Metal Cutting Mechanisms and Techniques
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Questions and Answers

What characterizes orthogonal cutting?

  • The cutting tool moves parallel to the workpiece material.
  • It requires the use of water to assist in cutting.
  • The cutting edge of the tool is perpendicular to the direction of tool travel. (correct)
  • The cutting tool is at an oblique angle to the workpiece.

    • Which type of cutting tool has a longer cutting life?

  • Waterjet cutting tool
  • Oblique cutting tool (correct)
  • Orthogonal cutting tool
  • Plasma cutting tool

    • What is a primary motion in metal cutting?

  • The axial movement of the workpiece.
  • The feed motion of the cutting tool.
  • The rotation of a workpiece in a lathe. (correct)
  • The rotation of the tool around the workpiece.

    • Which cutting method utilizes highly pressurized water?

    <p>Waterjet cutting</p> Signup and view all the answers

    What is a characteristic feature of oblique cutting?

    <p>The cutting edge makes contact at an angle less than 90 degrees.</p> Signup and view all the answers

    Which of the following statements about maintained cutting tool geometry is true?

    <p>It has a direct impact on surface finish and tool life.</p> Signup and view all the answers

    What is the primary purpose of cutting fluids?

    <p>To reduce heat and friction during the cutting process.</p> Signup and view all the answers

    Plasma cutting is characterized by which of the following?

    <p>Using an electric arc to ionize gas.</p> Signup and view all the answers

    Which type of cutting tool is classified as having a single cutting edge?

    <p>Turning tools</p> Signup and view all the answers

    What is the primary purpose of the rake angle in cutting tools?

    <p>To improve chip flow during machining</p> Signup and view all the answers

    What effect does a positive rake angle have on the cutting process?

    <p>Reduces cutting power requirement</p> Signup and view all the answers

    What is the primary function of the clearance angle in a cutting tool?

    <p>To avoid rubbing of the tool with the machined surface</p> Signup and view all the answers

    Which of the following describes a negative rake angle?

    <p>Increases edge-strength and tool life</p> Signup and view all the answers

    What type of cutting tool includes items such as hobs and gear shaping cutters?

    <p>Multipoint cutting tools</p> Signup and view all the answers

    Which characteristic is NOT associated with rake angles?

    <p>Rake angles primarily determine tool size</p> Signup and view all the answers

    Which statement about clearance angles is accurate?

    <p>A clearance angle is necessary to prevent tool surface rubbing</p> Signup and view all the answers

    What is the Back Clearance Angle (αY)?

    <p>Angle of orientation of tool's principal flank surface from the cutting velocity vector</p> Signup and view all the answers

    In the ASA system, the Nose Radius (r) is represented in which unit?

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

    Which angle cannot be zero or negative in the ASA system?

    <p>Back Clearance Angle</p> Signup and view all the answers

    What does the approach angle (Φs) represent?

    <p>Angle between the principal cutting edge and the machine transverse plane</p> Signup and view all the answers

    Which system measures the Nose Radius in millimeters?

    <p>ORS System</p> Signup and view all the answers

    How many features are specified in the tool nomenclature according to the ASA system?

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

    The Side Rake Angle (γX) can have which of the following values in the ASA system?

    <p>Positive, negative, or zero</p> Signup and view all the answers

    In a tool nomenclature specified as –8º, 6º, 5º, 10º, 15º, 30º, 1/8 (inch), what does the value –8º represent?

    <p>Back Rake Angle</p> Signup and view all the answers

    What is the primary function of the Reference Plane (πR) in the ASA system?

    <p>It is perpendicular to the cutting velocity vector.</p> Signup and view all the answers

    Which of the following angles is measured on the Machine Transverse Plane (πY)?

    <p>Back Rake Angle (γY)</p> Signup and view all the answers

    How many rake angles are specified in the tool signature of the ASA system?

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

    What does the Side Clearance Angle (αX) measure?

    <p>The orientation of the rake surface from the cutting velocity vector.</p> Signup and view all the answers

    What is the sequence followed when writing the tool signature in the ASA system?

    <p>Rake angles, clearance angles, cutting edge angles, nose radius.</p> Signup and view all the answers

    Which planes are used as reference in the ASA system?

    <p>Machine Longitudinal Plane, Machine Transverse Plane, Reference Plane</p> Signup and view all the answers

    What is indicated by the Nose Radius in the ASA tool signature?

    <p>The curvature of the tool's tip.</p> Signup and view all the answers

    What does the term 'Machine Longitudinal Plane (πX)' denote in the ASA system?

