81 Questions
What is the purpose of machining as explained in the text?
To remove excess material and achieve desired dimensions and surface finish
Which classification of metal working processes involves turning, drilling, and milling?
Cutting shaping or metal cutting process
How are engineering components like gears and bearings typically finished for accuracy and good surface finish?
By machining and grinding
What is the key function of cutting tools in the machining process?
To gradually remove excess material from the workpiece
Why do preformed parts called blanks need semi-finishing and finishing according to the text?
To provide dimensional accuracy and good surface finish
What distinguishes metal cutting or chip forming processes like turning from non-cutting shaping processes like forging?
The formation of chips during metal cutting processes
What type of cutting tools involve more than two major cutting edges?
Multipoint tools
What is the main purpose of providing a positive rake angle in cutting tools?
Simplify design and manufacture
In metal cutting operations, what does the clearance angle help to avoid?
Rubbing of the tool with the machined surface
Which system of tool description involves providing quantitative information about the angles?
Machine Reference System
What does the term 'ORS' stand for in tool geometry?
Orthogonal Rake System
Which type of cutting tool has a positive clearance angle between 30 and 150 degrees?
Turning tools
What role does the rake angle play in metal cutting?
Help with chip flow
'ASA' system in tool geometry stands for which of the following?
American Standards Association
'WRS' is associated with which system of describing tool geometry?
"Work" Reference System
'NRS' is a part of which system of tool description?
"Normal" Rake System
What is the main function of a machine tool in machining?
Firmly hold the blank and the cutting tool
How are machine tools broadly classified based on size?
Based on duty (heavy, medium, small, micro)
What is the purpose of a cutting fluid in machining?
To ease machining by cooling and lubrication
Which type of machine tool is used for mass production?
Special purpose machine tool
What is the classification of machine tools according to automation levels?
Based on degree of automation (non-automatic, semi-automatic, automatic)
Which type of machine tool is typically used for heavy-duty tasks like boring mills?
Heavy duty machine tool
What are the basic functions of a machine tool in machining?
Firmly hold the blank and the tool, transmit motions, provide power, control parameters
'Ordinary' and 'high precision' are classifications under which category related to machine tools?
'According to precision'
'Single spindle' and 'multi spindle' are classifications under which category related to machine tools?
'According to number of spindles'
Which type of automation is associated with CNC milling machines?
'Flexible automation'
What is meant by chip flow deviation angle in machining?
The angle between the chip flow and the orthogonal plane
In pure orthogonal cutting, what are the values of the angles a and f?
a = 0°, f = 90°
What is the main index of machining that is indicated directly or indirectly by the form of machined chips?
Specific energy requirement
What mainly determines the form of machined chips?
Work material
In machining ductile materials, what happens when shear stress exceeds the shear strength of the work material in the deformation region?
Shear deformation occurs
What is responsible for causing shear stresses in the region of the chip during machining ductile materials?
Both normal force and frictional force
How does slip or shear propagation stop during chip formation in machining ductile materials?
Forces causing shear stresses diminish and disappear
What does the Piispannen model of card analogy aim to explain in machining ductile materials?
Chip formation by shear in lamella
What characteristic of chips helps understand nature and behavior of work material under machining conditions?
Chip form
What mainly determines the nature and degree of interactions at the chip-tool interfaces?
Work material properties
What is the surface against which the chip slides upward on a single point tool?
Face
In the ASA system, what is the angle of inclination of the principal flank from the machined surface and measured on the machine's longitudinal plane (X plane)?
Side clearance angle
Which angle provides strengthening of the tool nose and better surface finish?
Nose radius
In metal cutting processes, what is characteristic of orthogonal cutting?
Tool face is at 90 degrees to the line of action or cutting velocity vector
What is the role of an inclination angle in the direction of chip flow according to Fig. 1.8?
Chip flows along orthogonal plane when inclination angle is 0 degrees
Which plane in metal cutting contains the principal cutting edge?
Reference plane (R)
What does the auxiliary flank in a single point cutting tool refer to?
