Term
|
Definition
| attractive means of joining the various layers and can be applied to both metallic and nonmetallic materials. The lamination of polymer matrix composites often utilizes films of unpolymerized resin that are introduced between the layers. Pressing at elevated temperature then cures the resin and completes the load |
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Term
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Definition
| in dealing with tempered glass, this can be used to reduce unfavorable residual stresses that might lead to cracking |
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Term
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Definition
| Higher heats and pressures can be used when the part is cured in this, which limits the size of the product. The supporting molds and vacuum-bagged layups are placed inside a heated pressure vessel where curing occurs under elevated temperatures and pressures in the range 0.4 to 0.7 MPa (50 to 100 psi). |
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Term
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Definition
| used to convert resins into bottles and other hollow shape containers |
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Term
|
Definition
| To overcome failures in laminar-type composites such as interlaminar cracking and delamination upon impact, high strength reinforcing fibers can also be interwoven into 3D performs by processes that include weaving, stitching and ____ though the thickness of stacked 2D performs |
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Term
| Bulk-Molding Compound (475 |
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Definition
| fiber reinforced materials where short fibers are distributed in random orientation |
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Term
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Definition
| In the ____ process, a mass of dough-like thermoplastic is forced between and over two or more counterrotating rolls to produce thin sheets or films of polymer, which are then cooled to induce hardening |
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Term
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Definition
| This is the simplest of the shape forming processes because no fillers are used and no pressure is required.The thermoplastic polymer is simply melted and the liquid is poured into a container having the shape of the desired part |
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Term
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Definition
| This is an alternative method of producing strength that does not require elevated temperature. A liquid binder material is used to coat the ceramic particles, and a subsequent chemical reaction converts the liquid to a solid, forming strong, rigid bonds |
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Term
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Definition
| The fabrication processes applied to ____ materials generally fall into 2 distinct classes, based on the properties of the material: glasses if the material can be shaped by means of viscous flow, or crystalline ____ if the material is hard and brittle, with high melting points |
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Term
| Ceramic-matrix Composites (477) |
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Definition
| Unlike polymeric or metal-matrix composites, where failures originate in or along the reinforcement fibers, _____ often fail due to flaws in the matrix. If the reinforcement is bonded strongly to the matrix, a matrix crack will propagate right through to the fibers. |
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Term
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Definition
| These are based on special types of ceramics blended with water and various additives to produce a material that can be shaped by most of the traditional forming methods |
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Term
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Definition
| this, the uncured thermosetting material is pressed to shape while cold and is then removed from the mold and cured in a separate oven. |
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Term
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Definition
| engineered materials made from two or more constituent materials with significantly different physical or chemical properties which remain separate and distinct on a macroscopic level within the finished structure |
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Term
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Definition
| When production quantities are large and quality needs to be high, matched metal dies can be substituted for the mold and bag, the process then becomes a modification of this. In this, a sheet-molding compound, bulk-molding compound, or a preformed mat is placed on the press, and heat and pressure are applied. |
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Term
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Definition
| have a characteristically brittle behavior and are normally manufactured into useful components; cannot be formed by techniques requiring either plasticity or melting. processed in the solid state by techniques that utilize particles or aggregates and resemble those used in powder metallurgy. |
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Term
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Definition
| a special heat treatment that controls the nucleation and growth of the crystalline component, used to fabricate glass ceramics. |
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Term
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Definition
| process used to produce relatively thin parts with uniform wall thickness, such as boots, gloves, and fairings. The simplest fabrication process for rubbers and elastomers. |
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Term
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Definition
| used in the fabrication of crystalline ceramics, this is a common technique that enables dry powders to be pressed into useful shapes |
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Term
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Definition
| A material that behaves like rubber but is made from synthetic polymers and is superior to rubber in several mechanical or chemical properties. |
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Term
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Definition
| his is another practical means of bonding layers of metals. In this a piece of explosive material progressively detonates above layers to be be joined, causing a pressure wave to sweep across the interface |
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Term
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Definition
| Products such as inner tubes, graden hoses, tubing and strip moldings (long plastic products with uniform cross sections) can be produced by this, where a compounded material is forced through a die by a screw device similar to that described for plastics. |
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Term
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Definition
| used to reinforce composites; these are embedded in a selected matrix with the proper alignment and spacing to produce the desired properties. Can be continuous or discontinuous. |
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Term
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Definition
| s a fabrication technique for creating composite material structures. The process involves winding filaments under varying amounts of tension over a male mould or mandrel. The mandrel rotates while a carriage moves horizontally, laying down fibers in the desired pattern. |
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Term
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Definition
