Production Technology

ENG124

Group:22

Name: Omar Aly Said

ID:20210301

Sheet for Production Technology

Supervised by Dr: Amir Aly

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1. Classify the Types of Engineering Materials?

2. What are the General Considerations for Manufacturing a Product?

• Material Selection
• Processing Methods
• Final Shape and Appearance
• Dimensional and Surface Finish
• Economics of Tooling
• Design Requirements
• Safety and Environmental Concerns.

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3. State the Advantages and Disadvantages of the Machining Process?
advantages with Machining:
Variety of work materials can be machined.
– Most frequently used to cut metals
• Variety of part shapes and special geometric features possible, such as:
– Screw threads
– Accurate round holes
– Very straight edges and surfaces
• Good dimensional accuracy and surface finish
• It may be more economical to machine the part than manufacture it by other
process, particularly if the number of parts required is relatively small.
Disadvantages with Machining:
• Wasteful of material
– Chips generated in machining are wasted material, at least in the unit operation
• Time consuming
– A machining operation generally takes more time to shape a given part than
alternative shaping processes, such as casting,
powder metallurgy or forming.
• Unless carried out properly, material-removal processes can have adverse
effects on the surface integrity of the product, including fatigue life (Disturbing
residual stresses equilibrium)

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4. Write Brief Notes on Two Types of Chips?
(a) Discontinuous chip:
• when relatively brittle materials (e.g., cast irons) are machined at low cutting
speeds, the chips often form into separate segments. This tends to impart an
irregular texture to the machined surface.
• secondly, high tool-chip friction and large feed and depth of cut also promote to
the formation of this kind of chip.

(b) Continuous chip:

• when ductile materials are cut at high speeds and relatively small feed and
depths, long continuous chips are formed. A good surface finish typically results
when this chip type is formed.
• a sharp cutting edge on the tool and low tool-chip friction also encourage the
formation of continuous chips.

5. Write Brief Notes on Two Types of Cutting Tool Materials?

A. Single-Point Tools:
One dominant cutting-edge.
Point is usually rounded to form a nose radius Turning uses single point tools.
B. Multiple Cutting Edge Tools:
More than one cutting edge.
Motion relative to work achieved by rotating Drilling and milling use rotating
multiple cutting-edge tools.

6. What are the composite materials? Give examples?

A composite is composed of two (or more) individual materials (metals, ceramics, and
polymers). A composite is made to achieve a combination of properties that is not
displayed by any single material.
Ex: - reinforced plastics (Carbon Fiber Reinforced Polymer), metal-matrix and
ceramic-matrix composites, honeycomb structures.
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7. State the manufacturing processes for metals?
• Casting: expendable mold and permanent mold.
• Forming and Shaping: rolling, forging, extrusion, drawing, sheet forming, powder
metallurgy, molding.
• Machining: turning, boring, drilling, milling, planing, shaping, broaching, grinding,
ultrasonic machining, chemical machining, electrical discharge machining (EDM),
electrochemical machining, high-energy beam machining
• Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical
joining
• Finishing: honing, lapping, polishing, burnishing, deburring, surface treating, coating,
plating.

8. Describe the relative motions between the workpiece and the cutting tool,
with examples?
There is relative motion between the workpiece and the
cutting tool, these are:
1. Primary motion: Cutting motion (defined by cutting speed)
2. Secondary motion: Feed motion (defined by the feed rate)
3. Depth of cut (defines the amount of plunging of the tool into the
workpiece)

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9. Describe with a sketch the function of tool angles?
# Rake angle: is important in controlling both direction of chips flow and the
strength of tool tip.
# Positive rake angles: improve the cutting operation by reducing forces and
temperatures. However, positive angles result in a small included angle of the tool
tip which may lead to premature tool chipping and failure.
# Side rake angle is more important than the back rake angle (Which usually
controls the direction of chip flow).
# Cutting-edge angle affects chip formation, tool strength, and cutting forces to
various degrees. Typically, they are around 15.̊

# Relief angle controls interference and rubbing at the tool workpiece interface.
# If the relief angle is too large, the tool tip may chip off, if it is too small, flank
wear may be excessive. Relief angles typically are 5.̊
# Nose radius affects surface finish and tool-tip strength.
# The smaller the nose radius (sharp tool), the rougher the surface finish of the
workpiece and the lower the strength of the tool. However, large nose radii can
lead to tool chatter.

