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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?
There are __ types of removal & machining processes.
3
Match the machining processes with their descriptions:
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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.
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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?
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_______ 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:
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What is the primary objective of the machining process?
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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.
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Match the type of turning operation with its description:
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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?
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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?
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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:
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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.
