Material Removal & Machining Processes
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Questions and Answers

What is the special form of lubrication involved in lubricant cutting fluids?

extreme pressure lubrication

At what cutting speeds are lubricant-type cutting fluids most effective?

  • High cutting speeds
  • Low cutting speeds (correct)
  • Medium cutting speeds
  • Varies depending on the material
  • There are __ types of removal & machining processes.

    3

    Match the machining processes with their descriptions:

    <p>Lathe / Turning process = Process involving turning Milling / Vertical &amp; Horizontal Milling process = Processes involving vertical and horizontal milling Drilling process = Process involving drilling holes</p> Signup and view all the answers

    What is the primary purpose of the turning process?

    <p>To shape metal parts by removing material</p> Signup and view all the answers

    Facing is a type of turning operation where the tool follows a contour other than straight.

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

    What is the name of the machining process in which a work part is fed past a rotating cylindrical tool with multiple cutting edges?

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

    _______ is the ability of a material to retain its hardness at high temperatures.

    <p>Hot hardness</p> Signup and view all the answers

    Match the cutting tool material with its type:

    <p>High-speed steel (HSS) = Tool material with good toughness and wear resistance Cast Cobalt Alloys = Material known for hot hardness Cemented Carbides = Tool material with high wear resistance</p> Signup and view all the answers

    What is the primary objective of the machining process?

    <p>Producing different kinds of shapes</p> Signup and view all the answers

    What is the tool used in turning process called?

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

    In _____, the tool follows a contour that is not straight, creating a contoured shape.

    <p>contour turning</p> Signup and view all the answers

    Match the type of turning operation with its description:

    <p>Facing = Tool is fed radially inward Chamfering = Tool is fed radially into the rotating work at some location along its length to cut off the end of the part Knurling = Produce rough textured surface for decorative and/or functional purpose</p> Signup and view all the answers

    Coolant-type cutting fluids are most effective at low cutting speeds.

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

    What is the special form of lubrication involved in lubricant cutting fluids?

    <p>Extreme pressure lubrication</p> Signup and view all the answers

    At what cutting speeds are lubricant-type cutting fluids most effective?

    <p>Low speeds</p> Signup and view all the answers

    Above what speed do lubricant-type cutting fluids tend to lose their effectiveness?

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

    During the machining processes, ______ and lubricant are needed for better cutting quality and protection of cutting tools. Thank You.

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

    Match the machining processes with the tools/bits required:

    <p>Lathe / Turning process = tools/bits for cutting Milling / Vertical &amp; Horizontal Milling process = tools/bits for cutting Drilling process = tools/bits for cutting</p> Signup and view all the answers

    Study Notes

    Material Removal & Machining Processes

    • Material removal & machining processes are used to produce different shapes by cutting away material from a workpiece.
    • The most common application is to shape metal parts, and it is the most versatile of all manufacturing processes in terms of producing a diversity of part geometries and geometric features with high precision and accuracy.

    Turning Process

    • Turning is a machining process where a single point tool removes material from the surface of a rotating cylindrical workpiece.
    • The tool is fed linearly in a direction parallel to the axis of rotation.
    • Turning is performed on a machine tool called a lathe, which provides power to turn the part at a given rotational speed and to feed the tool at a specified rate and depth of cut.
    • There are several types of turning operations, including:
      • Facing: the tool is fed radially inward to create a flat surface on the end of the workpiece.
      • Contour turning: the tool follows a contour that is other than straight, creating a contoured shape.
      • Straight turning: the tool is fed parallel to the axis of rotation, creating a cylindrical surface.
      • Taper turning: the tool is fed at an angle to the axis of rotation, creating a tapered surface.
      • Form turning: the tool is fed to create a curved or irregular shape.
      • Chamfering: the tool is fed radially inward to create a chamfer (a beveled edge) on the workpiece.
      • Cut off / parting: the tool is fed radially inward to cut off the end of the workpiece.
      • Grooving: the tool is fed radially inward to create a groove on the workpiece.
      • Knurling: the tool is fed to create a rough, textured surface on the workpiece.

    Milling Process

    • Milling is a machining operation where a work part is fed past a rotating cylindrical tool with multiple cutting edges.
    • The axis of rotation of the cutting tool is perpendicular to the direction of feed.
    • Milling is an interrupted cutting operation, and the tool material and cutter geometry must be designed to withstand impact forces and thermal shock.
    • There are two forms of milling:
      • Peripheral milling: the rotation direction of the cutter distinguishes two forms of milling, i.e., up milling and down milling.
      • Face milling: the cutter is fed back and forth across the workpiece along a curvilinear path to create a flat surface.
    • Types of face milling include:
      • Conventional face milling: the cutter is fed back and forth across the workpiece along a straight path.
      • End milling: the cutter is fed back and forth across the workpiece along a curvilinear path to create a flat surface.
      • Profile milling: the cutter is fed back and forth across the workpiece along a curvilinear path to create a curved surface.
      • Pocket milling: the cutter is fed back and forth across the workpiece along a curvilinear path to create a pocket or depression.

    Drilling Process

    • Drilling is a machining operation used to create a round hole in a workpart.
    • Drilling is performed with a rotating cylindrical tool which has 2 cutting edges on its working end.
    • There are two types of holes:
      • Through-holes: the drill exits the opposite side of the workpiece.
      • Blind-holes: the drill does not exit the opposite side of the workpiece.
    • Operations related to drilling include:
      • Reaming: enlarging a hole to provide a better tolerance on its diameter and improve its surface finish.
      • Tapping: providing internal screw threads on an existing hole.
      • Counterboring: providing a stepped hole, where a larger diameter follows a smaller diameter partially into the hole.
      • Countersinking: providing a cone-shaped hole for flat head screws and bolts.
      • Centering: drilling a starting hole to accurately establish its location for subsequent drilling.