10.Mention the properties of materials?

1. Mechanical Properties: strength, toughness, ductility, hardness,
elasticity, fatigue, creep.
2. Behavior Under Loading: tension, compression, bending, torsion,
shear.
3. Physical Properties: density, specific heat, thermal, expansion, thermal
conductivity, melting point, electrical and magnetic properties.
4. Chemical Properties: oxidation, corrosion, degradation, toxicity,
flammability.

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11.What are the classifications of machining processes?

12.State the independent and dependent variables of the cutting process?

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13.Why there are different types of cutting tools?
Cutting tools are typically made from high-speed steel, carbide, or ceramic materials,
and they must be sharp and properly maintained to achieve the best results.

14.Explain with Sketch the Cutting Tools Classifications?

1. Single-Point Tools
#One dominant cutting edge.
#Point is usually rounded to form a nose radius.
Turning uses single point tools.
2. Multiple Cutting Edge Tools
#More than one cutting edge
#Motion relative to work achieved by rotating.
Drilling and milling use rotating multiple cutting-edge tools.

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15.Explain in Detail the Positive, Negative and Zero rake angles?

1. Positive Rake:
As shown in the diagram, positive rake offers sharp cutting edge and also less
chip deformation during machining action. Cutting force and thus power
requirement during machining with positive rake is quite less. It also helps in
achieving better machinability. However, due to small value of wedge angle, tool
life reduces. Any impact loading during machining may cause catastrophic failure
of the tool, which is highly undesirable. High cutting temperature also makes
such tool vulnerable. Therefore, cutting tool with positive rake is beneficial
where the workpiece material is ductile and soft as well as when continuous chip
formation is desirable.

2. Negative Rake:
Negative Rake—Opposite to the positive rake, negative rake offers a strong tool
tip, which makes the tool more resilient under impact loading. It also resists
plastic deformation at high cutting temperature because of the thick cutting edge
which can absorb and at the same time dissipate more heat. Thus, tool with
negative rake provides longer tool life. However, due to large wedge angle, shear
deformation of the chip becomes more, and thus higher cutting force is required.
Negative rake usually provides discontinuous chips, which is bad in terms of
machinability.

3. Zero Rake:
Zero Rake—As shown in the figure, zero rake is the intermittent of the positive
and negative rake. It can provide advantages of both of them; however, to some
extent.

16.Differentiate between orthogonal and oblique cutting?

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17.What is the difference between roughing and finishing operations?
• Roughing:
- removes large amounts of material from starting work part.
- Creates shape close to desired geometry but leaves some material for finish cutting.

- High feeds and depths, low speeds.

• Finishing - completes part geometry
-Final dimensions, tolerances, and finish.
-Low feeds and depths, high cutting speeds.

18.Explain with drawing the generating and forming operations in

machining processes?
Generating:

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 the geometry of the work part is determined by the feed trajectory of the cutting
tool. Examples of generating the work shape in machining includes straight turning,
taper turning, contour turning, peripheral milling and profile milling.
Forming:
the shape of the part is created by the geometry of the cutting tool. In effect, the
cutting edge of the tool has the reverse of the shape to be performed on the part
surface. Form turning, drilling, and broaching are examples of the case.

19.Define with sketch the chip thickness ratio?

Chip thickness after cut always greater than before,
so chip ratio always less than 1.0
where r = chip thickness ratio; t o = thickness of the chip
prior to chip formation; and t c = chip thickness after
separation

20.Describe the Chip Formation Process?

The material of work piece is stressed beyond its yield point under the compressive
force. This causes the material to deform plastically and shear off. The plastic flow
takes place in a localized region called shear plane.
As shown in the figure, Regions of primary heat generation are also indicated:
• 1: shear deformation of the bone,
• 2: friction between the bone chip and tool and
• 3: friction between the tangential bone surface and tool.

