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Machining
Grinding Milling Tapping Holes etc
| Question | Answer |
|---|---|
| Surface Grinding | Its a semi automated process, where a grinding wheel passes over a flat surface to polish it. e.g. Slideways on a bed lathe |
| Cylindrical Grinding | Its a semi automated process, where a grinding wheel passes over a cylinder surface as the surface rotates at the same time to polish it. eg Drill spindle or quill |
| Loaded Wheel | When a very soft material is ground on a wheel, it will stick to the wheel before the chips break off. The wheel then becomes smooth and dangerous. |
| Glazed Wheel | When a very hard material is ground on a wheel, it will wear the chips before they can break off. This makes the wheel very smooth and it will no longer grind the workpiece. |
| Continuous chip | Formed when machining a ductile material. It comes off as one long strand and is a health hazard. However it is a sign of the formation of an excellent surface finish |
| Discontinuous chip | Formed when marching a hard material such as brass. The swarf is removed as a fine powder or small chips depending on feederate and spindle speed. |
| Build Up Edge | When a ductile material such as aluminum is machined, it can become plastic and stick to the Rake face, changing the tool geometry. This can impact energy usage and material finish. |
| Balancing a grinding wheel | This is a necessary Safety procedure. It is done by sticking small weights to the wheel to prevent vibration and catastrophic failure due to fatigue. |
| Generating a Surface | When a surface is created by the rotation of the work and tool movement. E.g. Parallel turning and facing off. |
| Forming a surface | When the shape / geometry on the workpiece match's the shape of the tool. |
| Rake Angle | This is the angle that deflects the swarf away from the cutting edge. |
| Clearance Angle | This angle allows the cutting edge to 'Dig In' or engage and cut the work. It prevents the tool from rubbing |
| Wedge Angle | This forms the cutting edge. It it is the cutting angle of the tool created by the rake and clearance angle. |
| Narcotic effects | Effects on the body due to inhaling vapors and substances such as paint and cutting fluids when they are rancid. It can causse headaches and sickness. |
| Servo Motor | Used to create movement in higher speed applications. It allows very precise rotation eg 3d printer |
| Stepper Motor | Used to create movement in low speed high load applications. It allows very precise rotation eg CNC Machine |
| G Code | Determine the tool movement in the CNC process. different codes are used for facing off and parallel Turing for example. |
| M Code | Determines the actions of the spindle. eg to go forward or reverse or turn on / off. |
| Tool Offset | It is the starting point of the tool prior to machining. It is the distance the tool, is on the Z axis from the work. |
| Toothed belt | Connects to a motor in a system to create rotary motion. it often can rotate a screw to create linear movement. e.g. the bed of a CNC Lathe. |
| Magnetic chuck | Used for rapid clamping and release of work of ferrous materials during milling and grinding. |
| Additive Manufacturing | When a material is added to generate an artefact eg 3d Printing |
| Subtractive manufacturing | When material is removed when creating an artefact eg milling and Turning. |
| Rancidity | When a cutting fluid gets old and used a lot it gets a bad smell like rotten eggs |
| Irritant | When chemicals react with the skin (paint and cutting fluids) causing it to get red, itching and crack. |
| Spindle Speed | The speed of a rotating chuck. It is measured in RPM. The smaller a workpiece gets on a lathe the faster it should spin in order to cut effectively. |
| Feed Rate | The movement of a cutting tool measure in mm/ min |
| Dept of cut | The thickness of material removed by the cutting tool. |
| Peripheral Milling | The axis of the tool is parallel to the workpiece. The surface finish results in parallel lines on the surface. Sometimes called SLAB Milling |
| End / Face Milling | The profile being created is machined by two surfaces on the work. One edge will end up with parallel lines and the other will result in eccentric circles as the surface finish |
| Backlash Eliminator | This removes any play on the leadscrew and is necessary for down cut milling to prevent the work being pulled into the cutter. |
| Upcut Milling | The chip starts small and increases in size. It allows the force on each tooth to gradually increase. It pushes the work away from the cutter. |
| Downcut milling | The chip starts wide and gets smaller. It places a sudden force on the tooth o the cutter. It can pull the workpiece into the cutter. |
| Straddle milling | A series of cutters are placed along an arbor and can be separated by spacers. |
| Purpose of the End Gear Train on the Lathe? | It connects the Spindle to the leadscrew to create a relationship between the chuck rotation and the tool movement to cut a screw |
| An application of a crank and slider in machining? | It changes rotary motion of a motor to reciprocating motion of a tool. e.g. Shaping Machine or old style Power Hacksaw. |
| An application of an eccentric cam on the Lathe | It creates the necessary movement for locking the Tailstock to the Bed. |
| Application of the worm and wormwheel in engineering | In the dividing head to connect the chuck to the crank using a gear ratio of 40:1 |
| Application of a dividing head | To index material on the dividing head such as cutting gears. |
| What is a Radial Force in Machining? | The cutting force pushes the tool perpendicular, and away from the work and towards the operator. E.g. when chamfering on the Lathe |
| What is a Tangential force in machining? | The chip forces the tool downwards on the Lathe |
| What is an Axial force in machining? | This deflects the tool parallel to the workpiece and away from the chuck eg when parallel turning |
Created by:
Engineeringmcs