Oblique vs Orthogonal Cutting in Machining Operations
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Questions and Answers

What does the chip-compression ratio measure?

  • Chip thickness compared to depth of cut (correct)
  • Depth of cut compared to cutting speed
  • Chip thickness compared to cutting speed
  • Shear strain of the material

    • How does the velocity of the chip (Vc) relate to the cutting speed (V)?

  • Vc is always higher than V
  • Vc is always lower than V (correct)
  • Vc is independent of V
  • Vc is always equal to V

    • Which type of chips are generally formed with ductile materials and high cutting speeds?

  • Serrated or segmented chips
  • Discontinuous chips
  • Built-up edge chips
  • Continuous chips (correct)

    • What is the depth of cut also referred to as?

    <p>Undeformed chip thickness</p> Signup and view all the answers

    How many main types of metal chips are commonly observed in practice?

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

    What is the primary goal of a machining process?

    <p>To remove excess material from a workpiece</p> Signup and view all the answers

    Which process involves a rotating cutting tool removing a layer of material from the workpiece?

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

    In which machining operation does the cutting tool move radially inward to separate a piece from the blank?

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

    Which type of machining operation produces a cavity by traveling to a certain depth in the workpiece?

    <p>End milling</p> Signup and view all the answers

    What are the two main types of machining operations mentioned in the text?

    <p>Conventional and non-conventional</p> Signup and view all the answers

    Which type of machining operation is used to remove a layer of material from the surface of the workpiece?

    <p>Slab milling</p> Signup and view all the answers

    Which element combines with oxygen to form aluminum oxide and silicates, causing tool wear and reduced machinability?

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

    What material can be used as substitutes for lead but are not as effective?

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

    What does the presence of gaseous elements like hydrogen and nitrogen do to steel properties?

    <p>Reduce machinability</p> Signup and view all the answers

    Which element can cause the formation of a built-up edge in low-carbon steels?

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

    At what hardness level can alloy steels be machined with polycrystalline cubic boron-nitride cutting tools?

    <p>45-65 HRC</p> Signup and view all the answers

    What effect does elevated temperatures have on steels?

    <p>Cause embrittlement</p> Signup and view all the answers

    What are the four factors that define the machinability of a material?

    <p>Surface finish, tool life, force requirements, chip control</p> Signup and view all the answers

    What is the key role of chip control in machining operations?

    <p>Preventing interference with the cutting area</p> Signup and view all the answers

    How does cold working impact the machinability of steels?

    <p>It improves machinability by hardening the material</p> Signup and view all the answers

    What role does sulfur play in free-machining steels?

    <p>Forms manganese-sulfide inclusions for stress reduction</p> Signup and view all the answers

    How does lead contribute to the machinability of steels?

    <p>Acts as a solid lubricant during machining</p> Signup and view all the answers

    Why is there a trend towards eliminating lead use in steels?

    <p>Due to environmental concerns</p> Signup and view all the answers

    What is the main difference between oblique cutting and orthogonal cutting?

    <p>The chip in orthogonal cutting becomes a spiral, while in oblique cutting it becomes helical.</p> Signup and view all the answers

    What defines the angle at which the chip leaves the workpiece surface in oblique cutting?

    <p>Inclination angle</p> Signup and view all the answers

    How is the effective rake angle calculated in oblique cutting?

    <p>In the plane of workpiece material approaching and chip leaving velocities</p> Signup and view all the answers

    What is assumed to be equal in order to calculate the effective rake angle?

    <p>Chip flow angle and inclination angle</p> Signup and view all the answers

    Which type of chip is produced with tools at increasing inclination angles in oblique cutting?

    <p>Continuous chips</p> Signup and view all the answers

    How does the chip leave the workpiece surface in orthogonal cutting?

    <p>Spiral shape</p> Signup and view all the answers

    Study Notes

    Chip Formation and Machinability

    • The chip-compression ratio measures the ratio of the thickness of the chip to the depth of cut.
    • The velocity of the chip (Vc) is proportional to the cutting speed (V).
    • Ductile materials and high cutting speeds typically form continuous and spiral chips.
    • The depth of cut is also referred to as the undeformed chip thickness.
    • There are two main types of metal chips commonly observed in practice: continuous and discontinuous chips.

    Machining Operations

    • The primary goal of a machining process is to produce a desired shape or surface finish.
    • Turning involves a rotating cutting tool removing a layer of material from the workpiece.
    • Parting involves the cutting tool moving radially inward to separate a piece from the blank.
    • Drilling produces a cavity by traveling to a certain depth in the workpiece.
    • There are two main types of machining operations: turning and drilling.

    Material Properties and Machinability

    • The presence of gaseous elements like hydrogen and nitrogen affects steel properties.
    • Aluminum combines with oxygen to form aluminum oxide and silicates, causing tool wear and reduced machinability.
    • Copper, silver, and tin can be used as substitutes for lead but are not as effective.
    • Sulfur plays a key role in free-machining steels.
    • Lead contributes to the machinability of steels, but there is a trend towards eliminating its use due to toxicity concerns.
    • The four factors that define the machinability of a material are: tool life, surface finish, cutting forces, and chip form.
    • The key role of chip control in machining operations is to ensure continuous and efficient cutting.

    Cutting and Chip Formation

    • Oblique cutting is characterized by a non-perpendicular angle between the cutting tool and workpiece surface.
    • The angle at which the chip leaves the workpiece surface in oblique cutting is defined by the inclination angle.
    • The effective rake angle in oblique cutting is calculated using the inclination angle and the normal rake angle.
    • To calculate the effective rake angle, the normal rake angle and inclination angle are assumed to be equal.
    • As the inclination angle increases in oblique cutting, a segmented chip is produced.
    • In orthogonal cutting, the chip leaves the workpiece surface perpendicular to the cutting edge.

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    Description

    Learn about the differences between oblique and orthogonal cutting processes in machining operations. Understand the characteristics of chips produced during turning and how they affect the workpiece and tool. Figure out how tool shapes influence the cutting action in machining.

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