Manufacturing Processes Home Work #6 Solutions Yr 102

Review Questions
20.6 How does a boring operation differ from a turning operation?
Answer. Boring produces an internal cylindrical shape from an existing hole,
while turning produces an external cylindrical shape.

20.10 How does a turret lathe differ from an engine lathe?

Answer. A turret lathe has a toolholding turret in place of a tailstock; the tools
in the turret can be brought to work to perform multiple cutting operations on
the work without the need to change tools as in operating a conventional
engine lathe.

20.15 (20%) What is pocket milling?

Answer. Pocket milling uses an end milling cutter to machine a shallow
cavity (pocket) into a flat workpart.

20.18 What is a machining center?

Answer. A machining center is a CNC machine tool capable of performing
multiple types of cutting operations involving rotating spindles (e.g., milling,
drilling); the machine is typically equipped with automatic tool-changing,
pallet shuttles to speed workpart changing, and automatic workpart
positioning.

Problems
20.2 (20%) Solution:
Starting with Tm = DoL/vf.
Rearranging to determine cutting speed: v = DoL/fTm
-3 3
v = (0.4)(0.15)/(0.30)(10 )(5.0) = 0.1257(10 ) m/min = 125.7 m/min

20.7 Solution:
First end: cut 31.25 cm of 62.5 cm length.
N = 90 100/10 = 286.4 rev/min,
fr = 286.4(0.0375) = 10.74 cm/min
Tm = (31.25 + 1.25)/10.74 = 3.0261 min; this reduces diameter to 9.375 cm
N = 90 100/9.375 = 305.5 rev/min,
1
 fr = 305.5(0.0375) = 11.456 cm/min
Tm = (31.25 + 1.25)/11.456 = 2.8369 min to reduce the diameter to 8.75 cm
Reverse bar, which takes 3.0 min and cut remaining 31.25 cm of 62.5 cm
length.
N = 90 100/10 = 286.4 rev/min,
fr = 286.4(0.0375) = 10.74 cm/min
Tm = (31.25 + 1.25)/10.74 = 3.0261 min; this reduces diameter to 9.375 cm
N = 90 100/9.375 = 305.5 rev/min,
fr = 305.5(0.0375) = 11.456 cm/min
Tm = (31.25 + 1.25)/11.456 = 2.8369 min to reduce the diameter to 8.75 cm
Loading and unloading bar takes 5.0 min.
Total cycle time = 5.0 + 3.0261+ 2.8369+ 3.0 + 3.0261+ 2.8369 = 19.726 min

20.17 (30%) Solution:

(a) N = 75(100)/7.5 = 318.3 rev/min
fr = 318.3(5)(0.015) = 23.87 cm/min
A= D/2=7.5/2=3.75cm
Tm = (30 + 3.75)/23.87 = 1.4137 min
3
(b) RMR = 6.25(0.375)(23.87) = 55.95 cm /min
(c) The cutter travels 1.25 before making contact with the work. It moves 3.75
cm before its center is aligned with the starting edge of the 30 cm
workpiece. It then feeds the length of the work (30 cm). The overtravel
consists of the cutter radius (3.75 cm) plus an additional 1.25 cm. Thus,
Tf = (1.25 + 3.75 + 30 + 3.75 + 1.25)/23.87 = 1.6755 min

20.19 (30%) Solution:

9.75
cutter

2
(a) N = 112.5(100)/10 = 358 rev/min

fr = 358(4)(0.015) = 21.48 cm/min

Tm = 9.75/21.48 = 0.454 min

(b) RMRaverage = total removed volume/total time

2 3
= 0.25(9.75) (0.8)/0.454 = 131.56 cm /min
(c) RMRmax = point where the cutter just about covers the entire cylinder. In this

case it would be the same as milling a rectangle so RMR = wdfr

3
RMR = wdfr = 9.75(0.8)(21.48) = 167.54 cm /min