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Questions and Answers
What is the special form of lubrication involved in lubricant cutting fluids?
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?
At what cutting speeds are lubricant-type cutting fluids most effective?
There are __ types of removal & machining processes.
There are __ types of removal & machining processes.
3
Match the machining processes with their descriptions:
Match the machining processes with their descriptions:
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What is the primary purpose of the turning process?
What is the primary purpose of the turning process?
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Facing is a type of turning operation where the tool follows a contour other than straight.
Facing is a type of turning operation where the tool follows a contour other than straight.
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What is the name of the machining process in which a work part is fed past a rotating cylindrical tool with multiple cutting edges?
What is the name of the machining process in which a work part is fed past a rotating cylindrical tool with multiple cutting edges?
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_______ is the ability of a material to retain its hardness at high temperatures.
_______ is the ability of a material to retain its hardness at high temperatures.
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Match the cutting tool material with its type:
Match the cutting tool material with its type:
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What is the primary objective of the machining process?
What is the primary objective of the machining process?
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What is the tool used in turning process called?
What is the tool used in turning process called?
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In _____, the tool follows a contour that is not straight, creating a contoured shape.
In _____, the tool follows a contour that is not straight, creating a contoured shape.
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Match the type of turning operation with its description:
Match the type of turning operation with its description:
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Coolant-type cutting fluids are most effective at low cutting speeds.
Coolant-type cutting fluids are most effective at low cutting speeds.
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What is the special form of lubrication involved in lubricant cutting fluids?
What is the special form of lubrication involved in lubricant cutting fluids?
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At what cutting speeds are lubricant-type cutting fluids most effective?
At what cutting speeds are lubricant-type cutting fluids most effective?
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Above what speed do lubricant-type cutting fluids tend to lose their effectiveness?
Above what speed do lubricant-type cutting fluids tend to lose their effectiveness?
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During the machining processes, ______ and lubricant are needed for better cutting quality and protection of cutting tools. Thank You.
During the machining processes, ______ and lubricant are needed for better cutting quality and protection of cutting tools. Thank You.
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Match the machining processes with the tools/bits required:
Match the machining processes with the tools/bits required:
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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.