Manufacturing Processes Quiz
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Questions and Answers

Which statement/statements is/are correct about the built-up edge on a cutting tool?

  • It alters workpiece surface roughness; (correct)
  • None of the other answers;
  • It alters the rake angle; (correct)
  • It cannot be avoided during a cutting operation;
  • It does not alter the rake angle;

    • Which statement/statements is/are not correct about wire drawing?

  • It requires lubrication
  • It is performed at high temperature
  • Drawing stress reduces at increasing drawing ratio (correct)
  • Under ideal plastic behavior, maximum drawing reduction depends on strain hardening exponent
  • Center burst is a defect that may appear

    • Which statement/statements is/are correct when the rake angle reduces in orthogonal cutting?

  • Shear area reduces; (correct)
  • Shear area increases;
  • Cutting force reduces; (correct)
  • Shear angle reduces; (correct)
  • Shear angle increases;
  • Chip thickness is unchanged;

    • Which statement/statements is/are correct about flat rolling?

    <p>The presence of an external front tension moves the neutral plane towards the exit region; (slide 36 cap.06 Rolling)</p> Signup and view all the answers

    Which of the following parameter/parameters is/are in the equation to calculate the chip thickness ratio (in an orthogonal cutting model)?

    <p>Feed rate;</p> Signup and view all the answers

    The ideal deformation in an extrusion process depends on

    <p>Extrusion stress;</p> Signup and view all the answers

    In flat rolling, which statement/statements is/are correct regarding the speed of the laminate?

    <p>At the neutral plane, the speed of the laminate is different from the peripheral speed of the rolls;</p> Signup and view all the answers

    Which statement/statements is/are correct about extrusion?

    <p>Aluminum extruded parts are most common than other metal alloys;</p> Signup and view all the answers

    Reducing strain rate tends to have which one/ones of the following effects on flow stress (σ=Κε^n) and metal behavior during cold forming of metal

    <p>Modifies strength hardening exponent, n</p> Signup and view all the answers

    A linear (i.e. not curved) groove could be made with which of the following machine tools?

    <p>Shaping machine (DUBBIA, pacchetto slide 12)</p> Signup and view all the answers

    Which of the following machining operation/operations commonly uses/use multiple-point cutting tools?

    <p>Broaching</p> Signup and view all the answers

    Which of the following process/processes is/are not chip removal operation

    <p>Thread rolling</p> Signup and view all the answers

    Which statement/statements is/are correct about upsetting?

    <p>Upsetting pressure decreases from the lateral side to the middle on the part</p> Signup and view all the answers

    The maximum thickness reduction (i.e. draft) possible in a flat rolling operation depends strictly on which of the following parameter/parameters

    <p>Position of the neutral plane</p> Signup and view all the answers

    A roughing operation generally involves which one/ones of the following combination of cutting conditions (where v = cutting speed, f = feed and d=depth)

    <p>low v, high f and d</p> Signup and view all the answers

    A shaping (i.e. performed with a shaper) operation during the cutting is described by which one/ones of the following statements:

    <p>a single point tool moves linearly past a stationary workpart (Slide 2 cap.13)</p> Signup and view all the answers

    In a single step of wire drawing, the maximum drawing reduction of a metal WITH strain hardening (but NO friction, NO redundant work) depends directly on:

    <p>strain hardening exponent of the hollomon equation</p> Signup and view all the answers

    In which manufacturing operation may locked and counterlocked dies be used?

    <p>Impression die forging</p> Signup and view all the answers

    Which of the following operation/s is/are closely related to open-die forging?

    <p>Upsetting</p> Signup and view all the answers

    Facing operation is tipically performed with which of the following machine tools?

    <p>Lathe</p> Signup and view all the answers

    In the orthogonal cutting model, the chip thickness ratio is defined as (where tc=thickness of the chip, wc= width of the chip, tm= thickness of the material to be cut, wm= width of the material to be cut, f=feed)

    <p>tc/wm</p> Signup and view all the answers

    Which are the forces that can be physically (directly) measured in a cutting process with a single-edged tool?

