Question

Figure Q4(a) a) Figure Q4(a) shows a product that is produced by various manufacturing processes. The processes include forging, casting, and machining. Explain at least 3 specific machining processes involved, in sequences and the effect of these machining processes on the environment. (7 marks) b) Turning operation is carried out on cast iron (200 BHN). Cutting speed = 4.5 m/s, feed = 0.2 mm/rev, and depth of cut = 2.0 mm. The lathe has a mechanical efficiency = 0.88. Based on the specific energy values in Table 21.2 (Attachment), determine (i) the cutting power and (ii) gross power in the turning operation, in Watts. (3 marks)

there is no information given regarding the energy values. I guess you can assume it.

Answer 1

(Page 1) a.) It is a Crank-shaft Manufacturing Process Involved are Forging, Casting and Machining After forging machining starts which is basically finishing stage- There are different machining process available such as Turning, milling, drilling etc. Sequence I Facing & Centering In this work piece is rotated to Produce a flat surface. After that centering allows to mark the centre point of cylinder 2. CAM Turning:

(Page 2) a.) Contd: 2. CAM Turning: It refers to the computer opelated turning process which produces Cylindrical components. Que Lathe machine is used for this cutting tool is traversed along ades of motion to produce precise diameters depth and 3 Drilling: This operation is also done on Lathe machine. All inner diameters are drilled in the crank-shaft geometry for oil-drilling holes.

(Page-3) a.) Contd Enviromental Machining Process generate many metal chips/dust, cutting Gluid, oil contaminated water, oil mist and un-necessary energy. These oil when flown in river, it affects the fishes and overall aquatic life. be) Given speed (V) = 4.5 m/s feed (f) - 0-2 mm/rev depth of cut (d)= 2.0mm Mechanical efficiency ( 2 mech )-0-88 # We assume specific energy U = 2.53/mm3

Workpiece rotation D D2 Feed direction Turning tool Copyright © 2007 CustomPartNet

(Page-4) b.) Conta! Cutting Power of Turning (Fc) = UX MRR - (ن) MRRC Material Removal Rate) = fx dxV - 0-2 x 2x4.5x10 mm/s MRR = 1800 mm/sec Now, from ean Fc= UX MRR = 2-55/mm3 2055/mm² x 1800 mm Fc 4 500 J/sec 4500 W 3 s ;;-) Gross Power For = Imech Fc usoo = 5113.636W 1) 0.88