| his is a subsequent heating process; slurry –type materials must first be dried in a controlled manner that is designed to control dimensional changes and minimize stresses. The material is then heated to temperatures between .5 to .8 times the absolute melting point. AKA sintering |
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Term
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Definition
| in this, a foaming agent is mixed with the plastic resin and releases gas or volatilizes when the material is heated during molding |
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Term
|
Definition
| Glass can be manufactured into useful articles by first heating the material to produce a molten or viscous state, shaping the material by means of viscous flow, and then cooling the material to produce a solid product. Typically brittle, and optically transparent. |
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Term
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Definition
| part crystalline, part glass |
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Term
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Definition
| the layers of pliable resin coated cloth are placed in an open mold or draped over a form |
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Term
| Hot-isostatic Pressing 467 |
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Definition
| common technique in fabricating crystalline ceramics because crystalline ceramics cannot be formed by techniques requiring either plasticity or melting. Exhibit features and limitations similar to those discussed in ch 16. |
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Term
| Injection Molding 466 - I |
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Definition
| Injection molding of fiber-reinforced plastics is a process that competes with metal die castings and offers comparable properties at considerably reduced weight. In the simplest variation, chopped or continuous fibers are placed in a mold cavity that is then closed and injected with resin. |
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Term
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Definition
| metal, often incorporated into plastic products to provide enhanced performance or unique features. Can be used to provide threaded cavities, holes, and alignment pins in plastic parts. |
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Term
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Definition
| used in fabricating crystalline ceramics. Exhibits features and limitations similar to those discussed in ch 16. |
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Term
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Definition
| prepregs, mats, or tapes are stacked to produce a desired thickness and cured under pressure and heat. Resulting products possess unusually high strength properties as a result of the integral fiber reinforcement. |
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Term
|
Definition
| (laser molting) Prototypes or small production quantities of ceramic products have also been made by the laser sintering of ceramic powders. Parts are made by building up successive layers of material by laser sintering of thin layers of heat-fusible powder. For ceramic parts, the polymer coating on the powder is bonded by the laser. |
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Term
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Definition
| stacked to produce a desired thickness and cured under pressure and heat in the lamination process. |
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Term
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Definition
| is composite material with at least two constituent parts, one being a metal. The other material may be a different metal or another material, such as a ceramic or organic compound. When at least three materials are present, it is called a hybrid composite. An MMC is complementary to a cermet. |
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Term
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Definition
| Where the layers of liable resin-coated cloth are simply placed in an open mold or draped over a form. |
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Term
|
Definition
| A round, solid-bottom, hollow-tube preform. It is made from heated plastic by either extrusion or injection molding. |
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Term
|
Definition
| Is shown to be substantially different from metals in both structure and properties. Tends to be used closer to their design limits, and many fabrication processes convert the raw plastic into a finished product on a single operation. |
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Term
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Definition
| Involves the formation of a woven fabric that has been infiltrated with a matrix material. |
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Term
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Definition
| A flexible membrane is positioned over the female mold cavity and pressurized to force the individual plies together and drive out entrapped air and excess resin. |
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Term
|
Definition
| A continuous process that is used to produce relatively simple shapes of uniform cross section, such as round, rectangular, tubular, plate, sheet, and structural products. |
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Term
| Reaction injection molding 455 459 - P |
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Definition
| Process, in which two or more liquid monomers are metered into a unit where they are intimately mixed by the impingement of liquid streams that have been pressurized to a value between 13 and 20 MPa (2000 and 3000 psi). |
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Term
|
Definition
| In RTM the resin is injected or drawn into a mold, which contains the fibres, from a homogeniser under low pressure. |
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Term
|
Definition
| sheets of materials are passed thru rolls of a rolling mill |
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Term
| Rotational molding 455 460 - |
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Definition
| used to produce hollow, seamless products of a wide variety of shapes and sizes |
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Term
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Definition
| (couldn't find in the book - from dictionary) a slightly twisted roll or strand of usually textile fibers |
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Term
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Definition
| - In ____ such as corrugated cardboard or the honeycomb shown in Figure 20-19, thin layers of facing material are bonded, usually by adhesive to a lightweight filler material. |
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Term
| Sheet-molding compound 457 475 - |
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Definition
| Bulk compound molding compound, or preformed mat is placed on the press, and heat and pressure are applied. Temps usually range from 110-160 F and pressures from 1-7 MPa. With heated dies, the thermoset curing occurs during the compression operation, and cycles range from 1 to 5 minutes. |
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Term
|
Definition
| The processes described previously can all be used to produce useful shapes from ceremic materials, but useful strength generally requires a subsequent hearing operation known as firing or ____. |
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Term
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Definition
| ceramic powder is mixed with a liquid to form slurry |
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Term
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Definition