    <p>A plane perpendicular to the reference plane in the longitudinal direction.</p> Signup and view all the answers

    What is the primary disadvantage of using mineral oils in machining operations?

    <p>They are corrosive and unsuitable for copper.</p> Signup and view all the answers

    Which property is commonly associated with synthetic liquids?

    <p>They are water-based with good cooling properties.</p> Signup and view all the answers

    What percentage of mineral oil is typically found in semi-synthetic fluids?

    <p>Approximately 5 to 20%</p> Signup and view all the answers

    What is an example of a solid lubricant?

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

    What are cutting oils primarily composed of?

    <p>Mixed minerals oil and fatty oil</p> Signup and view all the answers

    What is the main function of the headstock in a lathe machine?

    <p>To regulate the speed of the workpiece's rotation.</p> Signup and view all the answers

    In what operations are semi-synthetic fluids primarily utilized?

    <p>Grinding operations</p> Signup and view all the answers

    What component connects the headstock and the tailstock in a lathe machine?

    <p>The bed</p> Signup and view all the answers

    Study Notes

    Metal Cutting Mechanism

    • Metal cutting involves using a wedge-shaped tool to remove material from a workpiece in the form of a chip.
    • Two motions are involved: primary (workpiece rotation) and secondary (tool feed).
    • Orthogonal cutting: cutting face perpendicular to tool travel direction.
    • Oblique cutting: cutting edge inclined at an angle less than 90 degrees to tool travel direction.

    Types of Metal Cutting

    • Orthogonal cutting: Cutting tool moves directly into the workpiece at a right angle.
    • Oblique cutting: Cutting tool engages with the workpiece material at an angle other than 90 degrees.
    • Waterjet cutting: Uses high-pressure water for metal particle erosion.
    • Plasma cutting: Uses an electric arc through gas to cut metal.
    • Laser cutting: Uses focused laser beams to melt and vaporize metal.
    • Flame cutting: Uses an oxy-fuel torch to heat and cut metal.
    • Metal turning: Removes material from a rotating workpiece using a single-point cutting tool.

    Tool Geometry

    • Rake angle (γ): Angle of inclination of rake surface from reference plane.
    • Clearance angle (α): Angle of inclination of clearance surface from the finished surface.
    • Rake angle can be positive, negative, or zero.
      • Positive rake: Reduces cutting force and power requirement.
      • Negative rake: Increases edge strength and tool life.
      • Zero rake: Simplifies tool design and manufacture.
    • Clearance angle: Prevents rubbing between the tool and the machined surface, reducing energy loss and damage.

    Tool Signature in ASA System

    • Reference Plane (πR): Perpendicular to the cutting velocity vector.
    • Machine Longitudinal Plane (πX): Perpendicular to the reference plane, along the longitudinal feed direction.
    • Machine Transverse Plane (πY): Perpendicular to the reference plane, along the transverse feed direction.

    Tool Signature in ORS System

    • Similar to ASA system, but uses Cutting plane, Orthogonal plane, and Reference plane for reference.
    • Side Rake Angle (γX): Angle of rake surface measured in the machine longitudinal plane.
    • Back Rake Angle (γY): Angle of rake surface measured in the machine transverse plane.
    • Side Clearance Angle (αX): Angle of principal flank surface measured in the machine longitudinal plane.
    • Back Clearance Angle (αY): Angle of principal flank surface measured in the machine transverse plane.
    • Approach Angle (Φs): Angle between principal cutting edge and the machine transverse plane.
    • End Cutting Edge Angle (Φe): Angle between auxiliary cutting edge and the machine longitudinal plane.
    • Nose Radius (r): Curvature at the tool tip (measured in inches in ASA, millimeters in ORS).

    Cutting Fluids

    • Mineral Oil: Good lubricating properties, suitable for high production machines and heavy cutting operations.
    • Synthetic Liquids: Water-based, good cooling properties but not ideal lubricants, can cause corrosion.
    • Semi-Synthetic Fluids: Combination of synthetic fluid and soluble oils, provides both cooling and lubricating properties.
    • Solid and Paste Lubricants: Applied directly to the workpiece or tool, examples include molybdenum disulfide, graphite, wax stick.
    • Cutting Oil: Mixture of mineral oils and fatty oils, provides both cooling and lubricating properties.

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    Related Documents

    Metal Cutting Theory Notes PDF

    Description

    This quiz explores various metal cutting mechanisms, focusing on both orthogonal and oblique cutting methods. It also covers advanced techniques such as waterjet, plasma, laser, and flame cutting, alongside traditional metal turning. Test your knowledge on the principles and processes involved in effective metal cutting.

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