Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 27, Problem 30QLP
Why may different advanced machining processes affect the fatigue strength of materials to different degrees?
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Q3 (a) Describe the process of chip formation in machining ductile and brittle
materials.
(b) Discuss the formation of built up edge (BUE) in ductile material and state the
reason(s) why BUE will not take place in machining brittle materials.
Define specific energy for plane strain machining (cutting).
In plane-strain machỉning, the two main sources of energy dissipation are deformation along
the shear plane (~70%) and friction at the tool-chip contact along the rake face (~30%).
Consider machining of a rigid perfectly-plastic work material whose uniaxial yield stress is
700 MPa, and is independent of strain rate and temperature. A tool of zero-degree rake angle
is employed. Measurements showed the (deformed) chip thickness to be twice that of the
undeformed chip thickness. Based on the aforementioned distribution of energy, estimate the
specific energy for this process.
For the following application, identify one or more nontraditional machining processes that might be used, and present arguments to support your selection. Assume that either the part geometry or the work material (or both) preclude the use of conventional machining. The application is a matrix of 0.1 mm (0.004 in) diameter holes in a plate of 3.2 mm (0.125 in) thick hardened tool steel. The matrix is rectangular, 75 by 125 mm (3.0 by 5.0 in) with the separation between holes in each direction = 1.6 mm ( 0.0625 in).
Chapter 27 Solutions
Manufacturing Engineering & Technology
Ch. 27 - Describe the similarities and differences between...Ch. 27 - Name the processes involved in chemical machining....Ch. 27 - Explain the difference between chemical machining...Ch. 27 - What is the underlying principle of...Ch. 27 - Explain how the EDM process is capable of...Ch. 27 - What are the important features of the Blue Arc...Ch. 27 - What are the capabilities of wire EDM? Could this...Ch. 27 - Explain why laser Microjet has a large depth of...Ch. 27 - Describe the advantages of water-jet machining.Ch. 27 - What is the difference between photochemical...
Ch. 27 - What type of workpiece is not suitable for...Ch. 27 - What is an undercut? Why must it be considered in...Ch. 27 - Explain the principle of hybrid machining.Ch. 27 - Give technical and economic reasons that the...Ch. 27 - Why is the preshaping or premachining of parts...Ch. 27 - Explain why the mechanical properties of workpiece...Ch. 27 - Prob. 17QLPCh. 27 - Prob. 18QLPCh. 27 - Why has electrical-discharge machining become so...Ch. 27 - Prob. 20QLPCh. 27 - Which of the advanced machining processes would...Ch. 27 - Which of the processes described in require a...Ch. 27 - Describe your thoughts regarding the laser-beam...Ch. 27 - Are deburring operations still necessary for some...Ch. 27 - List and explain factors that contribute to a poor...Ch. 27 - What is the purpose of the abrasives in...Ch. 27 - Which of the processes described in this chapter...Ch. 27 - Is kerf width important in wire EDM? Explain.Ch. 27 - Comment on your observations regarding Fig. 27.4.Ch. 27 - Why may different advanced machining processes...Ch. 27 - A 200-mm-deep hole that is 30 mm in diameter is...Ch. 27 - If the operation in Problem 27.31 were performed...Ch. 27 - A cutting-off operation is being performed with a...Ch. 27 - A 0.80-in.-thick copper plate is being machined by...Ch. 27 - Explain why it is difficult to produce sharp...Ch. 27 - Make a list of the processes described in this...Ch. 27 - Would the processes described in this chapter be...Ch. 27 - Prob. 38SDPCh. 27 - Describe your thoughts as to whether the...Ch. 27 - Make a list of machining processes that may be...Ch. 27 - At what stage is the abrasive in abrasive...Ch. 27 - Describe the similarities and differences among...Ch. 27 - Describe the similarities and differences among...Ch. 27 - Describe any workpiece size limitations in...Ch. 27 - Suggest several design applications for the types...Ch. 27 - Based on the topics covered in Parts III and IV,...Ch. 27 - Review Example 27.1 and explain the relevant...Ch. 27 - Precision engineering is a term that is used to...Ch. 27 - With appropriate sketches, describe the principles...Ch. 27 - Make a table of the process capabilities of the...Ch. 27 - One of the general concerns regarding advanced...Ch. 27 - It can be seen that several of the processes...
