Q4/ Answer only 6 (six) of the following1) Some of Cutting tools are coated with (carbides, nitrides, oxides or a combination of them in a form of multiphasecoatings), give 5 purposes of these coatings.2)Give 3 advantages of filtration systems.3)Give 3 limitations of machining.4)Can a thick saw blade be used as a broach. Why.5)Why is it difficult to make heavy cuts if a form turning tool is complex in shape.6) Why are most broaches made from alloy or high-speed steel rather than from tungsten carbide.7)In water jet cutting, alcohol, oil products & glycerol are added and dissolved in water. why.

These questions are based on the concept of manufacturing processes.

Q4/ Answer only 6 (six) of the following 1) Some of Cutting tools are coated with (carbides, nitrides, oxides or a combination of them in a form of multiphase coatings), give 5 purposes of these coatings. 2) Give 3 advantages of filtration systems. Give 3 limitations of machining. 3) 41

Q4/ Answer only 6 (six) of the following 1) Some of Cutting tools are coated with (carbides, nitrides, oxides or a combination of them in a form of multiphase coatings), give 5 purposes of these coatings. 2) Give 3 advantages of filtration systems. Give 3 limitations of machining. 3) 41

Elements Of Electromagnetics

7th Edition

ISBN:9780190698614

Author:Sadiku, Matthew N. O.

Publisher:Sadiku, Matthew N. O.

