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245 Cards in this Set
- Front
- Back
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Turning
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A process in which the workpiece is turned while being machined// process in which straight, conical, curved or grooved workpieces are produced, such as shafts, spindles and pins
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Facing
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Produces a flat surface at the end of the part// useful for parts attached to other components or face grooving to produce grooves for O-ring seats
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Form tools
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Specially made tool for a particular geometry to produce a specific shape for functional purposes or appearance
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Boring
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Enlarges a hole or cylindrical cavity or to produce circular internal grooves
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Drilling
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Produces a hole, which can be expanded by boring to improve accuracy and surface finish
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Parting/Cutting off
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Cuts a piece from the end of the part// done in production of slugs or blanks for further manufacturing
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Threading
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Produces external or internal threads
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Knurling
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Produces a regularly shaped roughness on cylindrical surfaces, as in making knobs
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Lathe
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Maching turning operations can be performed on
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Rake angle
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Controls direction of chip flow and strength of tool tip// positive RA improved cutting by reducing forces and temp but result in small included angle and may chip and fail
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Side rake angle
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More important than back rake angle
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Back rake angle
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Controls direction of chip flow
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Relief angles
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Control interference and rubbing at the tool-workpiece interface// if too large, tip may chip of; if too small, flank wear may be excessive
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Cutting edge angles
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Affect chip formation, tool strength and cutting forces
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Nose radius
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Affect surface finish and tool tip strength// smaller = rougher finish and lower strength; large = chatter
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Material Removal Rate
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volume of material removed per unit time// = pi * average diameter * depth of cut * feed (per rev) * N (rev per min)
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Cutting force
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Acts downward on tool tip// supplies energy required for cutting
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Thrust force/feed force
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Acts longitudinally
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Radial force
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Pushes tool away from workpiece
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Roughing cuts
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High feed rates and large cut depth// doesn't care about surface quality of dimensions
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Finishing cuts
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Lower feed rate and depth// Better surface finish and accuracy
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Engine lathe
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Most common early lathe// powered with overhead pulleys and belts from nearby engines; requires skilled machinist b/c all controls manipulated by hand; inefficient
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Bed
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Supports all major components of the lathe// large mass and rigid; gray or nodular cast iron; top portion has two ways with various cross sections
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Ways
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Guide tracks on lathe bed that are hardened and machined for wear resistance and dimensional accuracy during use
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Carriage
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Slides along ways and consists of cross slide, tool post and apron
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Cross slide
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Moves radially in and out controlling radial position of tool in operations such as facing
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Tool post
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Place where cutting tool is mounted
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Compound rest
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Swivels for tool positioning and adjustment on tool post
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Apron
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Mechanism by which the carriage can be moved manually and automatically by means of lead screw
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Lead screw
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Controls how the apron/carriage moves along lathe
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Headstock
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Fixed to bed and is equipped with motors, pulleys and V-belts that supply power to spindle at various speeds// equipped with hollow spindle for chucks and collets and workpieces
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Spindle
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Part of lathe that rotates with pieces
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Tailstock
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Can slide along ways and clamped into place support other end of workpiece// Equiped with center that can be fixed or free to rotate
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Quill
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hollow cylindrical part of tailstock with tapered hole for installing drills and reamers
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Feed rod
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Automatically controls movement of lead screw by set of gears from headstock// used to cut threads accurately
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Swing
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Maximum diameter of workpiece that can be machined
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Bench lathe
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Lathe placed on a workbench// low power, hand feed, precision machine small pieces
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Toolroom lathes
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High precision
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Gap bed lathes
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Part of bed can be removed to hold large diameter workpieces
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Special purpose lathes
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Used to make things like railroad wheels, gun barrels and rolling mill rolls
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Chuck
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Devices with jaws used to hold device onto lathes
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3 jaw chuck
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3 depended, self centering jaws hold cylindrical workpiece into place
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4 jaw chuck
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4 independent jaws hold irregularly shaped workpiece into place
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Power chuck
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pneumatically or hydraulically operated chucks used in automated equipment
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Collet
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longitudinally split tapered bushing// grips more of device than chuck
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Face plates
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used for clamping irregularly shaped workpieces
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Mandrels