    Cutting Tools and Cutting Fluids

    • Cutting tools must possess certain properties to withstand tool failure, including:
      • Toughness: the capacity of a material to absorb energy without failing.
      • Hot hardness: the ability of a material to retain its hardness at high temperatures.
      • Wear resistance: the ability of a material to resist abrasive wear.
    • Types of cutting tools include:
      • High-speed steel (HSS)
      • Cast Cobalt Alloys
      • Cemented Carbides
    • Cutting fluids are used to improve cutting performance by:
      • Removing heat generated during the machining operation
      • Reducing friction at the tool-chip and tool-work interfaces
      • Washing away chips
      • Reducing cutting forces and power requirements
      • Improving dimensional stability of the workpart
      • Improving surface finish
    • Types of cutting fluids include:
      • Coolants: designed to reduce the effects of heat in the machining operation, usually water-based solutions or water emulsions.
      • Lubricants: usually oil-based fluids formulated to reduce friction at the tool-chip and tool-work interfaces, often used in low-speed operations.

    Material Removal & Machining Processes

    • Material removal & machining processes are used to produce different shapes by cutting away material from a workpiece.
    • The most common application is to shape metal parts, and it is the most versatile of all manufacturing processes in terms of producing a diversity of part geometries and geometric features with high precision and accuracy.

    Turning Process

    • Turning is a machining process where a single point tool removes material from the surface of a rotating cylindrical workpiece.
    • The tool is fed linearly in a direction parallel to the axis of rotation.
    • Turning is performed on a machine tool called a lathe, which provides power to turn the part at a given rotational speed and to feed the tool at a specified rate and depth of cut.
    • There are several types of turning operations, including:
      • Facing: the tool is fed radially inward to create a flat surface on the end of the workpiece.
      • Contour turning: the tool follows a contour that is other than straight, creating a contoured shape.
      • Straight turning: the tool is fed parallel to the axis of rotation, creating a cylindrical surface.
      • Taper turning: the tool is fed at an angle to the axis of rotation, creating a tapered surface.
      • Form turning: the tool is fed to create a curved or irregular shape.
      • Chamfering: the tool is fed radially inward to create a chamfer (a beveled edge) on the workpiece.
      • Cut off / parting: the tool is fed radially inward to cut off the end of the workpiece.
      • Grooving: the tool is fed radially inward to create a groove on the workpiece.
      • Knurling: the tool is fed to create a rough, textured surface on the workpiece.

    Milling Process

    • Milling is a machining operation where a work part is fed past a rotating cylindrical tool with multiple cutting edges.
    • The axis of rotation of the cutting tool is perpendicular to the direction of feed.
    • Milling is an interrupted cutting operation, and the tool material and cutter geometry must be designed to withstand impact forces and thermal shock.
    • There are two forms of milling:
      • Peripheral milling: the rotation direction of the cutter distinguishes two forms of milling, i.e., up milling and down milling.
      • Face milling: the cutter is fed back and forth across the workpiece along a curvilinear path to create a flat surface.
    • Types of face milling include:
      • Conventional face milling: the cutter is fed back and forth across the workpiece along a straight path.
      • End milling: the cutter is fed back and forth across the workpiece along a curvilinear path to create a flat surface.
      • Profile milling: the cutter is fed back and forth across the workpiece along a curvilinear path to create a curved surface.
      • Pocket milling: the cutter is fed back and forth across the workpiece along a curvilinear path to create a pocket or depression.

    Drilling Process

    • Drilling is a machining operation used to create a round hole in a workpart.
    • Drilling is performed with a rotating cylindrical tool which has 2 cutting edges on its working end.
    • There are two types of holes:
      • Through-holes: the drill exits the opposite side of the workpiece.
      • Blind-holes: the drill does not exit the opposite side of the workpiece.
    • Operations related to drilling include:
      • Reaming: enlarging a hole to provide a better tolerance on its diameter and improve its surface finish.
      • Tapping: providing internal screw threads on an existing hole.
      • Counterboring: providing a stepped hole, where a larger diameter follows a smaller diameter partially into the hole.
      • Countersinking: providing a cone-shaped hole for flat head screws and bolts.
      • Centering: drilling a starting hole to accurately establish its location for subsequent drilling.

    Cutting Tools and Cutting Fluids

    • Cutting tools must possess certain properties to withstand tool failure, including:
      • Toughness: the capacity of a material to absorb energy without failing.
      • Hot hardness: the ability of a material to retain its hardness at high temperatures.
      • Wear resistance: the ability of a material to resist abrasive wear.
    • Types of cutting tools include:
      • High-speed steel (HSS)
      • Cast Cobalt Alloys
      • Cemented Carbides
    • Cutting fluids are used to improve cutting performance by:
      • Removing heat generated during the machining operation
      • Reducing friction at the tool-chip and tool-work interfaces
      • Washing away chips
      • Reducing cutting forces and power requirements
      • Improving dimensional stability of the workpart
      • Improving surface finish
    • Types of cutting fluids include:
      • Coolants: designed to reduce the effects of heat in the machining operation, usually water-based solutions or water emulsions.
      • Lubricants: usually oil-based fluids formulated to reduce friction at the tool-chip and tool-work interfaces, often used in low-speed operations.

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    Description

    Introduction to engineering technology, covering material removal and machining processes including turning, milling, and drilling processes.

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