| Filaments, fibers, and yarns can be produced by spinning, a modified form of extrusion. Molten thermoplastic polymer is forced through a die containing many small holes. Where multi-strand yarns or cables are desired, the dies can rotate or spin to produce the twists and wraps. |
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Term
|
Definition
| used when continuous or woven fibers are not required to produce the desired properties. Produced by mixing chopped fivers and resin and spraying onto a mold |
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Term
|
Definition
| In the lamination process, prepregs, mats or _____ are stacked to produce a desired thickness and cured under pressure and heat |
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Term
|
Definition
| Glass created through special heat treatments. Applying forced cooling to the exposed surfaces, a residual stress pattern of surface compression can be induced creating tempered glass. This glass is stronger and more fracture resistant, since cracks tend to initiate on free surfaces. |
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Term
|
Definition
| thermoplastic sheet material is heated to a working temperature and then formed into a finished shape by heat, pressure, or vacuum. |
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Term
| Thermoplastic polymer 455 - |
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Definition
| These can be heated to produce either a soft, formable solid or a liquid. The polymerized material can then be cast, injected into a mold, or forced into or through dies to produce a desired shape. |
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Term
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Definition
| Untwisted assemblies of fibers. |
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Term
|
Definition
| Is sometimes used to reduce the turbulence and uneven flow that can result from the high pressures of hot-compression molding. Transfer molding combines elements of both compression molding and injection molding and enables some of the advantages of injection molding to be utilized with thermosetting polymers. |
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Term
| Vacuum-bag molding 474 - I |
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Definition
| In this process, air pressure holds the laminate against the mold while the resin cures (curing generally occurs at room temperature). |
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Term
|
Definition
| Process of shaping material at a molten state (glass in this case). |
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Term
| Vitrification (internet) - |
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Definition
| The transition of a substance into glass. |
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Term
|
Definition
| Twisted assemblies of filaments. |
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Term
|
Definition
| Ceramics are made of pure aluminum oxide. Used as a metallic binder. |
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Term
| BUE (built up edge) (512, 528) |
|
Definition
| variation of continuous chip, the hight temp/pressure cutting zone causes the work material to adhere or weld to the cutting edge of the tool forming a _______ |
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Term
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Definition
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Term
| Cast Cobalt Alloy(515, 523) |
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Definition
| AKA stellite tools, cobalt rich, chromium-tungsten-cast-alloys having properties between High speed steel and cemented carbides |
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Term
|
Definition
| ceramic material in a metal binder |
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Term
| Chemical Vapor Deposition(CVD)(520) |
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Definition
| atmosphere controlled process in the range of 950 to 1050 Celcius |
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Term
|
Definition
| wear on the rake face of the tool Think of wearing on the threads of a screw. |
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Term
|
Definition
| directly influence the productive of the machining operation ie. the hardness of the material to be cut, the speed of the cut...... |
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Term
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Definition
| is the depth the tool must travel trough the material this will effect the life of the tool and the time it takes to complete the task |
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Term
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Definition
| The hard material known. Man made diamonds are used as tools in machining very hard metals |
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Term
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Definition
| the ability of a steel to withstand high temperatures with out loosing its hardens. This is very attractive in tools that cut extremely hard materials |
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Term
|
Definition
| refers to the ease with which a metal can be machined to an acceptable surface finish. The principal definitions are based on material properties, tool life, and cutting speed. |
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Term
| Physical vapor deposition (PVD)(520) |
|
Definition
| an effective coating process for improving the life and performance of tools, used on about 15-20% of all tool steels. The three methods (preformed under a hard vacuum) in use are reactive sputtering, reactive ion plating, and arc evaporation. |
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Term
| Polycrystalline diamond tools(530) |
|
Definition
| consists of a thin layer of diamond particles sintered together and metallurgically bonded to a cemented carbide substrate. |
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Term
| Single-crystal diamonds(530) |
|
Definition
| used for precision machining of large mirrors. Also used to machine brass watch faces, and slice biological materials to view under microscopes. |
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Term
|
Definition
| also called cemented are carbides because they are manufactured by powder metallurgy techniques. |
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Term
|
Definition
| (523) also called cast cobalt alloys are cobalt rich, chromium-tungsten-carbon cast alloys and retain their hardness at high temperatures, so they can be used at higher cutting speeds. |
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Term
|
Definition
| the coating used in PVD and is formed by reacting free titanium ions with nitrogen away from the surface of the tool and using physical means to transport the coating |
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Term
|
Definition
|
|
Term
|
Definition
| The angle that the tool makes with respect to a vertical from the workpiece. |
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Term
|
Definition
| process of enlarging a hole that has already been drilled. |
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Term
|
Definition
| In this the cutting tool moves into the work while the work remains stationary. This operation uses a teethed tool to do work. |
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Term
|
Definition
| A self-excited vibration that is caused by the closed-loop force-displacement response of the machining process. |
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Term
|
Definition
| a formation on the cutting tool, is associated with a variation of the continuous chip, often encountered in machining ductile materials. |
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Term
|
Definition
| can be determined dynamically if a reliable means to measure Vc can be found. |
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Term
|
Definition
| the velocity of the chip being sheared. |
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Term
|
