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engineering
materials science engineering

Questions and Answers of Materials Science Engineering

What is the principal cause of tool wear in ECM?
How is STEM related to ECM or the electrostream process?
Upon what factors does the metal-removal rate depend in ECM?
Why might chipless machining processes have greater importance in the future?
Why is the tool insulated in the ECM schematic?
Is ultrasonic machining really a chipless process?
Where, in the ultrasonic stroke, is the acceleration and deceleration of the tool the greatest? Given that F = ma, what does this mean about the force given to the grits in the slurry?
What is the nature of the surface obtained by electrodischarge machining?
What is the principal advantage of using a moving-wire electrode in electrodischarge machining?
What effect would increasing the voltage have on the metal-removal rate in electrodischarge machining? Why?
If you had to make several holes in a large number of delicate parts, would you prefer ECM, EDM, EBM, or LBM? Why?
What process would you recommend to make many small holes in a very hard alloy where the holes will be used for cooling and venting?
How do the MRRs for most NTM processes compare to conventional metal cutting?
Explain (using a little physics and metallurgy) why the "chips" in a thermal process like EDM are often hollow spheres?
One of the problems with waterjet cutting is that the process is very noisy. Why?
In AWC, what keeps the abrasive jet from machining the orifice?
Would AFM be useful for finishing the insides of an engine block? Why or why not?
What is thermal deburring and why does it not work on thermoplastics?
What are the steps in chemical machining using photosensitive resists?
What are the advantages of chemical blanking over regular blanking using punch and die methods?
Explain how multiple depths can be produced by chemical machining.
What are the two primary functions of a workholding device?
What are two reasons for not having drill bushings actually touching the workpiece? Notice in Figure 29-8 how many of the designs violate this rule. It is not uncommon to have conflicts and
Why does the use of down milling often make it easier to design a milling fixture than if up milling were used?
What do we do to workholding devices to make them more flexible?
Explain why the use of a given fixture may not be economical when used with one machine tool but may be economical when used in conjunction with another machine tool.
What are roll-over jigs, and what advantages do they offer?
In the clamps shown in Figure 29-18, what is the purpose of the spherical washer?
What is the purpose of dimensioning the strap clamp assembly in Figure 29-18 with letters?
Figure 29-2 showed locator buttons. Why not have the part rest on the flat plate?
What distinguishes a jig from a fixture?
In Figure 29-7, where aren't there three points put on the X plane, two points on the Z plane and one point on the Y plane?
To prepare the workpiece shown in Figure 29-7, which surface would you have milled first, the bottom, the back, or the front?
For the part shown in Figure 29-7, why don't you drill the holes first, then mill? Why mill at all?
The holes are countersunk after they are drilled. How must the jig be designed to put the countersinks on the mounting holes while the part is in the jig or would this operation be done afterward?
An early treatise defined a jig as "a device that holds the work and guides a tool." Why was this definition incorrect?
Why would an ordinary vise not be considered to be a fixture?
What basic criteria should be considered in designing jigs and fixtures?
What are the critical surfaces of a part (i.e., what makes a part surface critical)? (This question requires an understanding of basic part drawings.)
What difficulties can result from not keeping clamping stresses low in designing jigs and fixtures?
Explain the 3-2-1 concept for workpiece location.
Using the following values, determine the number of pieces that would have to be made to justify the use of a jig costing $3,000.
Suppose in the sample problem in Section 29.14 that modular fixturing is used, which reduces the toolmaker's labor to 4 hours and the design cost to $100 (4 hours at $25 per hour), that the material
Here is a typical problem in clamping force analysis (Figure 29-A). A milling cutter is face milling the top surface of a 1500-lb casting. The cutting force is 1800 lb, and the thrust force is 900
Suppose the jig in Figure 29-7 could be improved by replacing the screw clamps with toggle clamps. Many things are needed to be able to cost justify the improvement in the jig. This problem requires
To install an overhead crane (Figure CS-29) in one bay of the Strom Manufacturing Company, an assembly plant, brackets for the rails of the crane are to be mounted on eight columns, four on each side
What is the reason for using a taper tap before a plug tap in tapping a hole?
What difficulties are encountered if full threads are specified to the bottom of the dead-end hole?
Can a fluteless tap be used for threading a hole in gray cast iron? Why or why not?
What is the major advantage of a spiral-point tap?
Can a fluteless tap be used for threading to the bottom of a dead-end hole? Why or why not?