"The additional flank surface besides the principal flank"
"Face" on a single point tool is defined as:
"The surface against which the chip slides upward"
"Base" of a single point tool refers to:
"The underside of the shank"
In ASA system, what is ax related to?
Side clearance angle (Side relief angle)
What material property favors the formation of discontinuous chips?
Brittle
What are the two basic mechanisms involved in chip formation during machining?
Yielding and brittle fracture
How is the final deformation primarily accomplished in machining ductile materials?
Shear
Which type of chip formation process consumes lesser power and results in metal being fractured into segments?
Segmental chips
What factor contributes to the formation of continuous chips without Built-Up Edge (BUE) chips?
Positive rake angle
What is the major reason that chip thickness (a2) becomes larger than the uncut chip thickness (a1) in machining?
Lamellar sliding effect
Which method is NOT suggested as a feasible experimental method to study the deformation of machining chips?
Exposing chips to extreme heat
In metal cutting, what role does cutting fluid play in chip formation?
Cooling and lubrication
What condition is favorable for producing continuous chips during metal cutting?
High cutting velocity and low feed rate
Why does yielding occur at the crack-tip for ductile materials during machining?
To reduce the effect of stress concentration
What causes total separation of chips from the parent workpiece in machining brittle materials?
Crack propagation
Which type of chip formation is associated with shearing the metal and requires a positive and large rake angle?
Continuous chips
What geometrical parameter represents the depth of cut during machining?
$t$
In machining, what happens to the width of the chip after the cut compared to before the cut?
It increases
'Chip reduction coefficient' or 'cutting ratio' is quantitatively assessed to understand which aspect of machining?
$Forces$ and $energy$ required
What is the primary factor that determines the pattern and extent of total deformation in machining chips?
Work material properties
What does a larger value of chip reduction coefficient, rc, indicate?
More effort in terms of forces or energy required
How is chip thickening often expressed in relation to the reciprocal of rc?
By the ratio of total length of the chip before and after cut
What plays a significant role in reducing the value of rc according to equation 1.4?
Increasing friction by using lubricant
What is the shear angle dependent on?
Chip thickness after cut and before cut
What does a decrease in shear angle indicate about machining conditions?
More favorable conditions requiring less specific energy
How can cutting strain be defined in machining processes?
The deformation that occurs along the shear plane
In equation 1.3, what does 'r' represent?
Cutting ratio
According to equation 1.8, how does Vf compare to VC?
$V_f$ is less than $VC$
'Shear angle increases both directly and indirectly with what factor?'
$f$ (principal cutting edge angle)
What is the main cause of Built-up-Edge (BUE) formation in machining ductile metals?
Strong bonding due to adhesion between chip-tool materials
How does the force, F, relate to the Built-up-Edge (BUE) formation?
Causes the BUE to break or shear off when it exceeds the bonding force
What factor influences the shape, size, and bond strength of Built-up-Edges (BUE) formed during machining?
Cutting fluid application
What harmful effect does the formation of Built-up-Edges (BUE) have on cutting forces and power consumption?
Leads to fluctuations in cutting forces
In the context of machining, what does excessive cutting temperature due to high cutting velocity favor?
Accelerated BUE formation
Why does the workpiece experience plastic deformation during machining to produce continuous chips?
To separate the metal along a ribbon-like path
What role do cutting fluid type and application method play in determining chip types in machining?
Affecting chip color and size
Under what condition do chips overflow towards the finished surface through the flank in machining soft and ductile metals?
'Uncoated carbide' tools are employed
Why does excessively high cutting velocity lead to squashing out of Built-up-Edges (BUE) before they grow?
Exceeds the bonding force of the BUE causing it to break off
What characteristic of chips gets deteriorated due to the presence of Built-up-Edges (BUE) during machining?
Surface finish quality
This quiz covers the theory and processes involved in metal cutting, including non-cutting shaping and cutting shaping methods. Topics include definitions of machining, turning, drilling, milling, forging, rolling, and pressing.
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