College of Technological Studies          Dept. of  Mech. Prod. Tech.     Production Technology (MEP232)

Final Exam – 2/2001/2002, Dec. 2001 – Group (1)  Time: [180 mins] -          Marks: [60]

 

 

Student Name:                                                                       Student Number:

 

Information for Student:

1) Answer All Three  questions

2) Answer should be  within the provided space on one side only.

2) Use descriptions and free-hand sketches as much as you can.

3) Assume any possible missing information.

4) No materials are allowed.

 

Question Number

Final [50]

Homeworks

Remarks

Question One [Twenty Marks]

 

 

 

Question Two [Fifteen Marks]

 

 

 

Question Three [Fifteen Marks]

Question Four [Ten Marks]

 

 

 

Total

 

 

 

Please note this is a cover page                      Exam starts ext page     


Question One: Milling Operations {Twenty Marks}

Cutter

Workpiece

Operation & Cutting Conditions

·           Coated Carbide Inserts.

·           Cutter Diameter (Dc)=20 cm.

·           Helical Teeth  Number (Z) = 20.

·           Hard Alloy Steel.

·           Specific Energy (Ks):40 kp/mm2

·           Material resistance (RI) : 0.5

·           Five gang slot milling with slot dimension 500*20*19 mm.

·           Cutting Speed (Vc): 2.0 m/sec.

·           Feed (F) =22.0  cm/min.

Part A) Operation Sketch   [Three and half Marks]

Part (B) Machining Time (Four and Half Marks)

 

 

 

a) Rough Machining Time (Tr) =  

 

b) Finish Machining Time (Tf) =

 

c) Total Machining Time (T) =


 


Results

Rough Time

Finish Time

Total Time

 

 

 

 

Part (C) Metal Removal Rate, Feed Power, Cutting Forces and Spindle Power and Torque [Seven Marks]

 

·          Metal Removal Rate (MRR) =

·          Feed (Table) Power =

·          Main Cutting Force (Fc) =

·          Radial Force Component (Fr) =

·          Axial Force Componet (Fa) =

·          Spindle Power (P) =

·          Torque on Cutter Arbor (Mtg) =

Results

MRR

Feed Power

Fc

Fr

Fa

P

Mtg

 

 

 

 

 

 

 

Part (D) Load Curve [Five Marks]

 

 

 

 

 

 

 

 

 

 

 

 


Discuss the above case from surface finish and dimensional accuracy point of views and, propose a better machining conditions

 

 

 

 

 

Question Two: Surface Grinding Operations [Fifteen Marks]

Cutter

Workpiece

Operation & Cutting Conditions

·           Grinding Wheel

·           Diameter (Dg)=100mm.

·           Width (bg) = 60 mm.

·           Hard Alloy Steel Block. [400*20*30 mm].       

·           Removed thickness (h) =3 mm. 

·           Work Strokes (Nw)= 2 ds/sec.

·           Wheel Speed=50 m/sec.

·           Rough & Finish depthes= 0.25 and 0.15 mm respectively.

·           Torque (Mtg) = 12 Kp.m.

 

 

 Part A) Operation Sketch (Three  Marks)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part (B) Speed, Feed, and Depth of Cut (Three  Marks)

 

 

 

a)    Wheel Speed (Vg) = 

b)     Vgf =

c)     Workpiece Speed (Vw) =

d)    & Vwf  =

e)     Relative Speed (Vr)

f)      Rough feed (Sr)

g)    Finish feed (Sf) =

h)     (itr) =

i)       (itf)   

 

 

j)      (iBr) =

k)     (iBf)

Results

Vgf

Vwf

Vr

Sr

Sf

Itr

itf

IBr

iBf

 

 

 

 

 

 

 

 

 

 

                                    Part (C) Machining Time (Three Marks)

 

 

a) Rough Machiming Time (Tr)    =

 

b) Finish Machining Time (Tf)       =

 

c)Total Machining time (T)           =         

 

 

Results

Rough Time

Finish Time

Total Time

 

 

 

Part (D) Cutting Forces and Power (Three Marks)

 