21.What are the different types of chips?

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 Chips are mainly classified into three types:
1. Discontinuous chip:
when relatively brittle materials (e.g., cast irons) are machined at low cutting speeds,
the chips often form into separate segments. This tends to impart an irregular texture
to the machined surface.

2. Continuous chip:
when ductile materials are cut at high speeds and relatively small feed and depths,
long continuous chips are formed. A good surface finish typically results when this
chip type is formed.

3. Continuous chip with Built-up Edge (BUE):

when machining ductile materials at low-to-medium cutting speeds, friction
between tool and chip tends to cause portions of the work material to adhere to
the rake face of the tool near the cutting edge. This formation is called a built-up-
edge (BUE).

4. Serrated chip:
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 and followed by low shear strain.

22.Explain in Detail the chip breakers and its purpose?

• Long, continuous chips are undesirable since:
– become entangled and greatly interfere with machining
– potential safety hazard

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 • chip-breaker: breaks chips intermittently with cutting tools.
• Traditionally are clamped to rake face: bend and break the chip.
• Modern tools: built-in chip breakers
• Ideal chip: “C” or “9” shape
• The purposes of chip breakers:
–The chip breakers are used to break the chips into small pieces for removal,
safety and to prevent both the machine and work damage.
–The chip breakers are classified into three types, step, groove and Clamp type.
23.What are the Three Main Regions of Heat Generation in the Cutting Process and
Describe How is it Dissipated in Cutting?
-There are three main sources of heat when cutting:
▪ Heat is produced as the tool deforms (works) the metal.
▪ Friction on the cutting face.
▪ Friction on the tool flank.

-Heat is mostly dissipated by:

▪ The discarded chip carries away heat.
▪ Coolant will help draw away heat.
▪ The work piece acts as a heat sink.
▪ The cutting tool will also draw away heat.
24.What are the bad effects of high cutting temperature?
• Reduce tool life.
• Produce hot chips that pose safety hazards to the machine operator.
• Can cause inaccuracies in part dimensions due to thermal expansion of work material.
25.Describe the tool wear in cutting process?
Tool wear is still a significant problem in cutting. Typical types of tool wear include flank
wear and crater wear.
26.State the types of the cutting tool materials?

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 1. CBN - Cubic Boron Nitride.
2. ceramic.
3. HSS - High Speed Steel.
4. PCD - Polycrystalline Diamond.
5. WC - Tungsten Carbide.
6. coated WC - Tools coated with Tungsten Carbide.
27.Define the Tool life and State the Factors Affecting it?
Tool life is the time a tool can reliably be used for cutting before it must be
discarded/repaired. Some tools, such as lathe bits are regularly reground after use.
State the Factors Affecting it:
1. cutting velocity=V
2. tool life=T
3. constant based on the tool material=n
4. constant based on the tool work=C

28.Explain with drawing three operations can be done by turning process?

▪ Facing:
The tool is fed radially into the rotating work on one
end to create a flat surface on the end.

▪ Contour turning:
Instead of feeding the tool along a straight line
parallel to the axis of rotation as in turning, the tool
follows a contour that is other than straight, thus
creating a contoured form in the turned part.

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 ▪ Form turning:
In this operation, sometimes called forming, the tool
has a shape that is imparted to the work by plunging
the tool radially into the work.

29.Describe the boring and reaming process?

➢ Boring:
consists of producing circular internal profiles in hollow workpieces or on a hole made by
drilling or another process and is carried out using cutting tools that are similar to those
used in turning.
➢ Reams:
• remove small amounts of material to ensure exact hole size and improve hole surface
finish.
• either hand operated or machined at slow speed

30.What are the advantages and disadvantages of turning process?