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placed inside hollow or tubular workpieces// used to hold pieces requiring work on ends or cylindrical surface
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Automatic bar machine
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High production rate machining of threaded parts// single or multiple spindles
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Turret lathe
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can perform multiple turning operations on same workpiece// tools held and changed on hexagonal turret on main and four on square on cross slide;
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Chip management
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Collecting chips from their source in the machine tool and removing them from the work area
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Diamond turning
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Ultraprecision machining with a single crystal diamond cutting tool
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Ductile regime cutting
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in ultraprecision machining, nanometer cuts in hard and brittle materials cause continuous chips
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Screw thread
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ridge of uniform cross section that follows a helical or spiral path on the outside or inside of a cylindrical (straight thread) or tapered/conical surface (tapered thread)
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Tapping
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cutting internal threads
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Boring mill
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Machine used for boring large workpieces// vert or horiz; capable of turning, facing, grooving and chamfering
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Jig borers
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vertical boring machines with high precision bearings
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Drilling
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process in which holes are created in a workpiece
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High speed machining
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machining done at speeds of 600-1800 m/min, 1800-18k (very high), >18k (ultrahigh)
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Hard turning
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cutting hard materials on a lathe using very hard cutting tools such as polycrystalline cubic boron nitride
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ultraprecision machining
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creating workpieces with dimensional tolerance demands in micrometer and nanometer ranges
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Twist drill
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most common type of drill// 2 spiral flutes run length of drill; chips produced guided upward by grooves; fluids runs down these grooves
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Gun drilling
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used to make deep holes// depth to diameter 300:1 plus; thrust force balanced by bearing pads on dril that slide along inside surface; high speed low feed, high pressure cutting fluid through longitudinal hole in drill
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Trepanning
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cutting tool produces hole by removing a disk shaped piece (core) from flat pieces
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Drill MMR
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area of drill * feed * N
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Drill life
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number of holes until drilling force and torque begin to increase due to dulling
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Drill press
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vertical drilling machine
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Reaming
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(1) makes existing holes more accurate; (2) improves surface finish
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Reamer
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multiple cutting edge tool with straight or helically fluted edges that removes very little material
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Reconditioning
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sharpening drills manually or with special fixtures
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milling
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a number of highly versatile machining operations capable of producing a variety of configurations
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Milling Cutter
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a multi-tooth tool that produces a number of chips in one revolution
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Slab milling
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axis of cutter rotation is parallel to the workpiece surface being machined
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Conventional/up milling
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maximum chip thickness is at the end of the cut// advantages: tooth engagement is not a function of workpiece surface characteristic, contamination or scale on the surface does not affect tool life; common method of milling; smooth process with sharp teeth; disadv: chatter in tool and workpiece is pushed upwards, necessitating clamping
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Climb/down milling
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cutting starts at surface of workpiece where chip is thickest// advantage: downward motion secures workpiece; rigid setup necessary b/c of high impact forces
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Cutting speed (V)
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pi * cutter diameter * rotational speed
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Undeformed chip thickness (t_c)
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2 * feed per tooth * depth of cut / cutter diameter
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Feed per tooth (f)
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linear speed (feed rate) / (rotational speed * number of teeth on periphery)
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Cutting time (t)
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(length of workpiece + extent of cutter's first contact with workpiece) / linear speed
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Material removal rate for milling
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Assuming extent of cutter first contact with workpiece << length of workpiece:
width of cut * depth of cut * linear speed |
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Face milling
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cutter is mounted on a spindle with axis of rotation perpendicular to workpiece surface
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End mill
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cutter used for end milling// longer length and smaller face surace area than face cutter; used for making flat surfaces and various profiles
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End milling
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used for making flat surfaces and profiles
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High speed milling
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using an end mill to achieve good surface finish and dimensional accuracy// similar principles as in turning
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Die sinking
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producing cavities in small forging dies
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Straddle milling
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two or more cutters are mounted on an arbor and are used to machine 2 parallel surfaces on workpiece
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Form milling
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produces curved profiles// uses specially shaped teeth
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arbor
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shaft on which cutters are mounted
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shank type cutters
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cutters and shank are one piece
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Planing
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flat surfaces produced on workpiece
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Shaping
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similar to planing, but on smaller parts
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Broaching
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shaping with multiple teeth and used to machine internal and external surfaces
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Pull broaching