Definition
| This is a material property related to shear flow stress, hardness and work hardening and is often described in a relative sense of the machinability of materials. |
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Term
|
Definition
| are mounted in machine tools, which provide the required movement of the tool with respect to the work (or vice versa) to accomplish the process desired. |
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Term
|
Definition
| _________ is the distance the tool has plunged into the surface. ______=(D1-D2)/2 D1:initial diameter, D2:final diameter |
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Term
|
Definition
| is a cutting process that uses a bit to cut or enlarge a hole in solid materials. It cuts by applying pressure and rotation to the workpiece, which forms chips at the cutting edge. |
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Term
|
Definition
| amount of material removed per revolution or per pass of the tool over the workpiece |
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Term
|
Definition
| Force resisting the relative movement. Gets stronger with increased surface area, and/or pressure. |
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Term
| Grinding (Abrasive Machining) |
|
Definition
| Using a rough(abrasive) grinding wheel to cut away at metal. Usually only useful for shallow cuts and finishing. |
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Term
|
Definition
| powered mechanical device used to fabricate metal components of by selective removal of metal. |
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Term
|
Definition
| _________ moves the workpiece radially against the rotating cutter, which cuts on its sides as well as its tip. |
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Term
|
Definition
| In _______ machining, the cutting edge and cutting motion are not perpendicular to each other. |
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Term
|
Definition
| done to test machining mechanics and theory. Is the measurement of two forces and can be obtained in laboratory practice by: machining a plate, end cutting a tube wall in a turning setup, and end cutting a plate feeding in a facing direction. |
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Term
|
Definition
| one of the seven basic chip formation processes. |
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Term
|
Definition
| the periodic response of the system to a constant input. The vibrations may grow in amplitude (become unstable) and occurs near the natural frequency of the system regardless of the input. |
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Term
|
Definition
| where the cutting edge and the cutting motion are not perpendicular to each other. |
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Term
|
Definition
| The onset of the shear process takes place along the lower boundary of the shear zone defined by this? |
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Term
|
Definition
| can be found by using sophisticated electronics and slow-motion playback. |
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Term
|
Definition
| Also known as shear. A deformation of a solid body in which a plane in the body is displaced parallel to itself relative to parallel planes in the body; quantitatively, it is the displacement of any plane relative to a second plane, divided by the perpendicular distance between planes. The force causing such deformation. |
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|
Term
| Shear force (flow stress) |
|
Definition
| External force that acts parallel to a plane, unlike compressive force and tensile force which act perpendicularly. |
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Term
|
Definition
| Specific horsepower is also known as the unit horese power (hp/lb/hr) |
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Term
|
Definition
| the speed of an object is the magnitude of its velocity (the rate of change of its position); it is thus a scalar quantity. |
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Term
|
Definition
| a plot that separates unstable combinations of chip width, or axial depth of cut in peripheral end milling, and spindle speed (i.e., those that produce chatter) from stable combinations. |
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Term
|
Definition
| Shaping a member on a lathe. |
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Term
|
Definition
| A continuing periodic change in a displacement with respect to a fixed reference. This is the mechanism by which a process dissipates energy. Also called chatter. |
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Term
|
Definition
| A device used to locate and hold a workpiece. The workholding device references the tool performing the operation on the part being held. |
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Term
|
Definition
| An object being worked on with a tool or machine. |
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Term
|
Definition
| a basic machining process by which a surface is generated by progressive chip removal |
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Term
|
Definition
| the cutting tool used in milling is known as a _____ |
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Term
|
Definition
| when equally spaced peripheral teeth intermittently engage and machine the workpiece |
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Term
|
Definition
| the surface is generated by teeth located on the periphery of the cutter body. The surface is parallel with the axis of rotation of the cutter |
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Term
|
Definition
| usually performed on horizontal milling machines. The tool rotates at some rpm while the work feeds past the tool at a table feed rate in inches per minute |
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Term
|
Definition
| done on both horizontal and vertical spindle machines |
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Term
|
Definition
| very common operation performed on both vertical and horizontal spindle milling machines or machining centers |
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Term
|
Definition
| the traditional way to mill, AKA conventional milling. The cutter rotates against the direction of feed of the workpiece |
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Term
|
Definition
| the cutter rotation is in the same direction as the feed rate |
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|
Term
| staggered-tooth milling cutter |
|
Definition
| narrow cylindrical cutters having staggered teeth, and with alternate teeth having opposite helix angles |
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Term
|
Definition
| two or more side milling cutters often are spaced on an arbor to straddle the workpiece |
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Term
|
Definition
| made for the purpose of milling the semi-cylindrical seats required in shafts for woodruff keys...they also come in standard woodruff key sizes |
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Term
|
Definition
| the column mounted on the base, is the main supporting frame for all the other parts and contains the spindle with is driving mechanism |
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Term
|
Definition
| milling machines that can duplicate external or internal geometries in two dimensions |
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Term
|
Definition
| produce forms in 3 dimensions |
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Term
|
Definition
| designed to specifically hold a part in the correct location with respect to the tool. They also reduce the time it takes to put the part in the machine...provide clamping forces that counteract the cutting forces |
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Term
|
Definition
|
|
Term
|
Definition
| holes are made by doing this |
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Term
