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4500_HW2_Sol - MAE4500 Manufacturing Method HW#2...

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MAE4500 Manufacturing Method HW#2 Solutions-Fall Semester 2006 Q1) In down milling the feed motion is given in the direction of cutter rotation. Advantages: - Cut begins with a well-defined uniform chip thickness - The surface finish is good - Cutting direction holds down work piece, which means lower clamping force Limitations: - High initial forces require more rigid machine tool - Machine tool must be free of backlash. In up milling the feed motion is given in the direction opposite of cutter rotation. Advantages: - The tooth engages at a minimum depth. Starting forces are lower. Limitations: - The surface may become smeared or wavy. - This was the preferred method for older machines before the arrival of more rigid machine tools. 16C-12) (a) First, the hardness of the work piece material must be found. The metallurgical condition is not defined; assume either annealed or, for greater strength, cold worked. It is similar to 302 SS; from table 8-2, TS = 600 MPa, thus HB = 3(600)/9.8 = 183.
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