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straightens the hole
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Push broaching
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follows hole irregularities
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Sawing
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cutting operation where cutting tool is a blade with a series of small teeth
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Kerf
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width of cut in sawing
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Tooth set
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how the teeth are arranged to prevent "catching" during sawing// causes kerf
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Turn broaching
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crankshaft rotates between centers and broach removes material tangential to workpiece
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Friction sawing
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mild steel blade or disk rubs against workpiece// friction and heat causes metal to soften and cut
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Filing
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small scale removal of material from surface, corner or hole
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Rotary files and burs
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remove material in die making, deburring, scale removal from surfaces and producing chamfers
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Gear generating
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creating gears using: pinion shaped cutter, rack shaped straight cutter or hob
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Pinion shaped cutter
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one of the gears in a conjugate pairs and other as a gear blank
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Rack shaper
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straight rack cuts as it translate and gear is fixed, then gear is rotated
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Hob
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a worm or screw made into a gear generating tool by machining a series of longitudinal slots or gashes into it to form the cutting teeth
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Shaving
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a process in which a cutter made in the exact shape of the finished tooth profile// motion is reciprocating
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Burnishing
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Surface plastic-deforming process using a special hardened gear shaped burnishing die that subjects the tooth surfaces to a surface rolling action// does not improve gear tooth accuracy
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Form Grinding on Gears
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shape of the grinding wheel is identical to that of the tooth spacing
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Generating
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grinding wheel acts in a manner similar to the gear generating cutter previously mentioned
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Honing
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plastic gear impregnated with fine abrasive particles// faster than grinding and improves surface finish
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Lapping of a gear
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Improves surface finishing using either a gear shaped lapping tool or a pare of mating gears that run together
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Fly cutting
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milling with a single cutting tooth mounted on a high speed spindle
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Work holding in milling
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various fixtures, clamps and vises that hold to moving table
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Machining and turning centers
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devices able to complete a wide variety of operation in a single machine with computer controls and automation
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Transfer lines
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a series of different machines a workpiece is passed along to perform a certain set of operations
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Machining center
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computer controlled machine tool capable of performing a variety of cutting operations on different surfaces and different directions on a workpiece// workpiece is stationary and cutting tools rotate
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Pallet
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slab that the workpiece is put on in a machining center that can be moved and swiveled in various directions
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Automatic pallet changers
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remove and install pallets into machining centers to maximize efficiency
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Automatic tool changer
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removes and installs tools onto machining center to maximize efficiency and versatility
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Tool exchange arm
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swings to pick up specific tool and installs on spindle, and vice versa
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Tool/part checking station
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feeds information to computer controller about tool wear and surface conditions so that machining parameters can be adjusted
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Touch probes
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can be installed into tool holder to determine reference surfaces
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Work envelope
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maximum dimensions the tools can work around in a machining center
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Vertical spindle machining centers
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suitable for performing machining operations on flat surfaces with deep cavities
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Horizontal spindle machining centers
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suited for large as well as tall workpieces that require machining on a number of their surfaces
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Turning center
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computer controlled lathes with several features
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Universal machining centers
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equipped with both vertical and horizontal spindles// capable of machining all surfaces of a workpiece
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Modular design
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parts, equipment and features can be installed, removed and modified based on machining needs
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Chip collection
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managing how chips are removed from workpiece and machining center efficiently and safely
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Gray iron in machine tools
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low cost and good damping; heavy
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Welded steels in machine tools
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low cost, size availability, good formability, machinablility and welability; bad damping
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Polymer concretes in machine tools
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mixture of crushed polymers and concrete, easily cast, good damping, low stiffness, poor thermal conductivity, low tensile strength and brittle
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Ceramic components in machine tools
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Good strength, stiffness, corrosion resistance, surface finish and thermal stability;
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Composites in machine tools
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Polymer, metal and ceramic matrix with various reinforcing metals
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Granite epoxy composite in machine tools
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good castability, high stiffness to weight, thermal stability, resistance to environmental degradation and good damping capacity
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Stiffness
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function of dimensions and geometry of structural components and its elastic modulus
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What does damping depend on?
