1) In the machining process, the basic method of removing material from the surf
ID: 2086869 • Letter: 1
Question
1) In the machining process, the basic method of removing material from the surface of a workpiece is by producing chips. A cutting tool moves along the workpiece at a certain velocity, and depth, and a chip is produced just ahead of the tool by shearing the material continuously. During this process, some common situations that you may encounter are listed below. Answer the questions to the best of your ability using the list of Independent variables in the textbook. These questions will likely all depend on the specifics of the project such as materials you are working with, tools you are using, and machines you are using, etc... but think through each question and come up with at least one educated and viable solution. a) If the surface finish of a machined workpiece is unacceptable, which of the independent variables would you investigate first and why? If the workpiece becomes too hot, thus possibly affecting its properties and dimensional accuracy, what modifications should be made to the process parameters? Why did you choose those parameters? If the cutting tool wears rapidly and becomes dull, what should be changed and why? If the dimensional tolerance of the machined part is over the specified limits, what modification should be made? Why? If the cutting tool begins to vibrate and chatter, what should be changed to eliminate or reduce this problem? Why? b) c) d) e)Explanation / Answer
(a) When surface finish is deteriorating, the feed rate need to be checked. Most of the time for a better finish, a small value of feed is preferred. Average peak to valley height is directly proportional to squar of feed rate.
(b) If the workpiece gets heated up this will finallyvresult in tool wear and high surface roughness. So a proper cutting fluid need to be used.
(c) This may happen if the workpiece is hard and abrasive in nature. In such cases one may require to regrind or change the tool insert, depending on type of tool used.
*d) This is a difficult to answer question. This situation can happen due to vibration or chatter associated with the machine tool, tool wear, unskilled operator, etc. So anayse the real reason behind it and resolve.
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