roughness; R_a=average R_rms=root mean square roughness; S_u=tensile strength; S_s=shear strength; S_y=yield strength; t_o=depth of cut; t_c=average chip thickness; P_c=cutting power;
V=cutting speed; MRR=material removal rate; U=unit power; R=resultant force; F=friction force; N=friction normal force; F_t=thrust force; F_c=cutting force; F_s=shear force; F_n=shear normal force;
f=feed; f_r=feed rate;
RELATIONSHIPS: -low/high tolerance : good/bad manufacturing -low/high unit power : easy/hard to machine -low/high unit power : soft/hard material -low/high resolution :
less/more precise measuring -slide/vernier caliper : less/more precise measuring -low/high ductility : low/high temperature -low/high strength : low/high tensile strength
-low/high strength : high/low temperature -low/high tensile strength : low/high hardness -low/high hardness : high/low temperature -low/high hardness : bad/good tool
performance -low/high shear angle : bad/good machining -low/high shear angle : high/low force -low/high shear angle : rough/smooth surface -small/high tool nose radius :
sharp/dull cutting edge -small/high tool nose radius : fragile/durable cutting edge -small/high tool nose radius : consistent/inconsistent shear angle -small/high tool nose radius :
smooth/rough cut -negative/positive tool rake : dull/sharp cutting edge -negative/positive tool rake : durable/fragile cutting edge -negative/positive tool rake : low/high shear angle
-down/up machining : smooth/rough surface -down/up machining : same/opposite direction of feed -low/high frequency (EDM) : big/small cut -low/high frequency (EDM) :
rough/smooth cut -low/high productivity : high/low time -low/high productivity : high/low cost -low/high productivity : low/high # of parts
TERMS: -Parallelism: height max minus height min (delta h) -Roundness: radius max minus radius min (delta R) +Eutectic Point: V-point on a phase diagram (liquid above the V),
lowest melting temperature
-Eutectoid Point: V-point on a phase diagram (solid above the V), optimal Carbon % and hardness -Depth of Cut: distance from the original height of the object to the height after the
cut -Shear Plane: extended line through the angle the chip gets forced up at -Shear Angle: angle between the shear plane and the original or final height of the object -Shearing Force:
force that is directed along the shear plane line -Average Chip Thickness: thickness/width of the chip, not the depth of the cut -Top Rake Angle: angle between the line perpendicular to
the object (line perpendicular to the velocity vector) and the face of the tool going towards the object - Chip Ratio: ratio between the depth of cut and the average chip thickness
(r=t_o/t_c) -Resultant Force: vector from the tip of the tool to the tail of the thrust force vector and the tip to the friction normal force vector - Friction Force: vector pointing away from
the object in the direction of the rake angle from the perpendicular line of the object surface (perpendicular to the velocity vector) - Friction Normal Force: vector from the tip of the
friction force vector to the tip of the resultant force vector -Thrust Force: vector from the tip of the resultant force vector to the tail of the cutting force vector, its tip is level with height
of the object after the cut, perpendicular to the surface of the object -Cutting Force: vector from the tip of the thrust force vector to the tip of the tool, along the line of the height of the
object after the cut, parallel to the surface of the object -Shear Force: vector along the line of the shear plane from the tip of the shear normal force to the tip of the tool - Shear Normal
Force: vector from the tip of resultant force vector to the tail of the shear force vector, perpendicular to the shear force vector - Friction Angle: angle between the resultant force vector
and the friction normal force vector -Point Angle: angle between the v-shape at the tip of the drill -Up Machining: the cutter is rotating toward the direction of the feed, rough surface
-Down Machining: the cutter is rotating in the same direction as the feed, smooth surface
UNITS: +Force: Newton (N) = [kg*m]/[s^2] +Pressure/Stress: Pascal (Pa) = [N]/[m^2] = [kg]/[m*s^2] +Energy/Work/Heat: Joule (J) = N*m= C*V = W*s = [kg*m^2]/[s^2]
+Power: Watt (W) = [J]/[s] = V*A = [kg*m^2]/[s^3] -Voltage: Volt (V) = [W]/[A] = [J]/[C] = [kg*m^2]/[A*s^3] -Electric Charge: Coulomb (C) = s*A -Volumetric Flow: [m^3]/[s]
-Angular Velocity: Omega ( ) = [rad]/[s] -Torque/Moment of Force: Newton Meter (N*m) = [m^2*kg]/[s^2] -Density/Mass Density: [kg]/[m^3] -Frequency: Hertz (Hz) = [1]/[s]
NOTES: +Surface Integrity: includes residual stress, cracks, plastic deformation, laps/folds/seams, voids/inclusions, hardness +Yield Strength: normally lower than tensile strength
+Tool Types (hardest to softest): Diamond, CBN, Coated WC, WC, HSS +Metrology includes measurement of dimension, form/shape, and surface +Standard time is bigger than
observed time +Manufacturing & Measurement: to assure product quality, to improve productivity; contact (mechanical principle), non-contact (physical principle) ;What: dimension,
form/shape, surface; -Gaging: determines whether the part characteristic meets or doesn't meet the design specifications - Calibration: process to correct an instrument -Resolution:
smallest measurable quantity -Effect of manufacturing process; Sand Casting: high tolerance, high R_a, worst quality Turning: medium tolerance, medium R_a, middle quality
Grinding/Honing: low tolerance, low R_a, best quality-Nominal Surfaces: the intended surface contour of the part; appear straight as lines, ideal circles, round holes, and other
