Mechanical Manufacturing Exam 3
aerospace and automotive
which industries rely heavily on machining?
true
true or false: complex parts can be made using CNC machines
yes
are high required for CNC machining
turning, cutting off, slab milling, and end milling
what are some common cutting processes?
depth of cutting, cutting speed, and feed rate
what are some cutting conditions?
continuous, built-up edge (BUE), serrated, and discontinuous
what are some types of chips produced in cutting?
it becomes more curly
what happens the chip as depth of cut decreases?
make them more curly
what do cutting fluids do to chips?
chip breaker
a special feature on cutting tools that decreases the radius of curvature of the chip and
eventually breaks it
heat
in cutting, nearly all energy consumed is converted into...
to keep the machine from melting
why are cutting temperatures important?
high localized stresses at the tip of the tool, high temperatures, sliding of the chip
at high speeds, and sliding of the tool along the machined surface
what is cutting tool wear caused by?
surface finish and surface integrity of the part, tool life, force and power
requirements, and the level of difficulty in chip control
what does machinability depend on?
cutting force (Fc), thrust force (Ft), and radial force (Fr)
what are the three different types of forces present in turning operations?
thrust force
also called feed force; force that acts in the direction of feed
radial force
force that tends to push the tool away from the workpiece being machined
drilling
a common hole-making process
fracture
drills are flexible and prone to ____
margins
provide a bearing surface for the drill against walls of the hole as it penetrates into the
workpiece
,improved guidance and accuracy
drills with 4 margins (double-margin) are available for...
true
true or false: drills with chip breaker features are available
boring
process which enlarges a cavity or hole that has been previously made; produces
circular internal profiles
counterboring, countersinking, twist, core, step, gun, center, and spot
what are some types of drills?
reaming
process that makes an existing hole dimensionally accurate and improves surface finish
tapping
process where internal threads can be produced
chip removal
what is a problem that occurs during tapping?
milling
process that uses a milling cutter which is a multi-edge (2/4 flutes) rotating tool to
remove material
flutes
a milling cutter has multiple cutting edges called ____
controlled axis
in milling, the workpiece moves along the ______
feed rate, spindle speed, and depth of cut
what determines the material removal rate during milling?
using precise interpolation of toolpaths
how does milling produce complex 2D and 3D features?
G-codes and M-codes
what defines the movement and machining operation codes?
parallel
in peripheral milling, is the axis of cutter rotation parallel or perpendicular to the
workpiece surface?
slab milling
type of peripheral milling when the cutter is longer than the width of cut
conventional milling (up milling)
type of milling where the cutting tool rotates against the direction of feed and the
maximum chip thickness is at the end of cut
climb millng (down milling)
type of milling where the cutting tool rotates in the direction of feed and cutting starts at
the surface where the chips are the thickest
because there is more friction in conventional milling
why is there more ware in conventional milling than climb milling?
face milling
type of milling where the axis of cutter rotation is perpendicular to the workpiece surface
end milling
type of milling where the axis of rotation is perpendicular to the workpiece surface and
the cutting tool used is called an end mill
, straddle milling, form milling, slotting and slitting, T-slot cutters, and shell mills
what are some types of milling operations
broaching
uses a long multiple-tooth cutter to machine internally or externally
sawing
process that uses a saw with a series of small teeth and can be used for all materials;
the width of the cut (kerf) is small
filing
process that involves the small-scale removal of materials
high speed steel bur and carbide bur rotary file
filing can have several different tooth forms such as...
computer numerical control
what does CNC stand for?
a manufacturing tool automated and pre-programmed by a computer software
what is CNC machining?
milling, turning, drilling, and grinding
CNC machining performs various machining operations such as...
it is accurate and repeatable
what is a benefit of CNC machining?
precision, repeatability, and complex shapes
what are some struggles of traditional manual machining that led to the creation of CNC
machining?
improve aircraft component accuracy and production efficiency
leading to the creation of CNC machining, the US air force sought to...
MIT's servomechanisms lab
who built the first NC (numerical control) machine in 1952?
they followed exact digital coordinates, eliminating human variability
what was a benefit og numerical control (NC) machines?
computers having real time control and programmable automation
what did the evolution from NC to CNC occur with?
milling
CNC machining operation that uses a rotating cutting tool; the tool moves across the
workpiece; creates flat surfaces, slots, and pockets; uses multiple axes (x,y,z) for
precise cutting
turning
CNC milling operation that uses a rotating workpiece and stationary cutting tool; makes
cylindrical shapes, tapers, grooves, and threads; excellent accuracy for circular
components
drilling
CNC milling operation that uses a rotating cutting tool which moves vertically into the
workpiece; creates holes for fasteners; accurate hole placement repeated over multiple
iterations
M-codes
type of code that controls machine functions
M03
m-code for spindle on, clockwise rotation
aerospace and automotive
which industries rely heavily on machining?