    <p>cutting force and thrust force (Slide 36 cap.9 Theory Of MM)</p> Signup and view all the answers

    Assuming you measure the engineering and true stresses simultaneously during a tensile test, which of the following statements are correct?

    <p>Engineering stress is always lower than true stress</p> Signup and view all the answers

    Which of the following statements is correct about milling?

    <p>In conventional milling (or up milling) the direction of cutter motion is the same as the feed direction when the teeth cut the work</p> Signup and view all the answers

    Which is/are the manufacturing process/processes that could be also used (with proper equipment and/or tools) to produce threaded part?

    <p>Rolling</p> Signup and view all the answers

    Which of the following statements is correct:

    <p>Pijspanen's theory is based on the analysis of the shear motion of the chip on a plane parallel to the tool rake surface</p> Signup and view all the answers

    In chip removal machining operations:

    <p>There is a decrease in hardness in the chip, compared to the base material</p> Signup and view all the answers

    The taylor's law for cutting tool life is applicable:

    <p>In most cases of cutting processes</p> Signup and view all the answers

    The built-up edge:

    <p>Alters the cutting edge angle</p> Signup and view all the answers

    For the determination of Taylor's law

    <p>The experimental values obtained from the measurement of the flank wear as a function of time and cutting speed are plotted (in a graph Vt-T)</p> Signup and view all the answers

    The reduction of the strain rate tends to have one of the following effects on the plastic flow stress and on the behaviour of the metal during cold plastic deformation (Hollomon equation (σ=Κε^n))

    <p>Reduces ductility</p> Signup and view all the answers

    The increase of the strain rate tends to have one of the following effects on the plastic flow stress and on the behaviour of the metal during cold plastic deformation (Hollomon equation (σ=Κε^n))

    <p>Modifies Young's modulus</p> Signup and view all the answers

    Which of the following factor most affects the rake angle:

    <p>None of the other answers</p> Signup and view all the answers

    The increase in temperature tends to have one of the following effects on the plastic flow stress and on the behaviour of the metal during cold plastic deformation (Hollomon equation (σ=Κε^n))

    <p>Reduces ductility</p> Signup and view all the answers

    Study Notes

    Cutting Tool Built-Up Edge

    • Alters workpiece surface roughness
    • Cannot be avoided during cutting
    • Does not alter rake angle

    Wire Drawing

    • Performed at high temperature
    • Under ideal plastic behavior, maximum drawing reduction depends on strain hardening exponent
    • Drawing stress reduces at increasing drawing ratio
    • Center burst is a possible defect

    Orthogonal Cutting Rake Angle Reduction

    • Shear area increases
    • Shear angle increases
    • Shear area (reduced)

    Flat Rolling

    • Thick laminates require smaller rolls
    • External front tension moves neutral plane towards exit region
    • External back tension moves neutral plane towards entry region
    • Roll bite condition influenced by roll diameter

    Orthogonal Cutting Chip Thickness Ratio

    • Clearance angle
    • Cutting speed
    • Shear angle
    • Feed rate
    • Solid angle
    • Rake angle

    Extrusion Process

    • Depends on extrusion stress, friction, plastic behavior of the metal part, and extrusion force
    • Die angle

    Flat Rolling Laminate Speed

    • Laminate speed reduces from entrance to exit of rolling mill
    • Laminate speed increases from entrance to neutral plane; decreases from neutral plane to exit
    • Laminate speed maximum at neutral plane
    • Peripheral speed of rolls lower than laminate speed at neutral plane

    Extrusion

    • Does not require lubrication
    • Aluminum extruded parts common
    • Mainly carried out at low temperatures
    • Direct extrusion requires higher pressures than indirect extrusion
    • Pressure doesn't significantly change during direct extrusion

