Production Engineering Lecture 6

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Questions and Answers

What is chip forming cutting primarily concerned with?

Joining two materials together

Increasing the size of the workpiece

Adding material to create new shapes

Separation or reduction of material by removal of chips (correct)

What does machining achieve in terms of tolerances?

Tolerances lower than ±0.005"

Tolerances greater than ±0.01"

Tolerances of exactly ±0.001"

Tolerances at least ±0.005" (correct)

What is a major advantage of using machining centers?

They use more manual labor compared to traditional methods

They require multiple tools to be transported to the workpiece

They can only perform one type of operation at a time

They reduce the extensive set-up and repositioning time (correct)

What does a turning center primarily do?

Turn cylindrical solid and hollow shapes Signup and view all the answers

What is a characteristic of modern automated turning centers?

They can have dual turrets with twin turret changers Signup and view all the answers

What is a lathe primarily used for?

Turning cylindrical shapes and threads Signup and view all the answers

How are cutting tools arranged in modern turning centers?

In turret heads with up to eight cutting tools each Signup and view all the answers

What is a key benefit of properly managing speed, feed, and rate of cutting in machining?

It improves the economic and tool-life considerations Signup and view all the answers

What is the primary function of a vertical mill?

To provide flexibility in axis of cutting and workpiece movement Signup and view all the answers

Which type of drill bit is specifically designed to cut through concrete?

Concrete Drill Bits Signup and view all the answers

How precise are the adjustments on a vertical mill's cutting table?

±0.005 inch Signup and view all the answers

What distinguishes a horizontal mill from a vertical mill?

A horizontal mill is specifically designed for extended horizontal milling Signup and view all the answers

In which application are traditional mills still commonly used?

Design and repair of tooling Signup and view all the answers

Which of the following statements about sawing is accurate?

Industrial saws can accurately cut to ±0.005 inch Signup and view all the answers

What is the unique feature of tile and glass drill bits?

They are designed for low speed drilling Signup and view all the answers

Which type of saw is not categorized under reciprocating or circular sawing?

Table saw Signup and view all the answers

Signup and view all the answers

Study Notes

Course Title & Instructor

Course title: Production Engineering
Instructor: M. Mohamed Ryead
Lecture: 6
Level: 1

Chip Forming Cutting

Chip forming cutting is the separation or reduction of a material by removing chips.
The cutting tool is harder than the workpiece.
Machining is a specific type of chip forming cutting.

Machining

Machining is a process where cutting achieves tolerances of at least ±0.005".
The workpiece and cutting tool are held in precise relationship.
Speed, feed, and rate of cutting, along with proper coolants and lubricants are crucial for economical and tool-life considerations.
Machining is often a secondary process following forming, but it precedes finishing and joining processes.

Machining and Turning Centers

Machining centers bring multiple cutters to the workpiece instead of moving the workpiece itself.
This significantly reduces setup repositioning time and related potential errors.
Modern machining centers are computer-controlled and fully automated, enabling tool changing and diverse cutting operations on multiple surfaces.
Turning centers are computer-controlled lathes that can have dual turrets with twin turret changers.

Lathe/Turning

A lathe is used for turning cylindrical solid and hollow shapes, threads, and similar forms.
The workpiece is held in a chuck and rotates while the cutter, parts of the tool assembly, is controlled by an operator.
Modern turning centers are automated with up to eight cutting tools.

Milling (Bridgeport)

Milling is a metal cutting operation where excess material is removed by a rotating multipoint cutting tool (milling cutter).
Milling machines use a power-operated tool where the workpiece is mounted on a moving table under a rotating serrated cutter to shape it.

Vertical Mill

Vertical mills resemble drills, but offer more flexibility in cutting and workpiece movement.
The head tilts and the cutting table is precisely adjustable.

Horizontal Mill

Horizontal mills resemble vertical mills, but are intended for extended horizontal milling operations.
These mills are still useful for tool design and repair, and smaller model shops.

Grinding

Grinding is a surface finishing operation.
It removes very thin layers of material, producing fine dust particles (0.25-0.5mm thick).
Grinding is the abrasive action between the rotating abrasive wheel and the workpiece.
Grinding machines use powerful, consistently rotating abrasive wheels against the moving workpiece.

Drilling

Drilling is a common machining process utilizing twist drill bits to create holes in the workpiece.
The process is mainly linear-axis centered.

Drill Bits (Types)

Wood drill bits are suitable for soft, hardwood, veneer, and plywood.
Metal drill bits are used for metal, and can also be used for wood.
Concrete drill bits are designed with thicker carbide tips to withstand concrete's high resistance.

Tile and Glass Drill Bits

Tile and glass drill bits are shaped like spears.
Material type and size are factors for using these bits.
Slow drilling speeds are necessary.

Sawing

Sawing is often for cutting stock to length for other cutting operations.
Most industrial machines can saw to extremely precise tolerances (±0.005 inch).
Basic types include reciprocating and circular (continuous band, disc blade).

Boring

Boring machines finish-cut internal cylindrical profiles.
The process uses a cutter mounted on a bar.
Originally designed for cannon barrel finishing.

Boring Machines (Details)

Some boring bars have vibration-dampening capabilities.
"Bore" refers to the internal diameter shaping process.

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Description

Dive into Lecture 6 of Production Engineering as we explore chip forming cutting, machining processes, and the significance of machining centers. Understand the critical parameters that influence tool life and machining efficiency. This quiz will test your knowledge of key concepts and techniques in this essential field.