Produc�on Technology

ENG124

Group:22

Name: Omar Aly Said

ID:20210301

Sheet for Produc�on Technology

Supervised by Dr: Amir Aly

1. Classify the Types of Engineering Materials?

2. What are the General Considera�ons for Manufacturing a Product?

• Material Selec�on
• Processing Methods
• Final Shape and Appearance
• Dimensional and Surface Finish
• Economics of Tooling
• Design Requirements
• Safety and Environmental Concerns.
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, par�cularly if the number of parts required is rela�vely small.
Disadvantages with Machining:
• Wasteful of material
– Chips generated in machining are wasted material, at least in the unit opera�on
• Time consuming
– A machining opera�on generally takes more �me to shape a given part than
alterna�ve shaping processes, such as cas�ng,
powder metallurgy or forming.
• Unless carried out properly, material-removal processes can have adverse
effects on the surface integrity of the product, including fa�gue life (Disturbing
residual stresses equilibrium)
4. Write Brief Notes on Two Types of Chips?
(a) Discon�nuous chip:
• when rela�vely britle materials (e.g., cast irons) are machined at low cu�ng
speeds, the chips o�en form into separate segments. This tends to impart an
irregular texture to the machined surface.
• secondly, high tool-chip fric�on and large feed and depth of cut also promote to
the forma�on of this kind of chip.

(b) Con�nuous chip:

• when duc�le materials are cut at high speeds and rela�vely small feed and
depths, long con�nuous chips are formed. A good surface finish typically results
when this chip type is formed.
• a sharp cu�ng edge on the tool and low tool-chip fric�on also encourage the
forma�on of con�nuous chips.

5. Write Brief Notes on Two Types of Cu�ng Tool Materials?

A. Single-Point Tools:
One dominant cu�ng-edge.
Point is usually rounded to form a nose radius Turning uses single point tools.
B. Mul�ple Cu�ng Edge Tools:
More than one cu�ng edge.
Mo�on rela�ve to work achieved by rota�ng Drilling and milling use rota�ng
mul�ple cu�ng-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 combina�on of proper�es that is not displayed by
any single material.
Ex: - reinforced plas�cs (Carbon Fiber Reinforced Polymer), metal-matrix and ceramic-matrix
composites, honeycomb structures.
7. State the manufacturing processes for metals?
• Cas�ng: 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 trea�ng, coa�ng,
pla�ng.

8. Describe the rela�ve mo�ons between the workpiece and the cu�ng tool,
with examples?

9. Describe with a sketch the func�on of tool angles?

# Rake angle: is important in controlling both direc�on of chips flow and the
strength of tool �p.
# Posi�ve rake angles: improve the cu�ng opera�on by reducing forces and
temperatures. However, posi�ve angles result in a small included angle of the tool
�p which may lead to premature tool chipping and failure.
# Side rake angle is more important than the back rake angle (Which usually
controls the direc�on of chip flow).
# Cu�ng-edge angle affects chip forma�on, tool strength, and cu�ng 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 �p 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-�p 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 chater.

10.Men�on the proper�es of materials?

1. Mechanical Proper�es: strength, toughness, duc�lity, hardness,
elas�city, fa�gue, creep.
2. Behavior Under Loading: tension, compression, bending, torsion,
shear.
3. Physical Proper�es: density, specific heat, thermal, expansion, thermal
conduc�vity, mel�ng point, electrical and magne�c proper�es.
4. Chemical Proper�es: oxida�on, corrosion, degrada�on, toxicity,
flammability.
11.What are the classifica�ons of machining processes?

12.State the independent and dependent variables of the cu�ng process?

13.Why there are different types of cu�ng tools?
Cu�ng 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 Cu�ng Tools Classifica�ons?

1. Single-Point Tools
#One dominant cu�ng edge.
#Point is usually rounded to form a nose radius.
Turning uses single point tools.
2. Mul�ple Cu�ng Edge Tools
#More than one cu�ng edge
#Mo�on rela�ve to work achieved by rota�ng.
Drilling and milling use rota�ng mul�ple cu�ng-edge tools.

