Metal Cutting Times Overview
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Questions and Answers

What process involves heating hypoeutectoid steels 30° above the upper critical temperature, soaking, and then cooling slowly to form a pearlite and ferrite structure?

  • Annealing (correct)
  • Hardening
  • Tempering
  • Normalising

    • In a eutectic system, how are two elements characterized in their solubility?

  • Soluble only in the solid state
  • Insoluble in the liquid state
  • Insoluble in both solid and liquid states
  • Soluble only in the liquid state (correct)

    • What is the name of the steel that contains 0.8% carbon?

  • Hyper-eutectoid steel
  • None of these
  • Eutectoid steel (correct)
  • Hypo-eutectoid steel

    • What composition does cementite contain?

    <p>6.67% carbon and 93.33% iron</p> Signup and view all the answers

    What is the primary phase formed when austenite decomposes during the austempering heat treatment process?

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

    What is the return time to cutting time ratio for the shaper operation described?

    <p>1:4</p> Signup and view all the answers

    How long will it take to machine a shaft turned from 70 mm to 64 mm over a length of 200 mm?

    <p>0.85 min</p> Signup and view all the answers

    What is the machining time for facing a workpiece of 165 mm diameter in one pass?

    <p>0.61 min</p> Signup and view all the answers

    What is the cutting speed when drilling a hole of diameter 20 mm to a depth of 80 mm?

    <p>22.3 m/min</p> Signup and view all the answers

    What is the total machining time for face milling a plain surface 70 mm wide and 600 mm long?

    <p>1.54 min</p> Signup and view all the answers

    What is the machining time for a surface 100 mm wide and 320 mm long to be face milled?

    <p>0.68 min</p> Signup and view all the answers

    How long is the machining time for peripheral milling of a 75 mm wide surface?

    <p>1.98 min</p> Signup and view all the answers

    What is the effect of decreasing grain size in a polycrystalline material?

    <p>Increases yield strength and corrosion resistance</p> Signup and view all the answers

    What is the primary reason for the higher endurance limit in carburised machine components?

    <p>Introduces a compressive layer on the surface</p> Signup and view all the answers

    Which property is most closely associated with wire drawing?

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

    Which mechanical property is measured by indentation?

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

    Which steel type is most suitable for making crane hooks?

    <p>Medium carbon steel</p> Signup and view all the answers

    What type of steel is most commonly associated with making blanking dies?

    <p>Tool steel</p> Signup and view all the answers

    What mechanical property is associated with the ability to store energy when deformed?

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

    Which steel type would likely be unsuitable for delicate tools like screwdrivers?

    <p>High carbon steel</p> Signup and view all the answers

    Isotropy in materials refers to:

    <p>Uniform properties in all directions</p> Signup and view all the answers

    Which of the following statements about the annealing of steels is incorrect?

    <p>Steels are heated to temperatures above 700°C</p> Signup and view all the answers

    What is the composition of duralumin alloy in terms of aluminium and copper?

    <p>94% Al and 4% Cu</p> Signup and view all the answers

    At what temperature does the eutectic reaction for the iron-carbon system occur?

    <p>723°C</p> Signup and view all the answers

    Which material is commonly used for making the blade of a power saw?

    <p>High speed steel</p> Signup and view all the answers

    Which statement correctly identifies quartz's electrical property?

    <p>It is a piezoelectric material</p> Signup and view all the answers

    Which of the following techniques is used for obtaining ductile iron?

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

    Which technique is used for the production of white cast iron?

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

    Ductility is increased during the annealing process, primarily due to which of the following reasons?

    <p>Relief of internal stresses</p> Signup and view all the answers

    What is the main characteristic of high speed steel used for cutting tools?

    <p>Ability to withstand high temperatures</p> Signup and view all the answers

    Which of the following best describes the composition of steel during the cooling phase of the annealing process?

    <p>Steel cools slowly to maintain toughness</p> Signup and view all the answers

    Which of the following pairs are correctly matched?

    <p>Piston......Cast iron</p> Signup and view all the answers

    What is the purpose of Babbit lining in brass/bronze bearings?

