BMM 4243 - MANUFACTURING TECHNOLOGY 2

TUTORIAL

1. What is metal cutting? Describe TWO (2) conditions of how metal cutting can be
carried out.

2. In general what are the characteristics of cutting tool materials?

3. What are the factors that affect the cutting speed and what is the effect of cutting
speed on the rate of material removal?

4. A zero or negative rake angle with smaller clearance angle is very suitable for
machining hard and brittle alloys. Explain why this is so.

5. List FOUR (4) different kinds of tool wear.

6. Cutting fluids are being effectively used in a machining operation. Describe what will
happen if the cutting fluid is turned off. Use the resulting impacts on the mechanics
of cutting operation (such as the tool-chip interface, shear angle, chip formation etc)
and the total energy consumption in your answer.

7. Differentiate between positive and negative rake angle in terms of

involved forces during metal machining.

8. Define Tangential Cutting Force and Axial Cutting Force using a diagram.

9. Machinability can be referred as the ability of a material to be machined. It depends

on too many factors. Give THREE (3) suggestions on how to improve machinability.

10. List EIGHT(8) types machining operations that can be done on a lathe machine.

11. Define turning processes or operations. Show the forces of cutting tool during
turning process using a diagram.

12. Describe the following types of cutting tools used in turning operations with a simple
sketchs: Turning tools, Facing tools and Cut-off tools.

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BMM 4243 - MANUFACTURING TECHNOLOGY 2

13. During turning process of a mild steel rod the tool life decreases from 80 min to 20
min due to the increase in cutting velocity, Vc from 60 m/min to 120 m/min. At what
cutting velocity of the life of that tool under the similar condition and environment
will be at 40 min?

14. The turning velocity with high speed steel (n: 1/5) cutting tool is 80 m/minutes in 60
minutes. Find the velocity if the cutting tool is the same as material where the time
given is 3 hours. Give conclusion on the effect of velocity toward the cutting tool life.

15. Forces involved in metal cutting can be estimated both experimentally and
theoretically. Experimentally, the material removal rate and specific cutting energy
are used. The workpiece is a mild steel bar with an initial diameter of 15 cm. The
rough cut is to be made at a feed rate F = 0.4 mm/rev and a depth of cut 0.4 mm.
The spindle rotates at 400 rpm. Calculate the material removal rate of the turning
process.

16. Explain the working of a boring and punching to create hole with a simple sketch.

17. What are the TWO (2) main causes or conditions for the tool wear to occur in
drilling? Which one of the operating parameters have the greatest effect on the
tool’s or cutter’s life?

18. Describe SIX (6) operations in drilling machine with some sketches.

19. Describe milling process.

20. With the aid of a sketch, explain the following:

i) Conventional Milling
ii) Climb Milling.

21. Differentiate between the sawing and broaching process with simple sketches.

22. Discuss the advantages and disadvantages of using high speed steel as a milling
cutting tool.

23. Define the terms abrasive grains.

24. Explain with neat sketches the following operations: Honing, Lapping and

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BMM 4243 - MANUFACTURING TECHNOLOGY 2

Superfinishing.

25. Describe a grinding wheel structure with the help of a neat sketch and state
different bonding and abrasive materials used in it. What would you like as an
abrasive for grinding steel?

26. What is non-traditional machining and when is it feasible? Give FOUR (4) conditions
of feasibility.

27. The choice of a correct electrode is important to increase productivity. Discuss the
important factors when selecting an electrode.

28. Describe the water jet cutting or machining process.

29. In general, explain the capabilities of photochemical machining?

30. Outline the list of process capabilities of Electrochemical Machining (ECM) and
Electrical Discharge Machining (EDM). Identify which is the appropriate product for
each process and why?