true
true or false: complex parts can be made using CNC machines
yes
are high required for CNC machining
turning, cutting off, slab milling, and end milling
what are some common cutting processes?
depth of cutting, cutting speed, and feed rate
what are some cutting conditions?
continuous, built-up edge (BUE), serrated, and discontinuous
what are some types of chips produced in cutting?
it becomes more curly
what happens the chip as depth of cut decreases?
make them more curly
what do cutting fluids do to chips?
chip breaker
a special feature on cutting tools that decreases the radius of curvature of the chip and
eventually breaks it
heat
in cutting, nearly all energy consumed is converted into...
to keep the machine from melting
why are cutting temperatures important?
high localized stresses at the tip of the tool, high temperatures, sliding of the chip
at high speeds, and sliding of the tool along the machined surface
what is cutting tool wear caused by?
surface finish and surface integrity of the part, tool life, force and power
requirements, and the level of difficulty in chip control
what does machinability depend on?
cutting force (Fc), thrust force (Ft), and radial force (Fr)
what are the three different types of forces present in turning operations?
thrust force
also called feed force; force that acts in the direction of feed
radial force
force that tends to push the tool away from the workpiece being machined
drilling
a common hole-making process
fracture
drills are flexible and prone to ____
margins
provide a bearing surface for the drill against walls of the hole as it penetrates into the
workpiece
,improved guidance and accuracy
drills with 4 margins (double-margin) are available for...
true
true or false: drills with chip breaker features are available
boring
process which enlarges a cavity or hole that has been previously made; produces
circular internal profiles
counterboring, countersinking, twist, core, step, gun, center, and spot
what are some types of drills?
reaming
process that makes an existing hole dimensionally accurate and improves surface finish
tapping
process where internal threads can be produced
chip removal
what is a problem that occurs during tapping?
milling
process that uses a milling cutter which is a multi-edge (2/4 flutes) rotating tool to
remove material
flutes
a milling cutter has multiple cutting edges called ____
controlled axis
in milling, the workpiece moves along the ______
feed rate, spindle speed, and depth of cut
what determines the material removal rate during milling?
using precise interpolation of toolpaths
how does milling produce complex 2D and 3D features?
G-codes and M-codes
what defines the movement and machining operation codes?
parallel
in peripheral milling, is the axis of cutter rotation parallel or perpendicular to the
workpiece surface?
slab milling
type of peripheral milling when the cutter is longer than the width of cut
conventional milling (up milling)
type of milling where the cutting tool rotates against the direction of feed and the
maximum chip thickness is at the end of cut
climb millng (down milling)
type of milling where the cutting tool rotates in the direction of feed and cutting starts at
the surface where the chips are the thickest
because there is more friction in conventional milling
why is there more ware in conventional milling than climb milling?
face milling
type of milling where the axis of cutter rotation is perpendicular to the workpiece surface
end milling
type of milling where the axis of rotation is perpendicular to the workpiece surface and
the cutting tool used is called an end mill
, straddle milling, form milling, slotting and slitting, T-slot cutters, and shell mills
what are some types of milling operations
broaching
uses a long multiple-tooth cutter to machine internally or externally
sawing
process that uses a saw with a series of small teeth and can be used for all materials;
the width of the cut (kerf) is small
filing
process that involves the small-scale removal of materials
high speed steel bur and carbide bur rotary file
filing can have several different tooth forms such as...
computer numerical control
what does CNC stand for?
a manufacturing tool automated and pre-programmed by a computer software
what is CNC machining?
milling, turning, drilling, and grinding
CNC machining performs various machining operations such as...
it is accurate and repeatable
what is a benefit of CNC machining?
precision, repeatability, and complex shapes
what are some struggles of traditional manual machining that led to the creation of CNC
machining?
improve aircraft component accuracy and production efficiency
leading to the creation of CNC machining, the US air force sought to...
MIT's servomechanisms lab
who built the first NC (numerical control) machine in 1952?
they followed exact digital coordinates, eliminating human variability
what was a benefit og numerical control (NC) machines?
computers having real time control and programmable automation
what did the evolution from NC to CNC occur with?
milling
CNC machining operation that uses a rotating cutting tool; the tool moves across the
workpiece; creates flat surfaces, slots, and pockets; uses multiple axes (x,y,z) for
precise cutting
turning
CNC milling operation that uses a rotating workpiece and stationary cutting tool; makes
cylindrical shapes, tapers, grooves, and threads; excellent accuracy for circular
components
drilling
CNC milling operation that uses a rotating cutting tool which moves vertically into the
workpiece; creates holes for fasteners; accurate hole placement repeated over multiple
iterations
M-codes
type of code that controls machine functions
M03
m-code for spindle on, clockwise rotation
