MSA Fall 2011 Manufacturing & Metal Cutting ISE 443X (Elective II) Dr.

Araby Ibrahim Assignment 2: Due Oct. 8 Answer the following: 1) Distinguish between generating and forming when machining workpart geometries. -Generating: it is known as a relative motion between tool and workpart where part geometry is determined by feed trajectory of cutting tool -Forming: it depends on the shape of the cutting tool where part geometry is created by the shape of the cutting tool. 2) Give two examples of machining operations in which generating and forming are combined to create workpart geometry. -Thread Cutting on a lathe machine -Slot milling on a vertical milling machine 3) What is the difference between threading and tapping? -Threading: it is a tool which is fed linearly across the surface of a rotating workpart parallel to axis of rotation and a large feed rate. -Tapping: a tool is used to provide internal screw threads on an existing hole 4) How does a boring operation differ from a turning operation? -Boring: it is performed on the inside diameter of an existing hole -Turning: it is performed on the outside diameter of an existing cylinder -Also, Boring is considered to be an internal turning operation 5) Describe the various ways in which a workpart can be held in a lathe. -Holding work between centers using a dog (clamps the work and is driven by a dog plate), a center (located at the headstock end.

-Chuck: it is 3 adjustable jaws that are used to clamp workparts. -Collet: it is a subtype of chucks; it forms a collar around the object to be held and exerts a
strong clamping force on the object when it is tightened. -Face plate: it is the same as a chuck but used for non-cylindrical workparts where it has 4 clamps in order to hold rectangular parts.

6) What is the difference between peripheral milling and face milling? -Peripheral milling:a. Cutter axis parallel to surface being machined b. Cutting edges on outside periphery of cutter -Face milling:a. Cutter axis perpendicular to surface being milled b. Cutting edges on both the end and outside periphery of the cutter

7) Describe profile and pocket milling. -Profile Milling: it is a form of end milling in which the outside periphery of a flat part is cut. -Pocket milling: it is another form of end milling used to mill shallow pockets into flat parts. 8) Describe the difference between up milling and down milling?

-Up milling: The direction of the cutter rotation opposes the feed motion.

-Down milling: The direction of cutter rotation is same as the feed motion 9) How do shaping and planning differ?

-Shaping machine: the tool moves back and forth to perform the cutting operation while the table moved to perform feed. -Planning machine: the work piece table moves back and forth to perform cutting operation while the tool moves performing the feed.

10) What is the distinguishing feature of a radial drill press? It is designed for large parts where the head can be moved along an arm that rotated from the machine's column and it is able to operate over a large area without having to reposition the workpiece.