|
Definition
| most common type of drill with 3 parts: body, point, and shank |
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Term
|
Definition
| contained in the body, spiral or helical grooves that are separated by lands |
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Term
|
Definition
| Principal rake angles behind the cutting edges are formed by the relation of the flute ________ to the work |
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Term
|
Definition
| the thin ______ between the flutes that forms a metal column or backbone |
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Term
|
Definition
| the intersection of the web and cone produces this |
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Term
|
Definition
| at the end of the taper shank, fits loosely in a slot at the end of the tapered hole in the spindle |
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Term
|
Definition
| AKA gun drills, used when deep holes are to be drilled |
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Term
|
Definition
| half-round drills, drilled axially with a coolant hole to deliver cutting fluids to the cutting edge |
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Term
|
Definition
|
|
Term
|
Definition
| widely used for making holes 1in or larger in diameter at low speeds, or with high-feeds |
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Term
|
Definition
| can produce a hole four times faster than a spade drill because they run at high speeds/low feeds and are really more of a boring process than a drilling process |
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Term
|
Definition
| holds straight-shank drills, are adjustable over a considerable size range and have radial steel fingers |
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Term
|
Definition
| Work that is to be drilled is held in a vise or in specially designed workholders called _____ |
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Term
|
Definition
| the common name for the machine tool used for drilling. consists of a base, a column that supports a pwerhead, a spindle, and a worktable |
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Term
|
Definition
| used when several related operations, such as drilling holes of different sizes, reamin, or counterboring, must be done on a single part |
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Term
|
Definition
| used when a series of holes of different sizes, or a series of operations must be done repeatedly in succession |
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|
Term
| radial drilling machine tools |
|
Definition
| used on large workpieces that cannot easily be handled manually. These machines have a large, heavy, round vertical column supported by a base |
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|
Term
| multiple spindle drilling machines |
|
Definition
| mass-production machines with as many as 50 spindles driven by a single powerhead and fed simultaneously into the work |
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Term
|
Definition
| provides an enlarged cylindrical hole with a flat bottom so that a bolt-head, or a nut, will have a smooth bearing surface that is normal to the axis of the hole |
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Term
|
Definition
| makes a beveled section at the end of a drilled hole to provide a proper seat for a flat -head screw or rivet |
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Term
|
Definition
| doen to provide a smooth bearing area on an otherwise rough surface at the opening of a hole and normal to its axis |
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Term
|
Definition
| intended to be turned and fed by hand and to remove only a few thousandths of an inch of metal |
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Term
|
Definition
| for use with various machine tools ar slow speeds. These reamers also have chamfers on the front end of the cutting edges |
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|
Term
|
Definition
| used for sizes over 3/4 in. in order to save cutting tool material |
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|
Term
|
Definition
| push something else backwards (usually friction or normal force) to accelerate yourself forwards |
|
|
Term
|
Definition
| together with the ____, provides the means for mounting and moving cutting tools. Is a part of the carriage assembly. |
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|
Term
|
Definition
| is the base and backbone of a lathe. Is usually made of well normalized or aged gray or nodular cast iron and provides a heavy, rigid frame on which all the other basic components are mounted. |
|
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Term
|
Definition
| Always involve the enlarging of an existing hole, which may have been made by a drill or may be the result of a core in a casting. Essentially, ______ is internal turning. _____ can use single-point cutting tools to produce internal cylindrical or conical surfaces. |
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Term
|
Definition
| a relatively flat H-shaped casting, rides on the outer set of ways on the bed. It is on the carriage assembly which provides the mean for mounting and moving cutting tools. |
|
|
Term
|
Definition
| A lathe chuck is a device on the driven spindle on the head (headstock) of the machine that holds the workpiece. It grips and spins it. |
|
|
Term
|
Definition
| is a holding device, specifically, a subtype of a chuck that forms a collar around the object to be held and exerts a strong clamping force on the object when it is tightened via a tapered outer collar. It may be used to hold a workpiece or a tool. |
|
|
Term
|
Definition
| When the tool is fed all the way to the axis of the workpiece, it will be cut in two. Also known as parting. |
|
|
Term
|
Definition
| p 572 Most lathe operations are done using single point ____, such as those illustrated in Figure 23-25. On right-hand (and left-hand turning) and facing tools, the ____ usually takes place on the side of the tool; therefore, the side rake angle is of primary importance, particularly when deep cuts are made. |
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|
Term
|
Definition
| p550 Roughing cuts may be as heavy as proper chip thickness, cutting dynamics, tool life, lathe horsepower, and the workpiece permit. Large _______ and smaller feeds are preferred to the reverse procedure, because fewer cuts are required and less time is lost in reversing the carriage and resetting the tool for the following cut. |
|
|
Term
|
Definition
| p553 This can be done on lathes with the ____ mounted in the tailstock quill of engine lathes or the turret on turret lathes and fed against a rotating workpiece. |
|
|
Term
|
Definition
| p556 The essential components of an _____ are the bed, headstock assembly, tailstock assembly, carriage assembly, quick-change gearbox, and the leadscrew feed rod. |
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|
Term
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Definition
| p579 These are used to support irregularly shaped work that cannot be gripped easily in chuck or collets. The work can be bolted or clamped directly on the ____ or can be supported on an auxiliary fixture that is attached to the _____. |
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Term
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Definition
| An operation called _________ is when the tool is fed at 90 degrees to the axis of rotation, using a tool that is wider than the width of the cut producing a flat surface |
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Term
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Definition
| p 585 The ___, fr, is given in inches per revolution. The depth of cut in drilling is equal to half the ____ rate, or t = fr/2. The ___ rate in inches per minute fm, is frN. In dealing with drilling, because the ___ may be manually controlled, care must be exercised, particularly in drilling small holes. |
