planing
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Cutting speed
Cutting speed
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Feed
Feed
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Feed Rate
Feed Rate
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Toughness
Toughness
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Resistance to Wear
Resistance to Wear
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Chip Formation
Chip Formation
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Medium Planing
Medium Planing
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Medium to High Cutting Speed
Medium to High Cutting Speed
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Low to Moderate Cutting Speed
Low to Moderate Cutting Speed
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Moderate to High Feed Rate
Moderate to High Feed Rate
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Low Feed Rate
Low Feed Rate
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Abrasive Media
Abrasive Media
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Post-Tumbling Treatment
Post-Tumbling Treatment
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Burnishing
Burnishing
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Barrel Burnishing
Barrel Burnishing
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Wet Barrel Burnishing
Wet Barrel Burnishing
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Shot-to-Work Ratio
Shot-to-Work Ratio
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Gear Burnishing
Gear Burnishing
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Fatigue strength
Fatigue strength
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Burnishing and Plating
Burnishing and Plating
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Benefits of Burnishing
Benefits of Burnishing
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Surface Irregularities
Surface Irregularities
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Surface Roughness
Surface Roughness
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Super-finishing
Super-finishing
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Roller/Ball Burnishing
Roller/Ball Burnishing
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Ball Burnishing (Ballizing)
Ball Burnishing (Ballizing)
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Powder Coating
Powder Coating
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Barrel Rotation Speed
Barrel Rotation Speed
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Shot Material Selection
Shot Material Selection
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Racking For Burnishing
Racking For Burnishing
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Hole Burnishing
Hole Burnishing
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Study Notes
Surface Finishing Processes
- Tumbling is an inexpensive cleaning method using various shapes of slug materials in a barrel. It's often done dry, but can also be wet.
- Tumbling is used for removing fins, flashes, and scales; cleaning forgings, stampings, and castings; deburring; improving micrometer finishes; finishing high-precision work to a high lustre; forming uniform radii; finishing gears and threaded parts without damage; removing paint or plating.
- After tumbling, thorough washing and drying (using sawdust or infrared lamps) is necessary, followed by oiling to prevent rust.
- Barrel rolling is similar to tumbling but used for cutting surfaces rather than cleaning. It uses abrasives (slag, cinders, sharp sand, etc.) in a barrel, loaded about 40-60% full.
- Rolling is done wet or dry (sometimes with sawdust).
- Rolling time varies from 10 minutes (non-ferrous) to 3 hours (steel). Results in a remarkably uniform surface.
- Tumbling may be employed for removing fins, cleaning, deburring, and improving micrometer finish (among other applications).
Super-Finishing
- Super-finishing is a micro-finishing process for controlled surface conditions.
- It's also called 'micro-stoning'. Involves scrubbing a stone against a surface to produce a fine metal finish.
- The process removes chatter marks and fragmented metal.
- Effective for metal removal of 0.03-0.05 mm, and most economical when the removal is limited to 0.005 mm.
- Rapid reciprocating a fine grit stone against a revolving work-piece, flooded with a cutting fluid.
- Parts can be finished to a smoothness of 0.075 µm in 15-50 seconds but 2-3 minutes may be required for better finish.
- The process is used for parts like computer memory drums, sewing machine parts, automotive cylinders, brake drums, bearings, pistons, piston rods, pins, axles, shafts, clutch plates, and tappet bodies, guide pins.
Burnishing
- Burnishing creates a smooth and shiny surface through contact and rubbing against a hard tool (punch/die, rollers, balls).
- It's a cold surface plastic deformation process, enhancing surface finish and fatigue life due to compressive residual stresses.
- Barrel burnishing is similar to barrel rolling, but uses slug material for peening and rubbing. Usually done wet with a lubricant.
- Roller/ball burnishing shapes (flat, cylinder, or conical) are burnished by hardened steel or carbide rollers/balls.
- Results in a smoother surface (by 20–50%) and increased wear resistance (by 1.5–2 times).
Powder Coating
- Powder coating involves spreading a pulverised plastic powder over the surface, then heating to fuse into a uniform coating.
- It uses thermo-plastic and thermo-setting resins (nylon, PVC, polyester, epoxy).
- Fluidized bed technique used for thermo-plastic resins.
- Immersion of heated part in a fluidized powder bed.
- Baking temperatures for epoxy resins range from 120°C to 135°C, with 20–30 minutes baking time.
- Used for thick coatings, as well as decorative coatings.
Polishing
- Polishing aims for a smooth and lustrous surface.
- It uses polishing wheels (felt, cloth, wood, etc.) coated with abrasive (like Al2O3 or diamond) paste or fluid carrying abrasives.
- Results in a surface roughness of 0.032-0.012 μm Ra.
- Unlike lapping, polishing doesn't improve machining accuracy.
- Polishing is categorized into roughing, dry fining, and finish polishing phases, based on grain size of the abrasive and lubricant use (roughing ranges from 20-80; dry fining from 90-120; and finish using fine grain sizes—150—with oil, tallow, or beeswax).
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Description
Test your knowledge on the principles of barrel tumbling and the machining of various materials. This quiz covers topics such as abrasive materials, cutting speeds, and specific characteristics of machining operations. Perfect for students and professionals in manufacturing and engineering fields.