Is it desirable for a tapping fluid to have lubricating qualities? Why?
How does thread milling differ from thread turning?
Why has thread rolling become the most commonly used method for making threads?
What five requirements must be met for gears to operate satisfactorily? Which of these are determined by the manufacturing process?
What are the advantages of helical gears compared with spur gears?
What difficulty would be encountered in hobbing a herringbone gear?
What modification in design is made to herringbone gears to permit them to be cut by hobbing?
When a helical gear is machined on a milling machine, the table lead screw and the universal dividing head have to be connected by a gear train. Why?
What is meant by the designation M20 × 2.5-6g6g? (What does the "×" mean?)
In cutting a thread on a lathe, how is the pitch controlled?
Calculate the cutting time needed to tap a 3/4 × 2 in. hole using a cutting speed of 30 sfpm.The tap has 10 tpi.
The new manufacturing manager has recommended to you that chipless tapping be adopted for tapping holes in the deep, dead-end holes on the 2 cylinder engine blocks that the company makes. Chipless
A hob that has a pitch diameter of 76.2 mm is used to cut a gear having 36 teeth. If a cutting speed of 27.4 m/min is used, what will be the rpm value of the gear blank?
If the gear in Problem 3 has a face width of 76.2 mm, a feed of 1.9 mm/rev of the workpiece is used, and the approach and overtravel distances of the hob are 38 mm, how much time will be required to
In Figure 30-19 a form-milling operation and cutters are shown. The gear is to be made from 4340 steel, Rc50 prior to heat treat and final grind. Select the proper speeds and feeds for the job (the
A gear broaching machine of the type shown in Figure 30-20 can do the gear in 15 seconds (about 240 parts per hour). How many additional gears per year are needed to cover the broaching tooling cost
Assume that 10,000 spur gears, 11 in. in diameter and 1 in. thick are to be made of 70-30 brass. What manufacturing method would you consider?
If only three gears described were to be made, what process would you select?
KC Stern, a design engineer for Boeing Commercial Airplane Group, is doing some design work and has a question regarding the hole size that is drilled before tapping internal threads. The book
The machine shop at the Pogi Space Laboratories received an order from their engineering department for 100 of the vented cap screws shown in Figure CS-30. The machine shop foreman returned the
What are some possible objectives of surface modification processes?
What is the ideal geometry for belt sanding? What types of geometric features would be difficult for belt sanding?
What are some of the mechanisms of alkaline cleaning, and what types of soils can be removed?
In view of its many attractive features, why has vapor degreasing become an unattractive process?
How are burrs made by the milling process?
Describe the process of thermal energy deburring.
What is the difference between coating and cladding operations?
What are some of the factors that should be considered when selecting a surface modification process?
What are some of the reasons that paints may be specified for manufactured items?
What are some of the functions of a prime coat in a painting operation? What features are desired in the final coat?
What features make industrial robots attractive for spray painting?
What are the attractive properties of hard chrome plate?
How is the surface and its integrity altered by the process of metal cutting?
What are some of the common process variables in an electroplating cell?
Why is it difficult to mix parts of differing size and shape in an automated electroplating system?
When anodizing aluminum, what features determine the thickness of the resulting oxide when the oxide is not soluble in the electrolyte? When it is partially soluble?
What types of particulate composites can be deposited by electroless plating?
What are some of the sources of foreign material on the surface of manufactured products?
Do all machining processes leave a residual stress?
Why would the depth of damage (i.e., plastic deformation) increase with negative rake angle cutting tools?
Why do fatigue failures almost always occur at the surface?
What is a "stress raiser"?
Why might processes that produce residual compressive stresses on product surfaces be attractive for mechanically loaded products?
Describe why there might be an optimum fill level in barrel finishing; an optimum rotational speed.
Describe the primary differences between barrel finishing and vibratory finishing.
Fishermen are among the most superstitious people in the world, and their superstitions affect the type of equipment that they use. As a result, hook manufacturers generally offer their products in a
The Tonto Company requires 25,000 collars as shown in Figure CS-31. They are to be made from AISI 304 (18-8) stainless steel by machining on a screw machine using transfer and slotting attachments.
What human attribute is replaced by a machine capability for the first five levels of automation?
How does feedforward differ from feedback in a process control system?

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