Machining Techniques and Mist Cooling Quiz

A cooling method where a fine mist of cutting fluid is sprayed at high velocity onto the cutting zone.

A key advantage of mist cooling is its ability to dissipate heat rapidly through convection currents created by the high velocity of the fluid.

The surface area of the coolant in mist form is much larger than in flood cooling, leading to enhanced cooling capacity.

The mist's expansion through the nozzle causes a significant temperature decrease, further aiding in heat dissipation.

Mist Cooling is a viable option for various cutting operations, but it excels when dealing with hard work materials.

Mist cooling is less effective than flood cooling at both extremely high and low temperatures.

The process of creating mist utilizes the Venturi effect, where high-pressure air draws cutting fluid into a nozzle, resulting in a fine mist.

A device used to hold and rotate a workpiece on a lathe between centers. It has a tail that engages with a drive plate on the spindle.

A rotating plate mounted to the lathe spindle that drives the lathe dog, which in turn rotates the workpiece.

A non-rotating center that supports one end of the workpiece while it is being turned on a lathe.

A type of center that can be used to support the end of a workpiece while also allowing it to rotate.

Used to hold and clamp workpieces with a length less than 4 times their diameter on a lathe.

A machine designed to create various articles by removing material from workpieces in the form of chips, using cutting tools.

Machines that produce articles by displacing material through plastic deformation, without removing material.

Machines that use cutting tools to remove material, shaping a workpiece by taking away metal in the form of chips.

The four essential functions of most machine tools are holding the workpiece, holding the cutting tool, providing movement (rotary or reciprocating) to one or both, and supplying a controlled feeding motion.

A metal cutting tool can be classified as a machine tool, which is the main power driven machine, and a cutting tool, which is the actual tool that removes metal.

Tool steels often contain two or three elements because they are carefully designed to balance specific characteristics that influence the tool's hardness and wear resistance.

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Adding chlorine to a cutting fluid improves its ability to prevent rust and corrosion on the workpiece and tool during machining.

Brass can be machined without a cutting fluid, BUT it's generally not recommended. Doing so can lead to excessive heat build-up, tool wear, and poor surface finish.

Paraffin in oil is a common addition to cutting fluids used for machining aluminum due to its ability to lubricate and reduce the risk of welding between the tool and the workpiece.

Additives like chlorine, fluoride, and phosphates are added to water to improve its properties as a cutting fluid. These additives help enhance the water's cooling ability, lubricity, and corrosion resistance, resulting in better cutting performance and tool life.

Coronite is a cutting tool material made with a cobalt-tungsten carbide mixture. This material offers excellent wear resistance, high hardness, and good toughness, making it ideal for machining tough materials.

Cast-cobalt tools primarily consist of cobalt, carbon, tungsten, chromium, and molybdenum. This combination gives them high red and hot hardness, excellent wear resistance, and good machinability.

Cermets are ceramic-metal composites offering several advantages. These include high wear resistance, high hardness, good toughness, and low thermal expansion. However, they can be brittle and require specific machining parameters.

Cubic Boron Nitride (CBN) is the second hardest material known, right after diamond. It offers excellent wear resistance and high hardness, making it suitable for machining hard materials like hardened steel.

H.S.S. (High-Speed Steel) tools are increasingly used as inserts instead of solid tools due to their high cost. These inserts are attached to the tool shank by clamping, brazing, or welding. This allows for better tool life and customization.

Coated H.S.S. tools have a thin coating (2-6 μm) of a refractory carbide or nitride applied to the cutting edge. This coating significantly improves wear resistance and cutting performance, increasing tool life by 5-10 times.

Whisker reinforced tool materials, like those containing SiC whiskers in an Al2O3 matrix, enhance toughness and wear resistance. This composite material is superior to coated carbides due to its chipping resistance and increased cutting speed.

Whisker reinforced tool materials are ideal for intermittent cutting and machining of Ni-based alloys due to their superior wear resistance and toughness. These materials are more resistant to chipping compared to coated carbides, offering better cutting performance and tool life.

Machine tools requiring high precision often need a stable environment, so they are kept in controlled temperature and humidity rooms.

Machine tools are categorized based on their weight, with classifications like light, medium, heavy, and extra-heavy, each indicating a weight range.

Engine and facing lathes, cutting-off lathes, multiple-tool lathes, turret lathes, automatics (single and multiple-spindle), vertical turning and boring mills are all types of lathes.

Vertical turning and boring mills are used to machine large-diameter, relatively small-height workpieces, often for large-scale projects.

Drilling and boring machines are used to create holes in materials. Different types include upright drill presses, semi-automatic drills, jig borers, radial drills, and horizontal drilling machines.

Planers, shapers, slotters, and broaching machines are used for cutting flat surfaces and shaping parts. This includes open-side planers, double-housing planers, shapers, slotters, and horizontal and vertical broaching machines.