15.Explain in Detail the Posi�ve, Nega�ve and Zero rake angles?

1. Posi�ve Rake:
As shown in the diagram, posi�ve rake offers sharp cu�ng edge and also less
chip deforma�on during machining ac�on. Cu�ng force and thus power
requirement during machining with posi�ve rake is quite less. It also helps in
achieving beter 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 cu�ng temperature also makes
such tool vulnerable. Therefore, cu�ng tool with posi�ve rake is beneficial
where the workpiece material is duc�le and so� as well as when con�nuous chip
forma�on is desirable.

2. Nega�ve Rake:
 Nega�ve Rake—Opposite to the posi�ve rake, nega�ve rake offers a strong tool
�p, which makes the tool more resilient under impact loading. It also resists
plas�c deforma�on at high cu�ng temperature because of the thick cu�ng edge
which can absorb and at the same �me dissipate more heat. Thus, tool with
nega�ve rake provides longer tool life. However, due to large wedge angle, shear
deforma�on of the chip becomes more, and thus higher cu�ng force is required.
Nega�ve rake usually provides discon�nuous chips, which is bad in terms of
machinability.

3. Zero Rake:
Zero Rake—As shown in the figure, zero rake is the intermitent of the posi�ve
and nega�ve rake. It can provide advantages of both of them; however, to some
extent.

16.Differen�ate between orthogonal and oblique cu�ng?

17.What is the difference between roughing and finishing opera�ons?
• Roughing:
- removes large amounts of material from star�ng work part.
- Creates shape close to desired geometry but leaves some material for finish cu�ng.

- High feeds and depths, low speeds.

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

18.Explain with drawing the genera�ng and forming opera�ons in

machining processes?
Genera�ng:
the geometry of the work part is determined by the feed trajectory of the cu�ng
tool. Examples of genera�ng 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 cu�ng tool. In effect, the
cu�ng 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 ra�o?

Chip thickness a�er cut always greater than before,
so chip ra�o always less than 1.0
where r = chip thickness ra�o; t o = thickness of the chip
prior to chip forma�on; and t c = chip thickness a�er
separa�on
20.Describe the Chip Forma�on Process?
The material of work piece is stressed beyond its yield point under the compressive
force. This causes the material to deform plas�cally and shear off. The plas�c flow
takes place in a localized region called shear plane.
As shown in the figure, Regions of primary heat genera�on are also indicated:
• 1: shear deforma�on of the bone,
• 2: fric�on between the bone chip and tool and
• 3: fric�on between the tangen�al bone surface and tool.

21.What are the different types of chips?

Chips are mainly classified into three types:

1. Discon�nuous chip:
when rela�vely britle materials (e.g., cast irons) are machined at low cu�ng speeds,
the chips o�en form into separate segments. This tends to impart an irregular texture
to the machined surface.

2. Con�nuous chip:
when duc�le materials are cut at high speeds and rela�vely small feed and depths,
long con�nuous chips are formed. A good surface finish typically results when this
chip type is formed.
 3. Con�nuous chip with Built-up Edge (BUE):
when machining duc�le materials at low-to-medium cu�ng speeds, fric�on
between tool and chip tends to cause por�ons of the work material to adhere to
the rake face of the tool near the cu�ng edge. This forma�on is called a built-up-
edge (BUE).

4. Serrated chip:
These chips are semi-con�nuous in the sense that they possess a saw tooth
appearance that is produced by a cyclical chip forma�on of alterna�ng high shear
strain and followed by low shear strain.

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

• Long, con�nuous chips are undesirable since:
– become entangled and greatly interfere with machining
– poten�al safety hazard

• chip-breaker: breaks chips intermitently with cu�ng tools.