❖ Advantages:
1. All Materials Are Interchangeable:
While turning is mainly used to machine metals, any material can be used in turning,
including wood and plastic. This makes turning a very flexible process.
2. Tolerance is Excellent:
Turning can be used to create parts with extremely high tolerances. Because of the high
tolerances and surface finishes that turning can offer, the process is often used for adding
precision rotational features to a part whose basic shape has already been formed
through a different method.
3. The Lead Time is Short:

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 Turning has a short lead time. Lead time is the time between when the customer places
an order and when the customer gets the final delivery. Because turning is a fast process,
the lead time is short.
4. There is No Need for a Highly Skilled Operator:
Turning does not require a highly skilled operator of the machine. To handle a CNC lathe,
a machinist can complete a set amount of coursework and earn certification from an
accredited industrial training organization.
5. The Pace of Material Removal is Adjustable:
Another advantage of turning is that the pace of removing material is adjustable. Lathes
can operate at different speeds depending on the machined material or the desired end
product.

❖ Disadvantages:
1. Only Rotatable Components Are Permitted:
Since turning requires the workpiece to be rotated, only rotatable components
can be turned. This means that the size of the parts that can be created with
turning is limited.
2. Parts May Need Many Procedures and Machines:
Turning may end up being only one process used to create a part. It is often
used in conjunction with other procedures, which means more than one
machine is required to make the final product.
3. Expensive Equipment:

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 Turning machines can be expensive, especially if CNC. In addition, turning
requires extra fittings and attachments, which increase the cost of the
equipment.
4. Tool Wear is Significant:
The repetitive motion of turning means that the cutting tool is subject to
significant wear.
5. It Creates a Substantial Amount of Scrap:
As with most machining processes, turning creates scrap metal. The bits of
metal produced from turning operations are known as chips in North America,
and in some areas, they may be called turnings.

31.What are the parameters affecting the energy required for turning process?
1-Workpiece Material properties. 2-Coolant.
3-Feed rate. 4-Part holding fixture.
5-Cutting speed. 6-Tool wear.
7-Diameter of the workpiece. 8-Geometry and set-up.
9-Turning time. 10-Depth of cut.
32.Discuss the differences between rotational parts and prismatic parts in
machining?

rotational work part:

rotational work part has a cylindrical or disk-like shape. The
characteristics operation that produces this geometry is one in
which a cutting tool removes material from rotating work part.
Examples include turning and boring. Drilling is closely related
except that an internal cylindrical shape is created, and the tool
rotates in most drilling operations.

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prismatic parts:
prismatic part is block-like or plate like. This geometry is achieved by linear motions of
the work part, combined with either rotating or linear tool motion. Operations in this
category include milling, shaping, planning, and sawing.

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 Sheet 2
Answer all the following Problems.

1) Let 𝑛 = 0.5 and 𝐶 = 90 in the Taylor equation for tool wear. What is the
percent increase in tool life if the cutting speed is reduced by (a) 50% and
(b) 75%?

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2) Taking carbide as an example and using the equation for mean temperature
in turning on a lathe, determine how much the feed should be reduced in
order to keep the mean temperature constant when the cutting speed is
doubled.

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3) An orthogonal cutting operation is being carried out under the following
conditions: 𝑡𝑜 = 0.1 𝑚𝑚, 𝑡𝑐 = 0.2 𝑚𝑚, width of cut =5 𝑚𝑚, 𝑉 = 2 𝑚/𝑠, 𝑟𝑎𝑘𝑒
𝑎𝑛𝑔𝑙𝑒 = 10º, 𝐹𝑐 = 500, and 𝐹𝑡 = 200 𝑁. Calculate the percentage of the total
energy that is dissipated in the shear plane.

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4) For a turning operation using a ceramic cutting tool, if the speed is increased
by 50%, by what factor must the feed rate be modified to obtain a constant
tool life? Use 𝑛 = 0.5 and 𝑦 = 0.6.

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5) Using the equation for surface roughness to select an appropriate feed for
𝑅 = 1 𝑚𝑚 and a desired roughness of 1 𝜇𝑚. How would you adjust this feed
to allow for nose wear of the tool during extended cuts? Explain your
reasoning.

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