Chapter 3 Manufacturing Processes

Examples of subtractive manufacturing Correct Answers Milling, drilling, and turning. Fundamental concept of subtractive manufacturing Correct Answers reduce the volume of materials throughout the process Subtractive manufacturing transformation can be seen as an economical one because value is added when comparing original shape to new shape. Correct Answers True How is shape obtained for revolution parts? Correct Answers By revolving a profile around an axis How are multiple parts designed for revolution parts? Correct Answers the revolution feature What are revolution parts a primary indication of? Correct Answers That a lathe will be used to perform the turning operations How is shape obtained for prismatic parts? Correct Answers by extruding a profile along an axis How are multiple parts designed for prismatic parts? Correct Answers the extrusion feature What are prismatic parts a primary indication of? Correct Answers that a milling machine will be used to perform the machining operations Prismatic is typically... Correct Answers Casting, then milling Revolution is typically... Correct Answers Forging, then turning (& Milling) matches the design with the manufacturing resources, requires human analysis Correct Answers Process planner Process planning is at the heart of the numerical chain. Correct Answers True How does process planning work? Correct Answers links resources with the design to generate the process plan, including cutting conditions and strategy, enabling the manufacturing process Example of process planning Correct Answers Fixture Ears, where the process planner plans the link between the part and the fall off section Thin features require special manufacturing operations Correct Answers True tool attacks the material, chips are formed and ejected, rotation of tool, feed at which its advanced to attack the material, depth of the contact constitutes the cutting conditions Correct Answers Milling concept The tool attacks the material with what angle? Correct Answers a tool rake angle based on the tool geometry The material forms a chip and 'shears' at a... Correct Answers shear angle The shear location is actually a volumetric shear zone simplified as a plane Correct Answers True from hard, brittle materials and from two-phase materials that separate easily, such as for processing leaded steels and grey cast irons. (Preferred, good surfaces & safety aspects) Correct Answers Discontinuous Chips Sharp, long, and can be hot and dangerous, for processing steel and aluminum Correct Answers Continuous chips