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Need a deep-dive on the concept behind this application? Look no further. Learn more about this topic, mechanical-engineering and related others by exploring similar questions and additional content below.Similar questions
- Which of the following is one of the disadvantages of machining methods? 1-Variety of machinable part material 2-Variety of piece shapes and special geometric fomms 3-High dimensional accuracy and surface quality (Aşağıdakilerden hangisi talaşlı imalat yöntemlerinin dezavantajlarındand ir? 1-İşlenebilen parça malzemesinin çeşitliliği 2-Parça şekillerinin ve özel geometrik formların çeşitliliği 3-Yüksek boyutsal doğruluk ve yüzey kalitesi ) 16 - O A) Only 3 (Yalnız 3) B) Only 1 (Yalnız 1) ) None (Hiçbiri) O D All (Heps i) O E Only 2((Yalnz 2)arrow_forwardA process engineer is trying to improve the life of a cutting tool. He has run a 23 experiment using (1) cutting speed, (2) metal hardness, (3) and cutting angle as the factors. The data from the 2 replicates are shown below. (a) Do any of the 3 factors affect tool life? (b)what combination of the factor levels produces the longest tool life? (c) Is there a combination of cutting speed and cutting angle that always gives good results regardless of metal hardness? Replicate Run I II (1) 221 311 a 325 435 b 354 348 ab 552 472 c 440 453 ac 406 377 bc 605 500 abc 392 419arrow_forward(a) Research the cutting tool alternatives which could be used for such operation. What are the parameters that could be optimized in the geometry of the cutting tool (The seven elements of tool geometry for a single point cutting tool)? What are some of the tool life criteria used in production machining operations? (b) In a turning operation on stainless steel with hardness = 200 HB, the cutting speed = 250 m/min, feed = 0.3 mm/rev, and depth of cut = 8 mm. How much power will the lathe draw in performing this of 7 operation if it's mechanical efficiency = 95%. Use Table below to obtain the annropriate specific enerey valuearrow_forward
- Question 2. The two sources of heat are (a) shearing in the primary shear plane and (b) friction at the tool-chip interface. What type of the tool wear or tool failure could be caused as a result of developing these heat sources on machining process? Explain your answer in accordance with following representation of tool wear. Insert cutting edgearrow_forward1. What are the factors that affect the machining quality (including machining accuracy and surface quality)?arrow_forward(a) Figure 1 shows surface roughness and tolerances obtained in Chemical Machining (CM) and Electrochemical Machining (ECM) process for different types of electronic products. Comment on the differences between chemical and electrochemical machining process in terms of surface roughness and tolerance of the machined product as illustrated in Figure 1. 0.9 CM 0.8 0.7 Z ECM 0.6 0.5 0.4 0.3 0.2 0.1 Product A Product B Product C Product D Products 25 E ČM 20 Z ECM 15 10 Product A Product B Product C Product D Products Figure 1: Surface roughness and tolerances of various electronic products Surface roughness, Ra Tolerance, (t mm x 10)arrow_forward
- For the following application, identify one or more nontraditional machining processes that might be used, and present arguments to support your selection. Assume that either the part geometry or the work material (or both) preclude the use of conventional machining. The application is a through-hole in the shape of the letter L in a 12.5 mm (0.5 in) thick plate of glass. The size of the "L" is 25 by 15 mm (1.0 by 0.6 in) and the width of the hole is 3 mm (1/8 in).arrow_forwardQ3(a) Assuming you have been given the responsibility of procuring some cutting tool for UCSI workshop. Based on your knowledge in manufacturing processes, one of the major properties of interest in a cutting tool material is the hot hardness. Explain the relationship between the cost of a cutting tool and its hot hardness citing at least FOUR (4) examples of cutting tools.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_forward
- 2 1.4 1 The Taylor tool-life equation is directly applicable to flank wear. Explain whether or not it can be used to model tool life if other forms of wear are dominant.arrow_forwardDuring a certain machining experiment at the UCSI workshop, it is observedthat temperature at the tool workpiece interface is 1200 oC at a cutting speed of300 mm/min with a feed rate of 0.002 mm/rev. (i) Analyse how the temperature will be affected if the cutting speed isincreased by 100 %.(ii) Determine the cutting speed necessary to achieve a maximum cuttingtemperature of 900 oCarrow_forwardWhat are the advanced strategies and technologies used in optimizing the precision, speed, and tool life of Vertical Machining Centers (VMCs) in modern manufacturing processes, and how do these advancements contribute to increased productivity and reduced production costs?arrow_forward
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