    <p>To increase wear resistance</p> Signup and view all the answers

    What property does the presence of small quantities of sulphur improve in low carbon steels?

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

    Match the heat treatment method with its effect on properties.

    <p>Normalising......Improves ductility</p> Signup and view all the answers

    Which of the following statements about the addition of Silicon to cast iron is true?

    <p>It promotes graphite nodule formation.</p> Signup and view all the answers

    Which heat treatment process increases hardness without affecting ductility too much?

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

    What is a likely outcome of performing annealing on steel?

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

    Which material is typically not used for piston construction?

    <p>Carbon fiber</p> Signup and view all the answers

    Which treatment would be best for enhancing surface hardness?

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

    What effect does martempering primarily have on steel?

    <p>Increases hardness significantly</p> Signup and view all the answers

    Which alloy is primarily used for thermocouple wire?

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

    For which application is Silicon Carbide typically not used?

    <p>Pipes for conveying liquid metals</p> Signup and view all the answers

    What is the correct pairing of Tungsten Carbide in its application?

    <p>Abrasive wheels</p> Signup and view all the answers

    Which of these materials is most suitable for making gas turbine blades?

    <p>Nimonic alloy</p> Signup and view all the answers

    What is the expected characteristic of Babbit alloy in applications?

    <p>Self-lubrication</p> Signup and view all the answers

    What is the formula for calculating the tool approach in face milling?

    <p>x = 0.5D - D^2 - B^2</p> Signup and view all the answers

    Which of the following is used to calculate the cross-sectional area of an uncut chip per tooth for a keyway broach?

    <p>Ac = fz * b</p> Signup and view all the answers

    What does MRR/pass represent in the context of machining?

    <p>Material Removal Rate per operation</p> Signup and view all the answers

    In cylindrical grinding, which of the following operations is NOT considered?

    <p>Face grinding</p> Signup and view all the answers

    What factor is used to calculate the machining time per piece when considering the stroke lengths and velocities in broaching?

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

    How is the machining time, T, expressed in relation to stroke lengths and cutting velocities?

    <p>T = (L + lb) / 1000 V</p> Signup and view all the answers

    In the context of broaching, what is the unit for the cross-sectional area of an uncut chip per tooth?

    <p>mm²</p> Signup and view all the answers

    What is the value of the Material Removal Rate (MRR) calculated for the given parameters in the slab milling operation?

    <p>79.56 × 10^3 mm³/min</p> Signup and view all the answers

    How many passes are required to complete the machining operation given a stock removal depth of 6 mm and a depth of cut of 4 mm?

    <p>2</p> Signup and view all the answers

    What is the determined total cutting time for the given slab milling operation?

    <p>8.05 min</p> Signup and view all the answers

    What cutting speed is associated with the given milling cutter parameters?

    <p>157 m/min</p> Signup and view all the answers

    What is the rise per tooth parameter specified for the broaching operation?

    <p>0.10 mm</p> Signup and view all the answers

    What is the formula used to determine the machining time (Tm) for the slab milling operation?

    <p>Tm = (l+x+y)/(F)</p> Signup and view all the answers

    In the given slab milling parameters, what is the diameter of the milling cutter?

    <p>100 mm</p> Signup and view all the answers

    What was the cutter speed in revolutions per minute (RPM) specified in the slab milling operation?

    <p>500 rpm</p> Signup and view all the answers

    What is the width of the workpiece in the milling operation specified?

    <p>80 mm</p> Signup and view all the answers

    What is the spindle speed (rpm) for a part with a diameter of 25 cm and a cutting speed of 135 mpm?

    <p>172 rev/min</p> Signup and view all the answers

    What length of workpiece is stated in the example for the slab milling operation?

    <p>50 cm</p> Signup and view all the answers

    What is the metal removal rate (MRR) for the machining process described with a feed of 1 mm per rev, depth of cut of 5 mm, and cutting speed of 135 mpm?

    <p>67.5 x 10^4 mm³/min</p> Signup and view all the answers

    How long does it take to drill a hole of 25 mm diameter to a depth of 62.5 mm with a feed of 1.25 mm/rev?

