Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 24, Problem 11RQ
What advantages do bed-type milling machines have over column-and-knee-type machines for production operations?
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d) A face milling operation is used to machine 6.0 mm from the top surface of a rectangular
piece of aluminum 300 mm long by 125 mm wide in a single pass. The cutter has four teeth
(cemented carbide inserts) and is 150 mm in diameter. The cutting speed = 2.8 m/s, and
chipload = 0.27 mm/tooth. Assuming that the cutter enters the workpiece from its short side
and follows a path that is centered over the workpiece, determine:
i) the actual machining time to make the pass across the surface and,
ii) the maximum metal removal rate during cutting.
1. In face milling, the axis of the cutter is tangent to the surface being milled.
(a) true or (b) false
2. When product variety is hard, the usual approach is batch production.(a) true or (b) false
3. In a turning operation, the change in diameter of the workpart is equal to which one of the
following:(a) 1 x depth of cut, (b) 2 x depth of cut. (c) 1 x feed, or (d) 2 x fe
feed?
4. A turning operation is normally performed on which one of the following machine tools:
(a) drill press, (b) lathe, (c) milling machine, (d) planer, or (e) shaper?
5. Machined parts can be classified as rotational or nonrotational. Which of the following are
examples of operations that create nonrotational geometries: (a) boring, (b) drilling,
(c) milling. (d) planning, and (e) turning?
Solve the question below- except that availability = 95%.
In a sequential batch machining operation, setup time is 1.5 hours, and the batch size is 120 units. The cycle time consists of part handling time of 30 sec
and processing time of 2.85 min. One part is produced each cycle. Tool changes must be performed every 10 parts, and this takes 2.0 min. Determine the
average production rate.
O O
Chapter 24 Solutions
Manufacturing Engineering & Technology
Ch. 24 - Explain why milling is such a versatile machining...Ch. 24 - Describe a milling machine. How is it different...Ch. 24 - Describe the different types of cutters used in...Ch. 24 - Define the following: face milling, peripheral...Ch. 24 - Can threads be machined on a mill? Explain.Ch. 24 - What is the difference between feed and feed per...Ch. 24 - Explain the relative characteristics of climb...Ch. 24 - Describe the geometric features of a broach and...Ch. 24 - What is a pull broach? A push broach?Ch. 24 - Why is sawing a commonly used process? Why do some...
Ch. 24 - What advantages do bed-type milling machines have...Ch. 24 - Explain why the axis of a hob is tilted with...Ch. 24 - What is a shell mill? Why is it used?Ch. 24 - Why is it difficult to saw thin sheet metals?Ch. 24 - Of the processes depicted in Fig. 24.2, which is...Ch. 24 - Describe the tool motion during gear shaping.Ch. 24 - When is filing necessary?Ch. 24 - Would you consider the machining processes...Ch. 24 - Why is end milling such an important versatile...Ch. 24 - List and explain factors that contribute to poor...Ch. 24 - Explain why broaching crankshaft bearings is an...Ch. 24 - Several guidelines are presented in this chapter...Ch. 24 - What are the advantages of helical teeth over...Ch. 24 - Explain why hacksaws are not as productive as band...Ch. 24 - What similarities and differences are there in...Ch. 24 - Why do machined gears have to be subjected to...Ch. 24 - How would you reduce the surface roughness shown...Ch. 24 - Why are machines such as the one shown in Fig....Ch. 24 - Comment on your observations concerning the...Ch. 24 - Explain how contour cutting could be started in a...Ch. 24 - Prob. 32QLPCh. 24 - Describe the parts and conditions under which...Ch. 24 - Explain the reason that it is difficult to use...Ch. 24 - Would you recommend broaching a keyway on a gear...Ch. 24 - Prob. 37QTPCh. 24 - A slab-milling operation is being performed at a...Ch. 24 - Show that the distance lc in slab milling is...Ch. 24 - Prob. 40QTPCh. 24 - Calculate the chip depth of cut, tc, and the...Ch. 24 - Estimate the time required to face mill a...Ch. 24 - A 12-in.-long, 1-in.-thick plate is being cut on a...Ch. 24 - A single-thread hob is used to cut 40 teeth on a...Ch. 24 - Assume that m the face-milling operation shown in...Ch. 24 - A slab-milling operation will take place on a part...Ch. 24 - Prob. 47QTPCh. 24 - In describing the broaching operations and the...Ch. 24 - The parts shown in Fig. 24.1 are to be machined...Ch. 24 - Would you prefer to machine the part in Fig. 24....Ch. 24 - Prob. 51SDPCh. 24 - Suggest methods whereby milling cutters of various...Ch. 24 - Prepare a comprehensive table of the process...Ch. 24 - Prob. 55SDPCh. 24 - Make a list of all the processes that can be used...