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Term
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Definition
| p 580 This is bolted to the lathe carriage. It has two contact fingers that are adjusted to bear against the workpiece, opposite the cutting tool, in order to prevent the work from being deflected away from the cutting tool by the cutting forces. |
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Term
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Definition
| this is mounted in a fixed position on the inner ways of a lathe and provides powered means to rotate the work at various rpm values. |
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Term
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Definition
| This produces a regularly shaped, roughened surface on a workpiece. In most cases this is done on external cylindrical surfaces using lathes; it is a chipless, cold forming process |
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Term
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Definition
| Workpieces that are relatively long with respect to their diameters are usually machined between __________. Two of these are used, one in the spindle hole and one in the hole in the tailstock quill. Two types are used, called dead and live |
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Term
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Definition
| Workpieces that must be machined on both ends or are disk-shaped are often mounted on ______________ for turning between centers. There are three common types: Gang, Solid, and Cone. |
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Term
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Definition
| This controls the trimmings and shavings that are created in turning and boring processes |
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Term
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Definition
| This can be done on a lathe but requires special attachments; it is the basic machining process by which a surface is generated by progressive chip removal. The act or process of grinding, cutting, pressing, or crushing |
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Term
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Definition
| this is the operation by which one section of a workpiece is severed from the remainder by means of a cutoff tool; If the tool is fed all the way to the axis of the workpiece, it will be cut in two. This is called ____________ or cuttoff and a simple, thin tool is used |
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Term
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Definition
| This is a hollow steel cylinder, usually about 2 to 3 inches in diameter that can be moved longitudinally in and out of the upper casting by means of a handwheel and screw. |
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Definition
| on a lathe involves no special precaution. To enlarge to desired size by means of a reamer. |
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Definition
| are lathes designed for completely automatic operations. |
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Term
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Definition
| provide means for supporting such work between the headstock and the tailstock. Can also be used in place of the tailstock as a means of supporting the end of long pieces, pieces having too large an internal hole to permit using a regular dead center, or work where the end must be open for boring. |
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Term
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Definition
| assembly containing three parts, a lower casting fits on the inner ways of the bed, an upper casting fits on the lower one, and the third major component of the assembly is the tailstock quill. |
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Term
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Definition
| when the tool is fed at an angle to axis of rotation and an external conical surface results. |
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Term
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Definition
| constitutes the majority of the lathe work and is the process of machining external cylindrical and conical surfaces. |
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Term
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Definition
| a longitudinally feedable, hexagon turret replaces the tailstock and the turret on which six tools can be mounted can be rotated about a vertical axis to bring each tool into operating position, and the entire unit can be translated parallel to ways. |
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Term
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Definition
| devices for lathes that are commonly used for supporting work pieces. |
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Term
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Definition
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Term
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Definition
| involves the use of a semisolid liquid or gel laden with abrasives to flow over or through a workpiece to perform edge finishing, deburring, radiusing, polishing, or minor surface machining. |
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Term
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Definition
| removes material by a focused jet of abrasives and is similar in many respects to AWC with the exception that momentum is transferred to the abrasive particles by a jet of inert gas. |
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Term
| Abrasive waterjet cutting |
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Definition
| is where abrasives are added to the waterjet in a mixing chamber on the dowstream side of the waterjet orifice. |
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Term
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Definition
| (also sometimes referred to as etch factor) is used to describe the directionality of the cut. The _____________, A, of a material/etchant interaction in photochemical machining is defined as: A = d/U |
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Term
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Definition
| Through-etching of the workpiece. Typically performed using double-sided etching to increase production rates and minimize taper on the etched walls of the feature. |
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Term
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Definition
| simplest and oldest of the chipless machining processes. Process of removing material from a workpiece by selectively exposing it to a chemical reagent or etchant. The mechanism for metal removal is the chemical reaction between the etchant and the workpiece resulting in dissolution of the workpiece. |
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Term
| Chemical-mechanical polishing |
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Definition
| uses the synergy of chemistry and mechanical grinding to obtain flatness on the order of 50 nm. |
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Term
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Definition
| The gross removal of material from a body by the corrosive action of an acid or an alkali that results in a substantial change of shape of the body. |
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Term
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Definition
| simplest method of applying a maskant applied to the entire surface of the workpiece by dipping or spraying. Once the coating dries, it is then selectively removed in those areas where etching is desired by scribing he maskant with a knife and peeling away the unwanted portions. |
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Term
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Definition
