Question & Answer

In an orthogonal cutting operation, the tool has a rake angle = 15°. The chip thickness before the cut = 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm. Calculate (a) the shear plane angle and (b) the shear strain for the operation.

There are 17 correct answers in the following multiple choice questions (some questions have multiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be given. Each correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point, and each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage score on the quiz is based on the total number of correct answers

21.1 Which of the following manufacturing processes are classified as material removal processes (two correct answers): (a) casting, (b) drawing, (c) extrusion, (d) forging, (e) grinding, (f) machining, (g) molding, (h) pressworking, and (i) spinning?

21.2 A lathe is used to perform which one of the following manufacturing operations: (a) broaching, (b) drilling, (c) lapping, (d) milling, or (e) turning?

21.3 With which one of the following geometric forms is the drilling operation most closely associated: (a) external cylinder, (b) flat plane, (c) round hole, (d) screw threads, or (e) sphere?

21.4 If the cutting conditions in a turning operation are cutting speed = 300 ft/min, feed = 0.010 in/rev, and depth of cut = 0.100 inch, which one of the following is the material removal rate: (a) 0.025 in3 /min, (b) 0.3 in3 /min, (c) 3.0 in3 /min, or (d) 3.6 in3 /min?

21.5 A roughing operation generally involves which one of the following combinations of cutting conditions: (a) high v, f, and d; (b) high v, low f and d; (c) low v, high f and d; or (d) low v, f, and d, where v = cutting speed, f = feed, and d = depth?

21.6 Which of the following are characteristics of the orthogonal cutting model (three best answers): (a) a circular cutting edge is used, (b) a multiple-cutting-edge tool is used, (c) a single-point tool is used, (d) only two dimensions play an active role in the analysis, (e) the cutting edge is parallel to the direction of cutting speed, (f) the cutting edge is perpendicular to the direction of cutting speed, and (g) the two elements of tool geometry are rake and relief angle?

21.7 The chip thickness ratio is which one of the following: (a) tc/to, (b) to/tc, (c) f/d, or (d) to/w, where tc = chip thickness after the cut, to = chip thickness before the cut, f = feed, d = depth, and w = width of cut?

21.8 Which one of the four types of chip would be expected in a turning operation conducted at low cutting speed on a brittle work material: (a) continuous, (b) continuous with built-up edge, (c) discontinuous, or (d) serrated?

21.9 According to the Merchant equation, an increase in rake angle would have which of the following results, all other factors remaining the same (two best answers): (a) decrease in friction angle, (b) decrease in power requirements, (c) decrease in shear plane angle, (d) increase in cutting temperature, and (e) increase in shear plane angle?

21.10 In using the orthogonal cutting model to approximate a turning operation, the chip thickness before the cut to corresponds to which one of the following cutting conditions in turning: (a) depth of cut d, (b) feed f, or (c) speed v?

21.11 Which one of the following metals would usually have the lowest unit horsepower in a machining operation: (a) aluminum, (b) brass, (c) cast iron, or (d) steel?

21.12 For which one of the following values of chip thickness before the cut to would you expect the specific energy in machining to be the greatest: (a) 0.010 inch, (b) 0.025 inch, (c) 0.12 mm, or (d) 0.50 mm?

21.13 Which of the following cutting conditions has the strongest effect on cutting temperature: (a) feed or (b) speed?

What is a tool-chip thermocouple?

What does the term size effect mean in metal cutting?

What is the specific energy in metal machining?

How is the power required in a cutting operation related to the cutting force?

Describe in words what the Merchant equation tells us

What is the relationship between the coefficient of friction and the friction angle in the orthogonal cutting model?

Identify the two forces that can be measured in the orthogonal metal cutting model.

Identify the four forces that act upon the chip in the orthogonal metal cutting model but cannot be measured directly in an operation.

Name and briefly describe the four types of chips that occur in metal cutting

Why is the orthogonal cutting model useful in the analysis of metal machining?

What is an orthogonal cutting operation?

What is a machine tool?

Explain the difference between roughing and finishing operations in machining.

What are the parameters of a machining operation that are included within the scope of cutting conditions?

What are the two basic categories of cutting tools in machining? Give two examples of machining operations that use each of the tooling types

Name the three most common machining processes.

Identify some of the reasons why machining is commercially and technologically important

What distinguishes machining from other manufacturing processes?

What are the three basic categories of material removal processes?

A 75 mm diameter tube is bent into a rather complex shape with a series of simple tube bending operations. The wall thickness on the tube = 4.75 mm. The tubes will be used to deliver fluids in a chemical plant. In one of the bends where the bend radius is 125 mm, the walls of the tube are flattening badly. What can be done to correct the condition?

Determine the shear strain that is experienced by the material that is shear spun in Problem 20.33

If the part illustrated in Figure P20.32 were made by shear spinning, determine (a) the wall thickness along the cone-shaped portion, and (b) the spinning reduction r.

Determine the starting disk diameter required to spin the part in Figure P20.32 using a conventional spinning operation. The starting thickness = 2.4 mm