geometrically perfect edges and surfaces +Surface Texture: consists of the repetitive and/or random deviations from the nominal surface of an object and is defined by roughness,
waviness, lay, and flaws +Surface Roughness: the average vertical deviations from the nominal surface over a specified surface length -Surface Finish: smoothness and general quality
of a surface -Surface Integrity: the study and control of the subsurface layer and any changes in it because of processing that may influence the performance of the finished part or
product -Primary (strong) Bonds: (ionic, covalent, metallic) strong atom-to-atom attractions that involve the exchange of valence electrons - Secondary (weak): (hydrogen, van der
waals) involve attraction forces between molecules - Crystalline Structures: closely packed, repeating pattern; BCC (body-centered cubic), FCC (face-centered cubic), HCP (hexagonal
close-packed) - Amorphous Structure (Non-crystalline Structure): ( glass, many plastics, rubber) less dense, random arrangement; - Super Alloys: can be used at high temperature; Liquidus Line: line above which material would be in liquid state; - Solidus Line: line below which material would be in solid state, - Steel: iron with less than 2% carbon, - Stainless
Steel: add Cr and Ni to suppress corrosion; - Cast Iron: iron with between 2%-5% carbon; - Hypo-Eutectoid Steel: iron with less than the carbon % at the eutectoid point, not enough
Carbon %, low carbon % weakens the alloy; - Hyper-Eutectoid Steel: iron with carbon percentage between the eutectoid point and where the solidus line levels out, too much Carbon
%, high carbon % weakens the alloy; -Optimal Carbon %: strengthens the allow, Junction of hypo-eutectoid steel and hyper-eutectoid steel; - Thermoplastics: repeat heating and
cooling (PMMA, ABS), no cross-linking, can be recycled; - Thermoset: heating and cooling once (epoxy), high degree of cross-linking; - Elastomers: stretch > 10X (rubber), lightly
cross-linked; - Cross-Linked Polymers: primary bonding between branches and other molecules at certain connection points; - Orthogonal Cutting: cutting edge perpendicular to
cutting direction; +Facing: squares up the end of a work piece, the tool is fed radially into the rotating work on one end to create a flat surface on the end + Taper Turning: the tool is fed
at an angle, thus creating a tapered cylinder/conical shape +Contour Turning: the tool follows a contour that is other than straight, thus creating a contoured form in the turned part
+Form Turning: (forming) the tool has a shape that is imparted to the work by plunging the tool radially into the work +Chamfering: the cutting edge of the tool is used to cut an angle
on the corner of the cylinder which is a "chamfer" +Cut-off: (parting-off) is like grooving but with a narrow tool advancing to center causing the finished part to fall off, the tool is fed
radially into the rotating work at some location along its length to cut off the end of the part +Threading: a pointed tool is fed linearly across the outside surface of the rotation work
part in a direction parallel to the axis of rotation at a large effective feed rate +Boring: enlarges and finishes a hole with a single point cutting tool like a turning tool, used to enlarge a
predrilled hole, drill set comes with fixed drill diameters +Drilling: (reaming) enlarges and finishes a previously drilled hole by removing a small amount of material with a rotating
fluted tool of the desired hole diameter, drilling can be performed on a lathe by feeding the drill into the rotating work along its axis + Knurling: not a machining process, it is a metal
forming operation used to produce a regular cross-hatched pattern in the work surface +Reaming: used to slightly enlarge a hole to provide a better tolerance on its diameter, and to
improve its surface finish +Tapping: performed by a tap and is used to provide internal screw threads on an existing hole +Counter-boring: provides a stepped hole in which a larger
diameter follow a small diameter partially into the hole +Counter-sinking: provides a cone shaped stepped hole, in which a large diameter follows a smaller diameter partially into the
hole for flat head screws and bolts +Centering: (center drilling) drills a starting hole to accurately establish its location for subsequent drilling +Spot Facing: used to provide a flat
machined surface on the work part in a localized area, similar to milling -Hole Making Procedure: center drill, drill, bore to size, ream, hone -Countersinking Procedure: center drill,
standard size drill, bore -Broaching: add features to a drilled hole, or make a non-circular hole -Peripheral/Plain Milling: the axis of the tool is parallel to the surface being machined,
performed by cutting edges on the outside periphery of the cutter -Face Milling: the axis of the cutter is perpendicular to the surface being milled, performed by cutting edges on both
the end and the outside periphery of the cutter -Adhesion: two metals are forced into contact under high pressure and temperature causing adhesion/welding to occur between them
-Tool Material Properties: toughness, hot hardness, wear resistance -Productivity: the most profitable procedure to produce parts
***Turning Operations***
***Drilling Operations***
***Milling Operations***
-Chapter Turning & Lathe Basics: shows turning, facing, reaming, knurling, parting off, and boring
-Chapter Grinding: demonstrates a ring test
-Chapter Measuring and Gaging: illustrates how to measure outer diameter