| a chemical entity consisting of two structurally similar subunits called monomers joined by bonds that can be either strong or weak. |
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Term
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Definition
| thinning in center due to improper agitation or stacking of parts in tank |
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Term
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Definition
| the on-time as a percentage of the total cycle time (inverse of the frequency) |
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Term
| electrical discharge machining- |
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Definition
| process removes metal by discharging electric current from a pulsating DC power supply across a thin interelectrode gap between the tool and the workpiece. |
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Term
| electrical discharge wire cutting- |
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Definition
| in this, the electrode is a wire used for cutting through-cut features driving the workpiece with a CNC table. |
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Term
| electrochemical deburring- |
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Definition
| a deburring process which works on the principal that electrolysis is accelerated in areas with small interelectrode gaps and prevented in areas with insulation between electrodes. |
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Term
| Electrochemical grinding (ECG) |
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Definition
| while the product is rotated low voltage high current used to remove some of the material the rest of the affected material is oxidized the oxidized material is then ground away |
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Term
| Electrochemical machining (EM) |
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Definition
| using high velocity stream of charged particles through a glass tube used to remove unwanted material |
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Term
| Electrochemical micromachining |
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Definition
| Removes material by anodic dissolution with a rapid flowing electrolyte uses electrical current to bring about chemical change |
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Term
| Electrochemical polishing |
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Definition
| low current density the charged particles are forced through a glass tube used to remove unwanted material at a slow rate fine finish |
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Term
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Definition
| A thermal process that uses a beam of high energy that vaporises the metal tat is to be removed |
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Term
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Definition
| low current density the charged particles are forced into wok piece with out a part specified had tool to remove unwanted material at a slow rate gives a fine finish |
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Term
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Definition
| using high velocity stream of charged particles through a glass tube used to drill holes usually multiple small holes at one time |
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Term
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Definition
| Something to consider in chemical machining. Etch Factor (E) describes the relationship between undercut (U) and depth of cut (d). See picture. |
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Term
| Fine Plasma Cutting/High-definition Plasma/Precision PAC |
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Definition
| Uses a special nozzle to stabilize the plasma pressure for a more finely defined PAC beam. Reduces problems of HAZ and dross on the bottom of parts. |
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Term
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Definition
| CHM where the etchant is applied in a gel form. |
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Term
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Definition
| In PAC(plasma arc cutting), the ____________ is a negative side-effect. (Not from book, this is just an inference) This makes it unusable where the workpiece is thermally delicate/sensitive. |
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Term
| Hydrodynamic(Waterjet) Machining |
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Definition
| uses a high-velocity fluid jet to perform a slitting operation. Water is ejected from a nozzle at very high pressure (up to 60,000 psi). |
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Term
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Definition
| Preferential etching due to ______________ can also be an issue in Chemical Machining. |
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Term
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Definition
| Nano-scale machining used to cleave wafers. Often used on defective wafers for characterization and failure analysis. |
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Term
| Photochemical milling (689) |
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Definition
| Milling using the photoresist method of applying maskants. Named photochemical because its earliest usage was for replacing mechanical miling on large componets. It is often used to remove weight on on aircraft componets (see fig 28-4) |
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Term
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Definition
| The most common and precise method for creating maskants involves using UV light sensitive emulsions called _____ |
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Term
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Definition
| A defect due to unequal etch rates |
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Term
| Plasma Arc Cutting (PAC) (714) |
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Definition
| Uses a superheated stream of electrically ionized gas to melt and remove material. 20,000 to 50,000 deg F.plasma is created inside a water cooled nozzle by electrially ionzing a suitable gas such as nitrogen, hydrogen, argon, or mixtures of these gases. The process can be used on almost any conductive metal. |
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Term
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Definition
| uses a special nozzle where either a high flow vortex or a magnetic field causes the plasma to spin rapidly and stabilizes the plasma pressure. The fast spinning plasma results in a finely defined beam that cuts a narrow kerf with a perpendicular edge |
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Term
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Definition
| high current densities (> 100 A/cmsq) are pulsed on for durations. The relaxation interval permits reaction byproducts to be removed from the interelectrode gap at low electrolyte flow rates without electrolytic desposition on the ECM tool. |
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Term
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Definition
| One of the two dfferent types of EDM based on the shape of the tool electrode used. In ____ the electrode is a die in the shape of the negative of the cavity to be produced in bulk material. By feeding the die into the workpiece, the shape of the die is machined into the workpiece |
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Term
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Definition
| a method of applying maskants that utilizes traditional sik-screen technology |
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Term
| Water jet Cutting (WJC) (701) |
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Definition