    Reducing Strain Rate and Flow Stress

    • Decreases flow stress
    • Modifies strength hardening exponent, n
    • Metals show lower ductility
    • Increases flow stress
    • Modifies Young's modulus
    • Modifies strength coefficient, K

    Linear Groove Machining

    • Deep drawing machine
    • Broaching machine

    Multiple-Point Cutting Tools

    • Sawing
    • Planing
    • Broaching
    • Milling
    • Turning
    • Drilling
    • Shaping

    Non-Chip Removal Processes

    • Rolling
    • Planing
    • Broaching
    • Thread rolling
    • Coining
    • Trimming

    Upsetting

    • Upsetting pressure reduces with increasing friction coefficient
    • Upsetting pressure is zero at the lateral side of the part
    • Dies are commonly flat
    • Upsetting pressure decreases from the lateral side to middle of the part

    Flat Rolling Operation Parameter

    • Friction coefficient between rolls and workpiece
    • Position of neutral plane
    • Initial thickness of the laminate
    • Rotational speed of rolls

    Roughing Operation

    • Low cutting speed, feed, and depth
    • High cutting speed, low feed, and depth

    Shaping Operation

    • Tool with multiple teeth moves linearly past a stationary work-part
    • Work-part moves linearly past a single point tool
    • Work-part fed linearly past a rotating cutting tool
    • Single point tool moves linearly past a stationary work-part

    Wire Drawing Strain Hardening

    • Drawing force
    • Strain hardening exponent of the Hollomon equation
    • Die angle
    • Friction
    • Drawing stress

    Locked and Counterlocked Dies

    • Extrusion
    • Upsetting
    • Impression die forging
    • Rolling
    • Drawing
    • Hobbing
    • Upsetting
    • Coining
    • Fullering
    • Cogging

    Facing Operation Machine Tool

    • Milling machine
    • Drill press
    • Planer
    • Shaper
    • Lathe

    Cutting Force Measurement

    • Cutting force
    • Friction force
    • Friction and normal friction force
    • Shear force and normal shear force
    • Thrust force and shear force
    • Cutting force and thrust force

    Engineering and True Stresses

    • Engineering stress always lower than true stress
    • Engineering stress is lower than true stress after necking

    Milling Operation

    • Vertical knee-and-column for peripheral milling
    • Cutter overhangs work on one side in end milling
    • Same feed direction for up milling
    • Horizontal knee-and-column for face milling
    • Opposite feed and cutter motion for climb milling (down milling)

    Threaded Part Manufacturing Processes

    • Turning
    • Planing
    • Broaching
    • Shaping
    • Rolling
    • Drawing

    Merchant-Ernst and Pijspanen Theories

    • Merchant-Ernst theory based on strain rate analysis
    • Pijspanen's theory based on shear motion analysis parallel to tool rake surface (introduces friction)

    Chip Removal Plastic Deformation

    • Decrease in hardness in the chip compared to base material
    • No plastic deformation
    • Plastic deformation highlighted by chip thickness ratio

    Taylor's Law Applicability

    • Applicable in most cases of cutting processes
    • Applies to sintered carbide and high-speed steel tools

    Built-Up Edge

    • Alters rake angle
    • Alters cutting edge angle
    • Alters relief (clearance) angle

    Strain Rate and Plastic Flow Stress

    • Reduction in strain rate decreases plastic flow stress
    • Increase in strain rate increases plastic flow stress
    • Strain rate may reduce ductility
    • Strain rate may change Young's modulus

    Rake Angle Affecting Factor

    • Flank wear
    • Nose radius wear
    • Crater wear
    • Built-up edge

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    Description

    This quiz covers various manufacturing processes including cutting tool performance, wire drawing, flat rolling, and extrusion. Each topic addresses specific parameters and conditions that affect the quality and efficiency of manufacturing techniques. Test your knowledge on these critical concepts!

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