MANU 2381 - Theory of Metal Machining

Multiple Choice

Machining process is considered under which category of manufacturing processes?

• Mechanical fastening

• Shaping processes

• Property enhancing processes

• Assembly operations

Multiple Choice

Define machining process.

• Material removal by hard, abrasive particles

• Various energy forms other than sharp cutting tool is used to remove material

• Material removal by a sharp cutting

Multiple Choice

Which one is NOT material removal process?

Multiple Choice

What are 1, 2, and 3?

• 1 - workpart

  2 - chip

  3 - cutting tool

• 1 - chip

  2 - workpart

  3 - cutting tool

• 1 - cutting tool

  2 - chip

  3 - workpart

• 1 - chip

  2 - cutting tool

  3 - workpart

Multiple Select

Pick the advantages of machining operations (more than 1 answer)

• Machining can be applied to a wide variety of work

  materials. Virtually all solid metals can be machined. Plastics and plastic composites can also be cut by machining. Ceramics can be successfully cut by the abrasive machining processes

• Machining can be used to create any regular geometries, such as flat planes, round holes, and cylinders. By introducing

  variations in tool shapes and tool paths, irregular geometries can be created,

  such as screw threads and T-slots.

• Machining can produce dimensions to very close

  tolerances. Some machining processes can achieve tolerances of 0.025 mm

  (0.001 in), much more accurate than most other processes.

• Machining is capable of creating very smooth surface

  finishes. Roughness values less than 0.4 microns can be achieved in

  conventional machining operations. Some abrasive processes can achieve even

  better finishes.

Multiple Select

What are the two relative motions in machining processes? (pick two)

• Depth of cut

• Cutting speed

• Table speed

• Feed

Multiple Choice

Which one is turning operation?

Multiple Choice

What is the difference between peripheral milling and face milling?

• The axis of workpiece rotation

• The feed direction

• The axis of tool rotation

• The value of cutting speed

Multiple Choice

What are the name of the two surfaces of a cutting tool and their corresponding angles?

• Rake face - rake angle

  &

  Flank face - relief angle

• Flank face - rake angle

  &

  Rank face - relief angle

• Chip face - rake angle

  &

  Machined surface - relief angle

• Machined surface - rake angle

  &

  chip face - relief angle

Multiple Choice

How do you define the material removal rate?

• How fast the cutting tool moves over time

• How much the workpiece material is being removed over time

• How long the cutting process takes place

• How much the cutting tool penetrate below the original work surface

Multiple Choice

What is the function of cutting fluid?

• to cool and lubricate the chip

• to cool and lubricate the machined surface

• to cool and lubricate

  the cutting tool

• to cool and lubricate the original workpart

Multiple Choice

What are the name of the machine tools used to perform turning operation?

• Drill press

• Lathe

• Milling machine

• Rotating machine

Multiple Choice

The ______ determines the

direction that the chip flows as it is formed from the work part;

and the ______ provides a small clearance between the tool flank and the newly generated work surface.

• relief angle,

  rake angle

• shear angle,

  relief angle

• rake angle,

  relief angle

• rake angle,

  shear angle

Multiple Choice

As the chip thickness increases, the shear strain will be _____.

• increased

• decreased

• maintained

Multiple Select

Formation of the chip depends on _____ and

_____.

• the cutting conditions of the operation

• the material of cutting tool

• the type of material being machined

• the shape of the material being machined

Multiple Choice

These chips are semi-continuous in the sense that they possess a saw-tooth

appearance that is produced by a cyclical chip formation of alternating high

shear strain followed by low shear strain. This fourth type of chip is most closely

associated with certain difficult-to-machine metals such as titanium alloys,

nickel-base superalloys, and austenitic stainless steels when they are machined

at higher cutting speeds. However, the phenomenon is also found with more

common work metals (e.g., steels) when they are cut at high speeds.

• Continuous chips

• Serrated chips

• Discontinuous chips

• Continuous chips with BUE

Multiple Select

Several forces can be defined relative to the orthogonal cutting model. Based on

these forces, what relationships can be defined? (more than one answer)

• coefficient of friction

• shear stress

• strain rate

• Feed rate

Multiple Select

Which types of forces can be measured? (more than one answer)

• Thrust force

• Shear force

• Normal force

• Cutting force

Multiple Choice

Based on the Merchant equation, it is suggested to _____ the rake angle and _____ the coefficient of friction.

• reduce, reduce

• reduce, increase

• increase, reduce

• increase, increase

Multiple Choice

Uncut chip thickness in turning is equivalent to ____.

• Depth

• Feed

• Cutting speed

• cutting force