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function of types of materials used and the number and nature of joints
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Linear motor drives
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sliding surfaces in the drive of the guideway are separated by an air gap and supported by magnetic forces
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Hexapods
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octahedral self contained machine frame
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Forced vibration
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periodic applied force present in machine tool from gear drives, imbalanced components and motors/pumps
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Self excited vibration/chatter
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caused by the interaction of the chip removal process and the machine tool structure// high amplitude, typically begin due to disturbance in cutting zone
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Regenerative chatter
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caused when a tool is cutting a surface that has a roughness of disturbance left from previous cut; process continues repeatedly making it regenerative
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Dynamic stiffness
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ratio of the amplitude of the force applied to the amplitude of the vibration
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Damping
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rate at which vibrations decay
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Abrasive machining
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method improving surface quality of a workpiece after other processes had been performed on it
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Abrasive
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small, nonmetallic hard particle having sharp edges and an irregular shape
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Conventional abrasives
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aluminum oxide, silicon carbide
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Superabrasive
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Cubic boron nitride, diamond; 2 hardest materials known
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Friability
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ability of abrasive grains to fracture into smaller pieces and self sharpen
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Aluminum oxide
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fusing bauxite, iron filings and coke;
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Seeded gel
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purest form of unfused alumina; small particle size, sintered to form larger sizes, used for difficult to grind materials
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Silicon carbide
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silica sand, petroleum coke and NaCl; higher friability than AlOxides
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Cubic boron nitride
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suberabrasive
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Diamond
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Synthetic or industrial diamon, suberabrasive
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Grit number
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size of an abrasive grain; smaller grain size, larger grit number
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Bonded abrasive
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method of using a large number of abrasive particles at the same time by bonding them together
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Grinding wheel
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bonded abrasive in the form of an axisymmetric body
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Vitrified/ceramic bond
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A glass type bond used to hold together bonded abrasives// feldspar and clay; mixed with abrasives, molded and made// strong stiff porous and resistance to oils, acid and water; brittle and lack resistance to mechanical and thermal shock
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Resinoid bond
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Thermosetting resins, wheels also called organic wheels// made by mixing abrasive with liquid of powered phenolic resins and additives and pressing mixture
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Reinforced wheels
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Used in resinoid wheels to provide reinforcement to the flimsy resinoid bonds// retards disintegration
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Rubber bond
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Mix of crude rubber, sulfur and abrasive grains and rolling// thin wheels can be made for cutting operations
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Metal bonds
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Abrasive grains are bonded to the periphery of metal wheel to depths of 6 mm or less// bonding under high pressure and temp
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Grade of a bonded abrasive
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measure of the bonds strength// includes type and amount of bond in the wheel// also related to hardness
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"Structure" (of a bonded abrasive)
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measure of the porosity// dense to open
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Grinding
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chip removal process that uses an individual abrasive grain as the cutting tool
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Wheel depth of cut
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how far down on the surface the wheel is cutting
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Grain depth of cut
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undeformed thickness of the cut grain
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Sparks
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metal chips that glow resulting from exothermic heat reaction hot chips with oxygen in atmosphere
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Energy dissipated in grinding process
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consists of energy required to form chip, plow the surface of the material and overcome friction caused by rubbing grain along surface
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Wear flat
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flatness on grain because of grinding without breakage
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Specific energy
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energy required per unit volume of material removed
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Surface temperature rise
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directly proportional to: the wheel diameter ^ 0.25, depth of cut ^ 0.75 and (wheel surface velocity/wheel translational velocity)^0.5
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Grain force
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tangential force on the cutting wheel; directly proportional to: (wheel translational velocity over wheel velocity) * sqrt(depth of cut/diameter of wheel)
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Tempering
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excessive temperature rise in grinding causes softening of workpiece surface
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Burning
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high temp on surface of workpiece that causes oxidation on surface// reduces surface ductility and toughness
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Heat checking
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cracking of surface due to high temps during grinding
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Residual stresses
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caused by temperature gradients caused by grinding
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Low stress grinding
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lowering wheel speed and increasing workpiece speed
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Free cutting wheels
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softer grad wheels
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Attritious grain wear
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cutting edges of a sharp grain become dull by attrition// low when materials are chemically inert with respect to each other
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Grain fracture
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how fast the abrasives break to form new cutting surfaces
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Bond fracture
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breaking bonds to dislodge dull abrasives and expose sharp ones underneath
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Dressing
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process of producing sharp new edges on grains, conditioning worn grains on the surface of a grinding wheel and producing a true circle on an out of round wheel
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Glazing
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shiny appearance on wheel showing its dullness
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Loading
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porosities on wheel become clogged with chips
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Truing
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wheel is returned to original round shape
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Shaping/shaped wheels
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making a unique profile along the surface of the wheel for specialized grinding
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Grinding ratio
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volume of material removed to volume of wheel wear
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Act soft
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wear is high on grinding wheel
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Act hard
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wear is low on grinding wheel
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Grindability
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how easy it is to grind a material
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Ductile regime grinding
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producing continuous chips with good surface integrity
