Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 24, Problem 46QTP
A slab-milling operation will take place on a part 300 mm long and 40 mm wide. A helical cutter 75 mm in diameter with 10 teeth will be used. If the feed per tooth is 0.2 mm/tooth and the cutting speed is 0.75 m/s, find the machining time and metal-removal rate for removing 6 mm from the surface of the part.
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A 78 mm thick plate is to be milled down to a thickness of 60 mm using an 80 mm face milling cutter. Calculate the processing time if the cutting depth is 6 mm, the feed/rev is 1.1 mm and the cutting speed is 15 m/min, and if the over run for a 620 mm long plate is 10 mm.
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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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- The orthogonal cutting of steel is done with 10° rake tool with a depth of cut of 4mm feed rate of 0.4mm/rev. The cutting speed is 200m/min. The chip thickness ratio is 0.35. The vertical cutting force is 1200N and the horizontal cutting force is 700N. Calculate from the Merchant's theory, the various work done in metal cutting and shear stress.arrow_forwardThe following data is given for slab milling of a 300 mm long 50 mm wide mild steel block: Cutter of diameter= 60 mm; Numbers of teeth =12; Cutter speed = 120 rev/min; Depth of cut = 3.2 mm; Feed is 0.25 mm/tooth.Determine (i) Table feed in mm/min, (ii) MRR (iii) Power (iv) Torque and (v) Total machining time. Assumesuitable approach and over-run and specific energy of mild steel as 5 Ws/mm3.arrow_forwardIn orthogonal turning of a low carbon steel bar of diameter 150 mm with uncoated carbide tool. the cutting velocity is 90 m/min The feed is 0.24 mm/rev and the depth of cut is 2 mm. The chip thickness obtained is 0.48 mm If the orthogonal rake angle is zero and the principal cutting edge angle is 90° Calculate the shear angle in degree.arrow_forward
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- across the surface and (b) the maximum metal removal rate during cutting A slab milling operation is performed on the top surface of a steel rectangular workpiece 12.0 in long by 2.5 in wide. The helical milling cutter, which has a 3.0 in diameter and ten teeth, is set up to overhang the width of the part on both sides. Cutting speed is 125 ft/min, feed is 0.006 in/tooth, and depth of cut = 0.300 in. Determine (a) the actual machining time to make one pass across the surface and (b) the maximum metal removal rate during the cut. (c) If an additional approach distance of 0.5 in is provided at the beginning of the pass (before cutting begins), and an overtravel distance is provided at the end of the pass equal to the cutter radius plus 0.5 in, what is the duration of the feed motion.arrow_forwardA 600mm*30mm flat surface of a plate is to be finish machined on a shaper .The plate has been fixed with 600 mm side along the tool travel direction. If the tool over-travel at each end of the plate is 20 mm, average cutting speed is 8 m/min, feed rate is 0.3 mm/stroke and the ratio of return time to cutting time of the tool is 1:2 Determine time required for machining?arrow_forwardA shaft groove with a length of 250 mm and a depth of 12 mm is cut by a 20 mm diameter slot cutter. What is the processing time if the cutting depth is to be 4 mm. The feed is 25 mm/min. Over run is 1/2 the cutter diameter.arrow_forward
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