Milling machines are used to cut complex shapes and contours in materials. They can be horizontal knee-type, vertical knee-type, tracer-controlled, continuous, vertical-spindle compound-table, fixed-bed, planer-type, or ram-head.

Grinding and micro-finishing machines are used for smoothing and finishing surfaces. Types include cylindrical grinders, internal grinders, snagging grinders, specialized grinders, tool and cutter grinders, surface grinders, and micro-finishing machines.

Gear and thread cutting machines are specialized for manufacturing gears and threads. They include shapers and planers for gears, bevel gear generators, hobbers, worm wheel and worm cutting machines, gear tooth chamfering machines, thread-milling machines, gear finishing machines, and gear and thread grinders.

Machine tools can be broadly categorized into nine groups based on the type of operation they perform and the tools they use. These groups include lathes, drilling and boring machines, planers, shapers, slotters, broaching machines, milling machines, grinding and micro-finishing machines, and gear and thread cutting machines.

Steady rests are used for long or slender workpieces to prevent bending during machining by providing additional support.

A fixed steady rest is mounted on the lathe bed and used to support the workpiece during turning. It has adjustable jaws to hold the workpiece securely.

A follower steady rest is mounted on the saddle and moves with the tool, providing continuous support for the workpiece as it's being turned.

A milling vise is used to hold the workpiece securely during milling operations on a lathe. It is mounted in place of the compound rest and allows for limited work movement.

Special fixtures are designed and used to hold workpieces during machining, especially when they cannot be secured in the standard workholding devices.

Applying cutting fluid directly to the cutting zone using a nozzle or jet, creating a continuous stream. This method is also known as "Hi-jet Method".

A method of applying cutting fluid as a fine atomized mist, combining air and small fluid droplets. This method offers efficient cooling and lubrication.

Increasing the surface area of the coolant through the fine mist increases its cooling capacity compared to flood application.

Using a pump to apply the cutting fluid, allowing for more control and precise application. This method is often used for heavy and continuous cutting.

The fine mist in Mist Cooling has a much larger surface area, allowing for faster heat dissipation.

Mist Cooling uses the Venturi effect, where high-pressure air draws cutting fluid into a nozzle, creating a fine mist. This mist is then directed onto the cutting zone.

The size of the fluid droplets in mist methods is typically 10-25 μm.

Machine tools used for a wide range of operations on various workpieces, often found in small-batch production and repair work.

Machine tools designed to perform a specific machining operation, like broaching or gear shaping.

Machine tools capable of a limited set of operations but can work on a variety of workpieces, like automatic cutting-off machines.

Machine tools used for high-volume production, featuring high power and rigidity, like multi-tool lathes or numerically controlled machines.

Machine tools that are designed to machine similar articles but different in size, they can be easily adjusted for different jobs, like unit built machine tools.

Machine tools individually designed for very specific operations on specific workpieces, they're customized for a particular task.

Plain turning lathes, turret lathes, milling machines, drilling machines, and grinding machines are all examples of what type of machine tools?

Broaching machines, thread cutting machines, gear shaping machines, and machines for machining specific parts like pistons or camshafts are all examples of what type of machine tools?

Why are Production Machine Tools important for large-scale production?

How do Specialized Machine Tools benefit manufacturing?

A mechanism found in engine lathes that controls the speed of the feed screw and feed rod, which in turn determines the cutting speed and depth.

A set of gears that transmits power from the lathe's spindle to the feed screw and rod, allowing for various feed rates.

A device that allows the change gears to be moved along a slot, adjusting the center distances and gear ratios.

A gearbox that allows for quick and easy selection of different feed rates by simply shifting levers.

The ratio between the number of teeth on the input and output gears in the change gear quadrant. This ratio determines the feed rate.

The input shaft of the change gear mechanism, connected to the lathe's reversing mechanism.

The output shaft of the change gear mechanism, connected to the quick-change gear box.

Two gears that rotate freely on a sleeve that can be adjusted along a slot in the quadrant.

A shaft that allows the quadrant to rotate freely, adjusting the gear ratio.

The main component of the change gear mechanism, which holds the gears and allows adjustment.

Coronite is a cutting tool material made from a mixture of cobalt and tungsten carbide. This material offers excellent wear resistance, high hardness, and good toughness, making it ideal for machining tough materials.

Coronite is produced through powder metallurgy. This method involves creating a fine powder mixture of cobalt and tungsten carbide, then pressing it into a mold, sintering it under high temperature and pressure, and finally finishing it to create the desired shape.

Compact diamond cutting tools are produced through a process known as high-pressure, high-temperature (HPHT) synthesis. This method involves exposing a mixture of carbon and other elements to extreme pressures and temperatures, resulting in the formation of diamond crystals.

Borazon and Elbor are cutting tool materials made from cubic Boron Nitride (CBN). Borazon is a trade name for CBN produced by General Electric Corporation, while Elbor is a trade name for CBN produced in Russia. Both materials are excellent for machining tough materials like hardened steels.