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Machining

The document is a worksheet for the Mechanical Engineering Program at Texas A&M University at Qatar, focusing on principles of materials and manufacturing in machining. It includes definitions, comparisons, calculations, and explanations related to machining processes, tool wear, and factors affecting surface finish. Students are required to complete various tasks, including labeling diagrams, answering questions, and performing calculations related to machining operations.

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Hamza Elhelw
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16 views4 pages

Machining

The document is a worksheet for the Mechanical Engineering Program at Texas A&M University at Qatar, focusing on principles of materials and manufacturing in machining. It includes definitions, comparisons, calculations, and explanations related to machining processes, tool wear, and factors affecting surface finish. Students are required to complete various tasks, including labeling diagrams, answering questions, and performing calculations related to machining operations.

Uploaded by

Hamza Elhelw
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Spring 2025

Mechanical Engineering Program


Texas A&M University at Qatar
MEEN 223: Principles of Materials and Manufacturing
Machining Worksheet

1. Define the following:

• Cutting Speed:

• Feed Rate:

• Depth of Cut:

2. Complete labeling the main components of the lathe machine shown below:

3. Fill in the following table to compare between Turning and Milling:

Turning Milling

Workpiece Motion _____________________________ ______________________________

Tool Motion _____________________________ ______________________________

Typical operations _____________________________ ______________________________


Spring 2025

4. List two types of chips and explain when they are likely to form:

5. Sketch or describe the following types of tool wear:

a) Flank Wear

b) Crater Wear
6. What is the function of a chip breaker? Why is it important?

7. Explain one benefit of using carbide tools over high-speed steel (HSS):

8. List three factors that influence surface finish in machining.

9. Explain why studying the types of chips produced is important in understanding cutting operations. Also
Explain why continuous chips are not necessarily desirable. Name the factors that contribute to the formation
of discontinuous chips.

10. Explain the difference between positive and negative rake angles. What is the importance of the rake angle?
Explain how a dull tool can lead to negative rake angles.

11. Explain what is meant by the term machinability and what it involves. Why does titanium have poor
machinability?

12. Is material ductility important for machinability? Explain

13. What are the effects of performing a cutting operation with a dull tool? A very sharp tool?

14. Tool life can be almost infinite at low cutting speeds. Would you then recommend that all machining be done
at low speeds? Explain.

15. Describe your thoughts regarding the recycling of chips produced during machining in a plant. Consider chips
produced by dry cutting versus those produced by machining with a cutting fluid.

16. How would you reduce the surface roughness shown in Figure? Explain.
Spring 2025

17. Given the equations in the lecture, how would you improve the wall roughness in drilling, and what would
improve surface roughness. Are there other factors that can help surface roughness but are not mentioned in the
equation? List the factors that contribute to poor surface finish in cutting.

18. Estimate the machining time required to rough turn a 0.50-m-long annealed copper-alloy round bar, from a 60-
mm diameter to a 58-mm diameter, using a high-speed steel tool. (See Table 23.4.) Estimate the time required
for an uncoated carbide tool. Note: the cutting time, t, for a workpiece of length, 𝑙, can be calculated by noting
that the tool travels at a feed rate of f v = fN with units of (mm/rev)(rev/min) = mm/min, therefore by knowing
that the distance traveled is 𝑙 mm, then you can find the cutting time.
Spring 2025

19. A 304 stainless steel rod is being turned on a lathe. The rod is initially 20 mm diameter and becomes 19 mm in
a single cut. The spindle speed is 300 rpm, and the tool feed rate is 200 mm/min. SCE is 4.0 J/mm3. Calculate:
a) MRR
b) Feed (f)
c) Cutting Speed
d) How much power is required?

20. A 150 mm long, 12.5 mm diameter 304 stainless steel rod is being reduced in diameter to 12.0 mm by turning
on a lathe. The spindle rotates at N = 400 rpm and the tool is traveling at an axial speed of 200 mm/min.
Calculate the cutting speed, MMR, cutting time, power dissipated and cutting force.
Note: The cutting force, Fc, is the tangential force exerted by the tool where
Torque = Fc Davg / 2 (Davg = Average diameter between the initial and final diameter)
Power is the product of the torque T, and the rotational speed in rad/min, i.e. Power = Torque x ω.

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