17.1 What are the three basic categories of material removal processes?
Answer. As organized in this text, the three basic categories of material removal processes are (1) conventional machining, (2) abrasive processes, and (3) nontraditional processes.
17.2 What distinguishes machining from other manufacturing processes?
Answer. In machining, material is removed from the work part so that the remaining material is the desired part geometry.
17.3 Identify some of the reasons why machining is commercially and technologically important.
Answer. The reasons include the following: (1) it is applicable to most materials; (2) it can produce a variety of geometries to a part; (3) it can achieve closer tolerances than most other processes; and (4) it can create good surface finishes.
17.4 Name the three most common machining processes.
Answer. The three common machining processes are (1) turning, (2) drilling, and (3) milling.
17.5 What are the two basic categories of cutting tools in machining? Give two examples of machining operations that use each of the tooling types.
Answer. The two categories are (1) single point tools, used in operations such as turning and boring; and (2) multiple edge cutting tools, used in operations such as milling and drilling.
17.6 What are the parameters of a machining operation that are included within the scope of cutting conditions?
Answer. Cutting conditions include speed, feed, depth of cut, and whether or not a cutting fluid is used.
17.7 Explain the difference between roughing and finishing operations in machining.
Answer. A roughing operation is used to remove large amounts of material rapidly and to produce a part geometry close to the desired shape. A finishing operation follows roughing and is used to achieve the final geometry and surface finish.
17.8 What is a machine tool?
Answer. A machine tool can be defined as a power driven machine that positions and moves a tool relative to the work to accomplish machining or other metal shaping process.
17.9 What is an orthogonal cutting operation?
Answer. Orthogonal cutting involves the use of a wedge shaped tool in which the cutting edge is perpendicular to the direction of speed motion into the work material.
17.10 Why is the orthogonal cutting model useful in the analysis of metal machining?
Answer. Orthogonal cutting is useful in the analysis of metal machining because it simplifies the rather complex three-dimensional machining situation to two dimensions. In addition, the tooling in the orthogonal model has only two parameters (rake angle and relief angle), which is a simpler geometry than a single-point tool.