ChapterMA: Math Assessment

Section: Chapter Questions

Problem 1.1MA

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Problem 2. Turning Consider Step 2 (Turn Shoulder) in machining the flashlight handle (Figure 2). STEP 1: CUT TO LENGTH STEP 2: TURN SHOULDER 0.600 1.0" 3.000 -0.440 Figure 2. Turning step for Problem 2. i) Calculate the (1) cutting time (in s), (2) the material removal rate (in in3 /s or mm3/s) for this cut, assuming you remove all of the material with one pass (i.e., depth of cut d = (1"-0.6")/2 = 0.2"), and (3) the power (hp or W) required for this turning operation: Consider the following scenarios: Feed (f) in/rev Rotational Speed Cutting Time MRR Power (n) in RPM 0.02 1000 ? ? ? 0.025 900 ? ? ? 0.03 800 ? ? ? 1 j) What changes could you make to the process if you needed to decrease the power requirement?
QUESTION 5 a) What are the four common materials used as abrasives in the grinding process? List them in their order of relative hardness-i.e. from hard, harder to hardest to extremely hard? (CO3, PO2, C4) b) Describe the advantages of the Computer Numerical Controlled (CNC) milling machine as compared to the conventional or manually operated one? (CO3, PO2, C4) c) What are the advantages and disadvantages of welding compared to other types of assembly operations? (CO3, PO2, C4)
QL Match list (1) with list (IT) and select the correct answer? Ja] Type of chip 1 Continuous chip. 2 Serrated chips. List I List II Type of material being machined and the cutting conditions. A cast irons are machined at low cutting speeds B ductile materials at low-to-medium cutting speeds Ctitanium alloys machined at higher cutting speeds ductile work materials are cut at high speeds and relatively small feeds and depths 3 Discontinuous chip. Continuous chip with 4 built-up edges. D Types of Welds Geometry No. Flange weld A. 2 fillet weld 3 Surfacing weld 4 Plug weld D Slot weld 6 groove weld lel Process Grain flow of the part 1 Forging 2 Machining в 3 Casting
1. Most common instrument used in the mechanical gages is the dial indicator, which of the following applications cannot be measured by the dial indicator? (a) All of them (b) Perpendicularity (c) Runout (d) Circularity (e) Roughness 2. The main mechanism for the flank wear on the single point cutting tool is: (a) Oxidation wear (b) Adhesion wear (c) None of them (d) Diffusion wear (e) Plastic deformation 3. Higher cutting speeds and temperatures are the main mechanism of the following tool wear mechanism: (a) Diffusion wear (b) Abrasion wear (c) None of them (d) Adhesion wear (e) Plastic Deformation
a) Discuss the tool wear with different values of Relief (flank or clearance) angle, Rake angle, Cutter nose radius and Cutting edge honing. b) Which type of the cutting tool material can be used for high productivity and good quality with reasonable cutting tool and machining time cost in turning and milling operations? Aluminum machining (at low cutting speed) Aluminum machining (at high cutting speed) Nickel based super alloys (roughing) Nickel based super alloys (finishing) Titanium alloys c) Please discuss the following values on the workpiece and tool depending on the machine tool vibration and rigidity? Deflection Surface finish Tool wear Part quality
QUESTION 2 Tool life is the most important factor in the evaluation of machinability. Tool life can be defined as the period of time which the tool cuts effectively and efficiently. A cutting tool should have a long tool life. On the other hand, the cutting speed decreases the tool life due to the abrasive action that occurs between the cutting tool and materials. The increase in cutting speed will decrease the machining time, thus reduce the total machining cost. Justify what actions should be taken to increase the tool life and at the same time shorten the machining time.
Question 1. Provide brief explanations to each one of the following questions: 1.a. Explain why studying the types of chips produced is important in understanding cutting operations. 1.b. Describe the reasons for and advantages of coating cutting tools with multiple layers of different materials. What are the possible effects of these coatings on the developed chip during cutting process 1.c. Describe the reasons for and advantages of coating cutting tools with multiple layers of different materials. 1.d. Emulsion cutting fluids typically consist of 95% water and 5% soluble oil and chemical additives. Why is the ratio so unbalanced? Is the oil needed at all? 1.e. What is the difference between a live center and a dead center, when these terms are used in the context of workholding in a lathe?
Tuming tests were performed using a coated carbide tool on steel workpiece at feed of 0.30 mm/rev and the depth of cut 4.0 mm. The tests have resulted in 20-min tool life for a cutting speedv 165 m/min and a 60-min tl mie ie a speed v = a) The n and C values in the Taylor tool life equation b) The cubic cm of steel removed in each case 96 m/min. Determine:
A pre-drilled hole of 010 mm in a block of 40 mm thick is required to be enlarged to O 16mm by core drilling process as shown in the figure below. The recommended cutting speed and the feed rate are 25 m/min. and 0.2 mm/rev respectively. The specific energy of block material is 4.0 W-s/mm³.Calculate the following a) Material removal rate (mm³/s) b) Power required for machining (W). c) Time required for machining. (Sec.) d) Total material removed (mm3) e) If the HSS core drill bit used obey the Taylor's tool life equation VT0.14 = 35 (m/min), how many holes the bit can enlarge before it is replaced? f) Is the above drilling operation can be done on an available drill press of 500 watts power with 80% efficiency? Check and show with calculation. o16 mm 40 mm H Fø10 mm Core drilling
Q.4 A single point cutting tool designated as follows 8-14-6-6-6-20-1 is used to machine a work with feed rate of 1mm/rev. Then the maximum height of roughness and average roughness, in mm, are respectively -3 A 0.0350, 8.76×10 B 8.76x10, -3 0.0350 C 0.10123, 0.0253 D 0.0253, 0.10123
We have a rectangular piece. We wish to manufacture a parallel slot along thepiece in a vertical milling machine and 50 cm from the edge. The width of the slot is 40 mm. TheDepth of the slot is 25 mm. For this, several rough cutting steps and aFine cut with a depth of 0.20 mm. The depth for each of the steps ofrough cut is limited to 1.75 mmAditional information:What is the number of blades used for the rough cutting steps?What is the number of blades used for the fine cutting step?
Question two a.Define the following terms. State the appropriate SI units i)Cutting speedii)Cutting feediii)Material remova rateb.A hole is to be driled in a steel plate of thickness 12mm at a feed of 0.35mm/rev and a spindle speed of 750 rpm. Calculate the i)Material remova rateii)Time taken to complete the process