Question

1. Define the four types of chips observed in machining. Explain how different chips are obtained from materials of different ductility. 2. According to the Merchant Equation, an increase in rake angle would have which of the following results, if all remaining factors are constant (more than one correct answer): a. Decrease in friction angle b. Decrease in power requirements c. Decrease in shear plane angle d. Increase in cutting temperature e. Increase in shear plane angle 3. State and describe the orthogonal cutting model. Define chip ratio and explain why chip ratio is always < 1.0. 4. Explain the effect of cutting temperature in machining on the chip formation and finish of the machined parts. 5. Describe and state the difference between roughing and finishing in machining operations. 6. Define (a) cutting power, (b) Gross Power, and (c) Specific Power along with pertinent equations. 7. State and briefly describe the 3 stages of Tool Wear Rate using a plot. 8. Turning tests have resulted in a 1 minute tool life for cutting speed v = 4 m/s and a 20 minute tool life at a speed v = 2 m/s. a. Determine the values of n and C in the Taylor tool life equation ( , T = tool life [min], v = cutting speed [m/min]) b. Project how long the tool would last at a speed of v = 1 m/s 9. What are the 3 time components of the total production cycle for a part? What is the equation for the cycle time (Tc)? 10. Whatarethe4mainingredientsofacuttingfluid?Whatarethe3mainmethodsbywhichcutting fluids are introduced in a machining operation? 11. Whatarethe4maincosts(withequations)involvedwithproductionofapart?Howiscycletime related to the unit cost of production?

Answer 1