 

 

a) Main Cutting Force (Pz) =

 

b) Wheel Motor Power (Pg) =

 

c)Work Motor Power (Pw)

 

Results

Pz

Pg

Pw

 

 

 

 

Part (E) Draw Sketches indicating( Three Marks)

a)       Vertical Rotational SurfaceGrinding Operations        B) Internal Floating Grinding Operation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Question Three: Broaching Operations {Fifteen   Marks}

Cutter

Workpiece

Operation & Cutting Conditions

·           Internal 3-bit keyway Pull Broach on round surface

 

·           Hard Alloy Steel Block       

·           Slot Dimensions: 50 × 3 × 1.5 cm.

·           Specific Energy (Ks):3000 kp/cm2

 

·           Max Pulling Speed : 3 cm/sec.

·           Rough Depth per tooth =0.12 mm.

·           S-Finish Depth /tooth (tsf)=0.08mm.

·           Finish Depth/tooth (tf)=0.04 mm.

 

Part A) Broach Dimensions & Operation Sketch   (Five Marks)


 Part (B) Pitch Calculations (One and Half Marks)

 

Rough Pitch (Pr) =

        ·          Semi-Finish Pitch (Psf)=                                                                                                                

        ·          Finish Pitch (Pf) =

Involved teeth (Zir                                                                                               

        ·          Involved Thickness (hir)=                                                                                                                           

Results

Pr

Psf

Pf

hir

 

 

 

 

 

Part (C) Broach Parts Lengths Calculations (Two and Half Marks)

 

Rough Length (Lr) =

Semi-Finish length (Lsf) =

Finish-Length (Lf) =

Effective Length (Le) =

        ·          Total Length (Lb) =

Results

Lr

Lsf

Lf

Le

Lb

 

 

 

 

 

Part (D) Force and Power calculations (Three Marks)

 

 

Cutting Force (Pz) =

Consumed Power (P) =

Minimum Motor Power (Pm) =

 

 

Results

Pz

P

Pm

 

 

 


 


Part (E) Draw a sketch indicating the hydraulic driven broaching machine (Three marks)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Question Three: CNC Dyna Program {Ten   Marks}

 

 

Write a computer program in Conversational format for DYNA Milling machine.

Program the continuous path; use End mill tool diameter 10 millimeters.  Feed Rate 50 millimeters / Minute in XY plane and 40 millimeters / Minute along Z-axis.  Your tool path should be on the part boundary. Using Point to Point positioning program the hole locations, drill two holes (use same tool for drilling programming).  Depth of cut should not increase 4 millimeters for continuous path; depth of cut for drill holes should be 10 millimeters.

 

 

Q: 1           Write a computer program in Conversational                          format for DYNA Milling machine.

Program the continuous path; use End mill tool diameter 10 millimeters.  Feed Rate 50 millimeters / Minute in XY plane and 40 millimeters / Minute along Z-axis.  Your tool path should be on the part boundary. Using Point to Point positioning program the hole locations, drill two holes (use same tool for drilling programming).  Depth of cut should not increase 4 millimeters for continuous path; depth of cut for drill holes should be 10 millimeters.


 


First movement  is a rapid movement at the distance of X 10 mm , Y 10 mm from program reference zero.

Q: 1           Write a computer program in Conversational                          format for DYNA Milling machine.

 

Program the continuous path; use End mill tool diameter 10 millimeters.  Feed Rate 50 millimeters / Minute in XY plane and 40 millimeters / Minute along Z-axis.  Your tool path should be on the part boundary. Using Point to Point positioning program the hole locations, drill two holes (use same tool for drill programming).  Depth of cut should not increase 4 millimeters for continuous path; depth of cut for drill holes should be 10 millimeters.


First movement  is a rapid movement at the distance of X 10 mm , Y 10 mm from program reference zero.

 

 

First movement  is a rapid movement at the distance of X 10 mm , Y 10 mm from program reference zero.

 

 

Block Seq.

DYNA COMMANDS

 

Block Seq.

DYNA COMMANDS

 

Block Seq.

DYNA COMMANDS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1