• Tradi�onally 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 Genera�on in the Cu�ng Process and
Describe How is it Dissipated in Cu�ng?
-There are three main sources of heat when cu�ng:
 Heat is produced as the tool deforms (works) the metal.
 Fric�on on the cu�ng face.
 Fric�on 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 cu�ng tool will also draw away heat.
24.What are the bad effects of high cu�ng 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 cu�ng process?
Tool wear is s�ll a significant problem in cu�ng. Typical types of tool wear include flank
wear and crater wear.
26.State the types of the cu�ng tool materials?
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 Affec�ng it?
Tool life is the �me a tool can reliably be used for cu�ng before it must be
discarded/repaired. Some tools, such as lathe bits are regularly reground a�er use.
State the Factors Affec�ng it:
1. cu�ng 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 opera�ons can be done by turning process?
 Facing:
The tool is fed radially into the rota�ng 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 rota�on as in turning, the tool
follows a contour that is other than straight, thus
crea�ng a contoured form in the turned part.

 Form turning:
In this opera�on, some�mes 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 cu�ng 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 plas�c. 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 o�en used for adding
precision rota�onal features to a part whose basic shape has already been formed
through a different method.
3. The Lead Time is Short:
Turning has a short lead �me. Lead �me is the �me between when the customer places
an order and when the customer gets the final delivery. Because turning is a fast process,
the lead �me 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 cer�fica�on from an
accredited industrial training organiza�on.
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 Permited:
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 o�en
used in conjunc�on with other procedures, which means more than one
machine is required to make the final product.
3. Expensive Equipment:
Turning machines can be expensive, especially if CNC. In addi�on, turning
requires extra fi�ngs and atachments, which increase the cost of the
equipment.
4. Tool Wear is Significant:
The repe��ve mo�on of turning means that the cu�ng tool is subject to
significant wear.
5. It Creates a Substan�al Amount of Scrap:
As with most machining processes, turning creates scrap metal. The bits of
metal produced from turning opera�ons are known as chips in North America,
and in some areas, they may be called turnings.

31.What are the parameters affec�ng the energy required for turning process?
1-Workpiece Material proper�es. 2-Coolant.
3-Feed rate. 4-Part holding fixture.
5-Cu�ng speed. 6-Tool wear.
7-Diameter of the workpiece. 8-Geometry and set-up.
9-Turning �me. 10-Depth of cut.
32.Discuss the differences between rota�onal parts and prisma�c parts in
machining?

rota�onal work part:

rota�onal work part has a cylindrical or disk-like shape. The
characteris�cs opera�on that produces this geometry is one in
which a cu�ng tool removes material from rota�ng 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 opera�ons.

prisma�c parts:
prisma�c part is block-like or plate like. This geometry is achieved by linear mo�ons of
the work part, combined with either rota�ng or linear tool mo�on. Opera�ons in this
category include milling, shaping, planning, and sawing.
 Sheet 2
Answer all the following Problems.

1) Let 𝑛𝑛 = 0.5 and 𝐶𝐶 = 90 in the Taylor equa�on for tool wear. What is the
percent increase in tool life if the cu�ng speed is reduced by (a) 50% and
(b) 75%?
2) Taking carbide as an example and using the equa�on 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 cu�ng speed is
doubled.
3) An orthogonal cu�ng opera�on is being carried out under the following
condi�ons: 𝑡𝑡𝑡𝑡 = 0.1 𝑚𝑚𝑚𝑚, 𝑡𝑡𝑡𝑡 = 0.2 𝑚𝑚𝑚𝑚, width of cut =5 𝑚𝑚𝑚𝑚, 𝑉𝑉 = 2 𝑚𝑚/𝑠𝑠, 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟
𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 10º, 𝐹𝐹𝐹𝐹 = 500, and 𝐹𝐹𝐹𝐹 = 200 𝑁𝑁. Calculate the percentage of the total
energy that is dissipated in the shear plane.
4) For a turning opera�on using a ceramic cu�ng tool, if the speed is increased
by 50%, by what factor must the feed rate be modified to obtain a constant
tool life? Use 𝑛𝑛 = 0.5 and 𝑦𝑦 = 0.6.
5) Using the equa�on for surface roughness to select an appropriate feed for
𝑅𝑅 = 1 𝑚𝑚𝑚𝑚 and a desired roughness of 1 𝜇𝜇𝜇𝜇. How would you adjust this feed
to allow for nose wear of the tool during extended cuts? Explain your
reasoning.