Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 22, Problem 47SDP
One of the principal concerns with coolants is degradation due to biological attack by bacteria. To prolong the life of a coolant, chemical biocides often are added, but these biocides greatly complicate the disposal of the coolant. Conduct a literature search concerning the latest developments in the use of environmentally benign biocides in cutting fluids.
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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
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1.c. Describe the reasons for and advantages of coating cutting tools with multiple layers of
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1.d. Emulsion cutting fluids typically consist of 95% water and 5% soluble oil and chemical
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1.e. What is the difference between a live center and a dead center, when these terms are used in
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2 2 .4 1 Emulsion cutting fluids typically consist of 95% water and 5% soluble oil and chemical additives. W hy is the ratio so unbalanced? Is the oil needed at all?
An electrochemical machining (ECM) is to be used to cut a through hole into a 12 mm
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Chapter 22 Solutions
Manufacturing Engineering & Technology
Ch. 22 - What are the major properties required of...Ch. 22 - What is the composition of a typical carbide tool?Ch. 22 - Why were cutting-tool inserts developed?Ch. 22 - Why are some tools coated? What are the common...Ch. 22 - Explain the applications and limitations of...Ch. 22 - List the major functions of cutting fluids.Ch. 22 - Why is toughness important for cutting-tool...Ch. 22 - Is the elastic modulus important for cutting-tool...Ch. 22 - Explain how cutting fluids penetrate the toolchip...Ch. 22 - List the methods by which cutting fluids are...
Ch. 22 - Describe the advantages and limitations of (a)...Ch. 22 - What is a cermet? What are its advantages?Ch. 22 - Explain the difference between M-series and...Ch. 22 - Why is cBN generally preferred over diamond for...Ch. 22 - What are the advantages to dry machining?Ch. 22 - Explain why so many different types of...Ch. 22 - Which tool-material properties are suitable for...Ch. 22 - Describe the reasons for and advantages of coating...Ch. 22 - Make a list of the alloying elements used in...Ch. 22 - As stated in Section 22.1, tool materials can have...Ch. 22 - Explain the economic impact of the trend shown in...Ch. 22 - Why does temperature have such an important effect...Ch. 22 - Ceramic and cermet cutting tools have certain...Ch. 22 - What precautions would you take in machining with...Ch. 22 - Can cutting fluids have any adverse effects in...Ch. 22 - Describe the trends you observe in Table 22.2.Ch. 22 - Why are chemical stability and inertness important...Ch. 22 - Titanium-nitride coatings on tools reduce the...Ch. 22 - Describe the necessary conditions for optimal...Ch. 22 - Negative rake angles generally are preferred for...Ch. 22 - Do you think that there is a relationship between...Ch. 22 - Make a survey of the technical literature, and...Ch. 22 - In Table 22.1, the last two properties listed...Ch. 22 - It has been stated that titanium-nitride coatings...Ch. 22 - Note in Fig. 22.1 that all tool materials,...Ch. 22 - Referring to Table 22.1, state which tool...Ch. 22 - Which of the properties listed in Table 22.1 is,...Ch. 22 - If a drill bit is intended only for woodworking...Ch. 22 - What are the consequences of a coating on a tool...Ch. 22 - Discuss the relative advantages and limitations of...Ch. 22 - Emulsion cutting fluids typically consist of 95%...Ch. 22 - List and explain the considerations involved in...Ch. 22 - Review the contents of Table 22.1. Plot several...Ch. 22 - Obtain data on the thermal properties of various...Ch. 22 - The first column in Table 22.2 shows 10 properties...Ch. 22 - Describe in detail your thoughts regarding the...Ch. 22 - One of the principal concerns with coolants is...Ch. 22 - How would you go about measuring the effectiveness...Ch. 22 - There are several types of cutting-tool materials...Ch. 22 - Assume that you are in charge of a laboratory for...Ch. 22 - Tool life could be greatly increased if an...Ch. 22 - List the concerns you would have if you needed to...
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- Orthogonal cutting is performed on a metal whose mass specific heat = 1.0 J/g-C, density = 2.9 g/cm, and thermal diffusivity = 0.8 cm2/s. Cutting speed = 3.5 m/s, uncut chip thickness = 0.25 mm, and width of cut = 2.2 mm. Cutting force = 950 N. Determine the cutting temperature if the ambient temperature = 22°C.arrow_forwardThe frontal working area of the electrode in an Electrochemical Machining (ECM) operation is 1000 mm. The applied current is 900 amps and the voltage is 12 volts. The resistivity of the electi olyte is 140 Q-mm. The material being cut has a valency of 4 and specific removal rate of 0.0342 mm /A-s. If the process efficiency is 90%, determine the material remova! rate (MRR) and inter-electrode gap after 30 minutes of machining when the resistivity of the electrolyte has dropped to 75% of its original value.arrow_forward8 - Orthogonal cutting is performed on a metal whose mass specific heat = 1.0 J/g-C, density 2.9 g/cm3, and thermal diffusivity = 0.8 cm2/s. The cutting speed is 4.5 m/s, uncut chip thickness (feed) is 0.25 mm, and width of cut (depth) is 2.2 mm. The cutting force is measured at 1170 N. Using Cook's equation, determine the cutting temperature. a) 417.09 b) O 707.60 C) 528.03 d) O 316.82 Boş bırakarrow_forward
- (a) An engineer would like to drill a square hole of 20 mm x 20 mm with depth of 25 mm on a layered structure of natural fibre-reinforced polymer composite. He encountered delamination problem in the workpiece (Figure 3) when he used conventional cutting tool to drill the hole. Instead of using conventional machining process, discuss ONE suitable advanced machining process that can be applied for this machining purpose and predict TWO possible limitations for the selected process. Cutting Tool Delamination Composite Material Figure 3. Delamination of the composite material.arrow_forward5. What are the adverse effects of tool wear in cutting processes? 6. What characteristics are required for cutting tool materials? V. Comprehensive questions. 1. Match each part with the most proper manufacturing process. (1) Aluminum beverage can Centrifugal casting (2) Copper wire Closed-die forging (3) Engine cylinder Die casting (4) Lathe body Drawing (5) Link rod of an engine Sand casting (6) Magnesium alloy camera frame Sheet-metal formingarrow_forwardWhat two ingredients are often used as additives to improve lubrication qualities of cutting oils?arrow_forward
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