1.

Haw can to calculate: Engineering stress, Engineering strain and Hooke's

Law, True stress, and True strain

Engineering stress σ=F/Ao

Engineering strain e=(L-Lo)/Lo
Hooke’s Law (elastic region): σ=Ee
Truestresss σ=F/A
Truestrain ƹ=dL/L=ln(L/Lo)

2. Draw the Stress - strain diagrams

3. Camper between Temperatures in Metal Forming

Cold working Warm working Hot working

 Performed at room ◼ Performed at temperatures ◼ Deformation at temperatures

temperature or above room temperature but above the recrystallization
slightly above below recrystallization temperature
 Many cold forming temperature ◼ Recrystallization temperature =
processes are ◼ Dividing line between cold about one-half of melting point on
important mass working and warm working absolute scale
production operations often expressed in terms of – In practice, hot working usually
melting point:– 0.3Tm, where performed somewhat above 0.6Tm
 Minimum or no
Tm = melting point (absolute – Metal continues to soften as
machining usually
required temperature) for metal temperature increases above 0.6T
m, enhancing advantage of
hot working above this level
4. What are the advantages and disadvantages of Cold working
Advantages
◼ Better accuracy, closer tolerances
◼ Better surface finish
◼ Strain hardening increases strength
and hardness
◼ No heating of work required
5. What are the advantages and disadvantages of Warm working
Advantages
◼ Lower forces and power than in cold
working
◼ More intricate work geometries
possible
◼ Need for annealing may be reduced or
eliminated
◼ Low spring back
6. What are the advantages and disadvantages of Hot working
advantages
◼ Workpart shape can be significantly
altered
◼ Lower forces and power required
◼ Metals that usually fracture in cold
working can be hot formed
◼ Strength properties of product are
generally isotropic
◼ No work hardening occurs during
forming
disadvantages
◼ Higher forces and power required in
the deformation operation
◼ Ductility and strain hardening limit the
amount of forming that can be done
– In some cases, metal must be annealed
to allow further deformation
– In other cases, metal is simply not ductile
enough to be cold worked
disadvantages
◼Scaling of part surface
disadvantages
◼ Lower dimensional accuracy in case of
bulk forming
◼ Higher total energy required (due to
the thermal energy to heat the workpiece)
◼ Work surface oxidation (scale), poorer
surface finish
◼ Shorter tool life
7. Draw the Effect of annealing temperature on recovery, recrystallization
and grain growth of a clod-worked structure
 1. Define and Draw the shape of Machining Processes

Cutting action involves shear deformation of work material to form a chip.

• As chip is removed, a new surface is exposed.

2. Why Machining is Important? and what are Disadvantages

Important
• Variety of work materials can be machined
– Most frequently applied to metals.
• Variety of part shapes and special
geometry features possible, such as:
– Screw threads.
– Accurate round holes.
– Very straight edges and surfaces.
• Good dimensional accuracy and surface
finish.
Disadvantages
• Wasteful of material.
-Chips generated in machining are
wasted material, at least in the unit operation.
• Time consuming.
-A machining operation generally
takes more time to shape a given part than
alternative shaping processes, such as casting,
powder metallurgy, or forming.

3. Define and Draw the Turning process?

4. Define and Draw the Drilling process?

5. Define and Draw the Milling process?

6. Camper between the type of Cutting Tool

Single-Point Tools Multiple Cutting Edge Tools
 -One cutting edge
-Turning uses single point tools
-Point is usually rounded to form a
nose radius
-More than one cutting edge
-Motion relative to work usually
achieved by rotating
-Drilling and milling use rotating
multiple cutting edge tools.

7. Define the
- Speed ) V) : Relates velocity of the cutting tool to the work piece
(Primary motion).
- Feed (f): Amount of material removed per revolution or per pass of the
tool over the work piece. linear translation of tool with respect to the
work piece (Secondary motion)
- Depth of Cut (d) : Distance the tool has plunged into the surface
MRR = vfd

8. Haw can to calculate N, F ,Tm ,d, MRR

Rotational Speed: N (RPM’s) Feed Rate: fr (Dist/Min)
  fr = Feed Rate (Dist/Min)
N = Rotational Speed N = Rotational Speed
v = Cutting Speed f = Feed (Dist/Rev)
DO = Original Diameter
 
 Machining Time (Min.) Material Removal Rate
Tm = Machining Time (Min.) MRR = Material Removal Rate
L = Length of Cut v = Cutting Speed
fr = Feed Rate (In./Min.) f = Feed (Dist./Rev.)
d = Depth of Cut

where

DO = Original Diameter , Df = Final Diameter , d = Depth of Cut