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Surface grinding
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grinding flat surfaces
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Cylindrical grinding
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cylindrical surfaces are ground and shoulders
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Thread grinding
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cylindrical grinding with specially dressed wheels matching shape of thread
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Internal grinding
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small wheel used to grind inside of part
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Centerless grinding
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grinding where workpiece is not held by it center but by a blade
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Snagging
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rough grinding of castings
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Creep feed grinding
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high wheel depth of cut (up to 6 mm) and workpiece speed is low
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Chatter marks
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marks left on the work piece due to chatter in grinding and other operations
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Bursting speed
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speed at which a freely rotating wheel bursts
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Ultrasonic machining
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material is removed from a surface by microchipping and erosion with fine abrasive grains in a slurry
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Rotary ultrasonic machining
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abrasive slurry replaced by a tool with metal bonded diamond abrasives impregnated or electroplated on tool surface// tool is ultrasonically vibrated while rotate and the workpiece is pressed against it at constant pressure
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Coated abrasives
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sandpaper and emery cloth with grains more pointed than those in grinding wheel
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Belt grinding
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belt of coated abrasive rotated and used to grind
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Microreplication
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controlling abrasive location on a coated abrasive
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Wire brushing
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workpiece held against a wire brush that rotates at high speeds
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Honing in milling
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used to give holes a fine surface finish// rotates stone in a hole applying a radial force with reciprocating axial motion
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Superfinishing
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light pressure applied honing and motion of stone has short stroke
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Lapping
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flattening operation by abrasive particles embedded in lap or carried in a slurry
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Polishing
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fine scale abrasive removal and softening and smearing the surface of a workpiece
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Chemical mechanical polishing
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chemically reactive surface is polished with a ceramic slurry in NaOH solution
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Electropolishing
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revese of electroplating// electrolyte attacks projections and peaks on surface at higher rate than rest of the surface
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Magnetic float polishing
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magnetic fluid surrounds workpieces in chamber within a guide ring; pieces are located between a drive shaft and a float; abrasive grains, workpieces and nonmagnetic float are suspended by magnetic forces and pieces are pressed against the rotating drive shaft and polished by abrasive action
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Magnetic field assistance polishing
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workpiece is clamped and rotated on a spindle/ magnetic poles are oscillated, causing a magnetic abrasive conglomerate to polish the surface of the workpiece
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Buffing
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similar to polishing, but very fine abrasives are used on soft disks made of cloth or hide
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Burrs
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thin ridges, usually triangular in shape, that develop on workpieces during manufacturing
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Deburring
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process by which burrs are removed
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Vibratory/barrell finishing
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improves surface finish and removes burrs from a large number of small workpieces// abrasive pellets are place in a container along with parts to be deburred and shaken
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Shot blasting/grit blasting
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abrasive particles propelled by high velocity jet of air or by rotating wheel onto surface of the workpiece
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Microabrasive blasting
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small scale polishing and etching on bench units, similar to shot blasting
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Abrasive flow machining
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abrasive grains are mixed into putty like matrix then forced back and forth through the opening and passageways of the workpiece
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Thermal energy to remove burrs
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burrs are melted away as the piece is put into an oven and baked
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Robotic deburring
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force feedback control of robots to remove burrs at locations where they are known to occur on a part
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Chemical machining
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based on principle that chemicals attack metals and etch them
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Reagents/etchants
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acids or alkaline solutions used to carry out chemical machining
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Chemical milling
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shallow cavaties are made on flat surfaces by causing reagents to selectivly attack certain sites
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Masking
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covering areas of a metal workpiece you dont want chemcially milled
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Chemical blanking
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Blanks a workpiece chemically by penetrating through thickness of material without burrs
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Photochemical blanking
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Similar to chemical milling, but done with photographic techniques
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Electrochemical machining
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reverse of electroplating; material is removed by elecric current
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Electrochemical grinding
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Combines electrochemical machining with conventional grinding
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Electrochemical honing
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combines fine abrasive action of honing with electrochemical action
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Electrical discharge machining
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eroding metal by spark discharges
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Overcut
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gap between tool and workpiece in EDM
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No-wear EDM
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Reversing the polarity and using copper tools
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Die sinking machining centers
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centers that use EDM to produce die cavities for large automotive body components
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Electrochemical discharge grinding
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electrochemical grinding + electrical discharge machining
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Wire EDM
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Wire travels through workpiece by cutting it with EDM as it goes along its desired path
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Laser beam machining
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cuts workpiece with optical energy// melts and evaporates workpiece in controlled manner
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Laser
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light amplification by stimulated emission of radiation
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Electron beam machining
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electrons strike workpiece and generate heat to cut workpiece// must be in vacuum
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Plasma arc cutting
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plasma beams (ionized gas) are used to rapidly cut ferrous and nonferrous sheets and plates
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Water jet machining/ Hydrodynamic machining
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highly concentrated jet of water used to cut material
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Abrasive water jet machining
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water jet machining with abrasive particles mixed into liquid
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Abrasive jet machining
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dry air, nitrogen or co2 containing abrasive particles are used for cutting
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