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- What is a benefit of using a DRO instead of micrometer collars for positioning on a vertical milling machine?arrow_forwardConsider a profile milling operation, where the initial (stock) geometry has (X,Y,Z) dimensions of 100 mm x 75 mm x 50 mm. The target part has dimensions of 95 mm x 70 mm x 50 mm. The target part is located in the centre of the stock part, i.e. the stock to be removed from all sides is equal. The operation has a cutting time of 1 minute. The tool axis is along the Z direction and the tool diameter is 12 mm having 6 cutting edges. The takes place at 54m/min feed rate of 0.2 mm/rev/tooth. Calculate the axial depth of cut ? process at aarrow_forwardprovide helpful related details about Milling Machine Operationsarrow_forward
- In the horizontal milling machine, plain milling is accomplished on the top surface of a rectangular workpiece with dimensions (length 600 mm and width 50 mm). The cutter milling protrudes on both sides of the part. A cutter diameter is 60 mm; the number of teeth is 6. Cutting condition are 60 m/min, 0.25 mm/tooth, and 6.5 mm. Determine :- (a) machining time of the operation. (b) material removal rate during the cut.arrow_forwardExpert Q&A Done The top surface of a rectangular workpart is machined using a peripheral milling operation. The workpart is 735 mm long by 50 mm wide by 95 mm thick. The milling cutter, which is 60 mm in diameter and has five teeth, overhangs the width of the part equally on both sides. Cutting speed = 80 m/min, chip load = 0.30 mm/tooth, and depth of cut = 7.5 mm. (a) Determine the time required to make one pass across the surface, given that the setup and machine settings provide an approach distance of 5 mm before actual cutting begins and an overtravel distance of 25 mm after 1.2 9. 20 65 73 actual cutting has finished v in seconds. (b) What is the maximum material 3.9 239 removal rate during the cut v in mm3/sec? 0.127 5arrow_forwardProblems 1. Peripheral milling is performed on the top surface of a rectangular work part that is 400 mm long by 50 mm wide. The milling cutter is 70 mm in diameter and has five teeth. It overhangs the width of the part on both sides. Cutting speed 60 m/min, chip load 0.25 mm/tooth, and depth of cut 6.5 mm. Determine maximum material removal rate during the cut. 2. A face milling operation removes 6.0 mm from the top surface of a rectangular piece of aluminum that is 300 mm long by 90 mm wide by 75 mm thick. The cutter follows a path that is centered over the workpiece. It has four teeth and is 100 mm in diameter. Cutting speed 2.0 m/s, and chip load 0.27 mm/ tooth. Determine maximum metal removal rate during cutting.arrow_forward
- What are the key considerations and best practices in programming multi-axis CNC machines to achieve complex machining tasks, and how does advanced CAM (Computer-Aided Manufacturing) software play a role in streamlining the process?arrow_forwardA job has to be machined in shaping and the process parameters are given below: Length of the job=120 mm Speed of the motor=640 rpm Cutting speed=248 m/min Tool allowance before cutting =31.5 mm Tool allowance after cutting=10 mm Determine the cutting to return stroke ratio for the above operation and draw the arrangement of machining with tool head and allowances.arrow_forwardE Expert Q&A 1. Shaper (#X) Machine function and design requirements: The main function of this machine is to make surface more smooth; The required movements are: Reciprocating movement of planer knife and feed movement of the bow. It is required that the cutting speed is uniform, while the quirkily return is included. The basic data is: principal axis rotation speed is 60 r/min, the max length is less than 450 mm, the distance between working surface and the floor is 800 mm. Travel speed ratio co-efficient is 1.5, allowable pressure angle 15°, cutting quantity is 0.1~0.5 mm. Requirements: 1. Freedom calculations; 2. Force analysis; 3. Make this machine, and display; please give a solution with given condition.arrow_forward
- Feed rate in slab milling operation is equal to (a) rotation per minute (rpm) (b) product of rpm and number of teeth in the cutter (c) product of rpm, feed per tooth and number of teeth in the cutter (d) product of rpm, feed per tooth and number of teeth in contactarrow_forward1. Peripheral milling is performed on the top surface of a rectangular work part that is 400 mm long by 50 mm wide. The milling cutter is 70 mm in diameter and has five teeth. It overhangs the width of the part on both sides. Cutting speed 60 m/min, chip load 0.25 mm/tooth, and depth of cut 6.5 mm. Determine maximum material removal rate during the cut.arrow_forwardIn 3-axis milling, the table feedrate is 703.00 mm/min. Using a 10mm endmill to cut the material with a radial depth of 4.60 mm and axial depth of 4.20 mm, what is the material removal rate (Cm³ /min) in this operation? Your Answer: Answerarrow_forward
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