    <p>0.0707 min</p> Signup and view all the answers

    What is the feed speed for drilling a hole with a feed of 1.25 mm/rev and a spindle speed of 764 rev/min?

    <p>955 mm/min</p> Signup and view all the answers

    What is the total length of the workpiece when the machining considers the clearance height of 5 mm?

    <p>67.5 mm</p> Signup and view all the answers

    What is the ratio of time taken in the return stroke to the cutting stroke for the shaper operation described?

    <p>0.5</p> Signup and view all the answers

    What is the maximum allowable depth of cut for the turning operation described?

    <p>5.0 mm</p> Signup and view all the answers

    What is the calculated total cutting time for the described drilling operation?

    <p>0.0707 min</p> Signup and view all the answers

    Which parameter affects the spindle rpm for a drilling machine when using a certain diameter and cutting speed?

    <p>Cutting speed</p> Signup and view all the answers

    What is the value of the machining time (Tm) obtained when face-milling a surface with a length of 320 mm, given a feed per tooth of 0.25 mm, a cutter diameter of 160 mm, and a spindle speed of 125 rev/min?

    <p>0.68 min</p> Signup and view all the answers

    How much is the feed per minute (F) when a cutter with 16 teeth operates at a spindle speed of 125 rev/min with a feed per tooth of 0.25 mm?

    <p>500 mm/min</p> Signup and view all the answers

    What is the added table travel (x) in mm for a cutter diameter of 160 mm and a table width of 100 mm?

    <p>17.5 mm</p> Signup and view all the answers

    If the machining allowance for a slab with a cutting speed of 18.8 m/min is 10 mm, how does this impact the overall machining time?

    <p>It increases machining time slightly</p> Signup and view all the answers

    What is the effective cutting speed (V) in m/min for a planing operation with a length of job and table overtravel totaling 4325 mm?

    <p>18.8 m/min</p> Signup and view all the answers

    What is the total length of travel during the face milling operation, considering a length of 320 mm, added table travel of 17.5 mm, and over travel of 3 mm?

    <p>340.5 mm</p> Signup and view all the answers

    To determine the total machining time (Tm) for a given operation, which factors are taken into account?

    <p>Length of job, added table travel, and feed per tooth</p> Signup and view all the answers

    What is the approach angle taken into consideration when calculating machining time for a planing operation?

    <p>45 degrees</p> Signup and view all the answers

    What formula represents the cutting speed V based on the length of table stroke and machining parameters?

    <p>$V = \frac{LN(1 + K)}{1000}$</p> Signup and view all the answers

    What is the return speed (given as 75 m/min) indicative of in a machining operation involving a planer?

    <p>Speed at which the tool moves back to the starting position</p> Signup and view all the answers

    Study Notes

    Metal Cutting Times

    • Factors that influence cutting time include return time to cutting time ratio, cutting speed, feed per tooth, length of job.
    • Drilling, specific formulas and equations are provided for machining time calculation, drill diameter, rotational speed, metal removal rate (MRR).
    • Milling, equations related to machining time, cutting edge engagement (width of job), depth of cut, feed per tooth, number of teeth in the cutter, metal removal rate (MRR).
    • Broaching, cross sectional area(Ac), cut per tooth (f), width of broach (b), number of splines (n), metal removal rate per pass, number of teeth simultaneously in operation (z).
    • Grinding operations like cylindrical grinding, traverse grinding, and plunge-cut grinding. Equations for machining time, depth of cut (d), work diameter - final diameter (Dw - Df), cross feed/rev (F), feed per stroke (f), peripheral speed (Vw), cutting speed of wheel (Vw), metal removal rate (MRR).
    • Metal Removal Rate (MRR): Key factor in all processes, formulas are provided for calculating in different operations (drilling, milling, broaching, grinding).
    • Machining time calculation: Formulas and equations for all processes are given, Variables such as length of job, feed rate, cutting speed, etc. are used.

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    Description

    This quiz examines various factors affecting metal cutting times, including machining time calculations for drilling, milling, broaching, and grinding operations. It covers key formulas, parameters, and specific equations related to cutting speeds, feeds, and machining processes. Perfect for students and professionals in manufacturing and engineering fields.

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