Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 33, Problem 51SDP
Describe your thoughts on the desirability of integrating surface-roughness measuring instruments into the machine tools described in Parts III and IV? How would you go about doing so, giving special consideration to the factory environment in which they are to be used? Make some preliminary sketches of such a system.
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(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
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Product B
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25
E ČM
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Z ECM
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Figure 1: Surface roughness and tolerances of various electronic products
Surface roughness, Ra
Tolerance, (t mm x 10)
Estimate the manufacturing cost for a simple machined component: a. Compare the costs for manufacturing volumes of 1, 10, 100, 1000, and 10,000 pieces with an intermediate tolerance and surface finish. Explain why there is a great change between 1 and 10 and a small change between 1000 and 10,000 pieces. b. Compare the costs for fit, intermediate, and rough tolerances with a volume of 100 pieces. c. Compare the costs of manufacturing the component out of various materials.
A turning machining experiment was performed at the UCSI University's
Mechanical Engineering workshop using a lathe machine with palm oil as
lubricant. It was observed that during the entire machining, the technician set
cutting tool perpendicular to the direction of tool motion. A further investigation
revealed that the tool rake angle was 25° while the dynamometer results'
analysis showed that the frictional force and the normal force to the friction was
5 kN and 25 kN respectively. Analyze how the chip thickness will be affected
if the machining is performed without any lubricant and the frictional force is
increased by 100 %. Assume that, all other parameters were kept constant during
the entire operation for both machining with lubricant and the dry machining
process.
Chapter 33 Solutions
Manufacturing Engineering & Technology
Ch. 33 - What is tribology?Ch. 33 - Explain what is meant by (a) surface texture and...Ch. 33 - List and explain the types of defects typically...Ch. 33 - Define the terms (a) roughness, and (b) waviness.Ch. 33 - Explain why the results from a profilometer are...Ch. 33 - Prob. 6RQCh. 33 - List the types of wear generally observed in...Ch. 33 - Define the terms wear, friction, and lubricant.Ch. 33 - How can adhesive wear be reduced? Abrasive wear?Ch. 33 - Prob. 10RQ
Ch. 33 - Explain the functions of a lubricant in...Ch. 33 - Prob. 12RQCh. 33 - Prob. 13RQCh. 33 - Describe the factors involved in lubricant...Ch. 33 - Prob. 15RQCh. 33 - Prob. 16QLPCh. 33 - Explain the significance of the fact that the...Ch. 33 - Prob. 18QLPCh. 33 - Explain why identical surface-roughness values do...Ch. 33 - Prob. 20QLPCh. 33 - Prob. 21QLPCh. 33 - Prob. 22QLPCh. 33 - Prob. 23QLPCh. 33 - Comment on the surface roughness of various parts...Ch. 33 - Prob. 25QLPCh. 33 - Do the same as for Problem 33.25, but for surface...Ch. 33 - Describe your observations regarding Fig. 33.7.Ch. 33 - Give the reasons that an originally round specimen...Ch. 33 - Prob. 29QLPCh. 33 - Explain the reason that the abrasive-wear...Ch. 33 - Prob. 31QLPCh. 33 - List the similarities and differences between...Ch. 33 - Explain why the types of wear shown in Fig. 33.11...Ch. 33 - List the requirements of a lubricant.Ch. 33 - List manufacturing operations in which high...Ch. 33 - List manufacturing operations in which high wear...Ch. 33 - Prob. 37QLPCh. 33 - Prob. 38QTPCh. 33 - A surface with a triangular sawtooth roughness...Ch. 33 - List the steps you would follow if you wished to...Ch. 33 - Discuss the tribological differences between...Ch. 33 - Section 33.2 listed major surface defects. How...Ch. 33 - Describe your own thoughts regarding biological...Ch. 33 - Prob. 48SDPCh. 33 - Prob. 49SDPCh. 33 - Prob. 50SDPCh. 33 - Describe your thoughts on the desirability of...
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