| uses a high- velocity fluid jet impinging on the workpiece to perform a slitting operation (Fig. 28-16), at high pressure (up to 60,000 psi) and has a jet typically 0.003in - 0.020in in diameter; AKA Waterjet machining or hydrodynamic machining |
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Term
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Definition
| uses a high- velocity fluid jet impinging on the workpiece to perform a slitting operation (Fig. 28-16), at high pressure (up to 60,000 psi) and has a jet typically 0.003in - 0.020in in diameter; AKA Waterjet cuttng or hydrodynamic machining |
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Term
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Definition
| involves the use of a thin, conductive wire as the tool that cuts thru the metal. |
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Term
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Definition
| AKA electrical discharge wire cutting; the electrode is a wire used for cutting through-cut features driving the workpiece on a CNC table; capable of producing complex 2-D patterns(Fig. 28-22) in hard to machine materials |
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Term
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Definition
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Term
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Definition
| isolated high spots that can be the result of improper agitation on large parts. They can also be formed due to inadequate cleaning or inhomogeneity with the work material. |
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Term
| Laser beam machining, LBM – |
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Definition
has heat affected zone and recast layers that may require removal
Laser beam is focused on the WP and is transferred to thermal energy to perform operations (cutting, drilling, etc) |
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Term
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Definition
| etch resistant. Covers selected areas of the work piece in CHM. |
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Term
| Nontraditional machining – NTM |
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Definition
| have been developed since WWII to address the growing list of machining requirements which cannot be handled by conventional machining alone. |
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Term
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Definition
| the distance between the surface of the electrode and the surface of the workpiece. Is constrained by the minimum interelectrode distance necessary for a spark. It depends on the gap voltage plus the chip size. |
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Term
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Definition
| can result if the etchant is not properly agitated, particularly on deep cuts. |
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Term
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Definition
| PCM – the use of photoresists in chemical machining. Limited to thin material. Tooling cost low. Used in microelectronics. |
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Term
| Shaped-tube electrolytic machining |
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Definition
| created in response to jet engine industry. Uses acidic electrolyte to minimize clogging while drilling shaped holes |
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Term
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Definition
| also known as ram EDM, or simply EDM, uses an electrode that is a die in the shape of the negative of the cavity to be produced in a bulk material. By feeding the die into the workpiece, the shape of the die is machined into the workpiece |
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Term
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Definition
| process used in EDM by which a spark is generated in a thin interelectrode gap between a tool and a workpiece where a pulsating DC current is fed across the gap using a dielectric fluid. The dielectric fluid is ionized and a spark is created which vaporizes a tiny portion of the workpiece, leaving a void. |
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Term
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Definition
| uses two iterations of the cut and peel method of applying a maskant to etch a stepped formation into a surface |
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Term
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Definition
| when a second photon strikes the energized atom, the atom gives off 2 photons of identical wavelength moving in the same direction and with the same phase. p.712 |
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Term
| Thermal deburring or thermal energy method |
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Definition
| developed for the removal of burrs and fins by exposing the workpiece to hot corrosive gases for a short period of time typically on the order of a few milliseconds p.715 |
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Term
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Definition
| through etching of the workpiece also called chemical blanking |
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Term
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Definition
| also called precision PAC or fine plasma cutting. Uses a special nozzle, where either a high flow vortex or a magnetic field causes the plasma to spin rapidly and stabilizes the plasma pressure. |
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Term
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Definition
| is a material-removal process that involves the interaction of abrasive grits with the work piece at high cutting speeds and shallow penetration depth. |
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Term
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Definition
| is the most widely used artificial abrasive. Also produced in an arc furnace from bauxite, iron filings, and small amounts of coke, it contains aluminum hydroxide, ferric oxide, silica, and other impurities. |
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Term
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Definition
| refers to the abrasive wear action of the grits resulting in dulled edges, grit flattening, and wheel glazing. |
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Term
| CBN (cubic boron nitride) |
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Definition
| is not found in nature. It is produced by a combination of intensive heat and pressure in the presence of a catalyst. ______ is extremely hard, registering at 4700 on the Knoop scaled. It is the second hardest substance created by nature or manufactured and is often referred to, along with diamonds, as a superabrasive. |
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Term
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Definition
| makes it possible to grind both external and internal cylindrical surfaces without requiring the workpiece to be mounted between centers or in a chuck. This eliminates the requirement of center holes in some workpieces and the necessity for mounting the workpiece, thereby reducing the cycle time. |
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Term
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Definition
| are being used increasingly in finishing both metal and nonmetal products. These are made by gluing onto a cloth or paperbacking. |
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Term
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Definition
| (Natural ) and diamonds are other nauturally occurring abrasive materials. |
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Term
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Definition
| the work is fed very slowly past the wheel and the total downfeed or depth is accomplished in a single pass. |
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Term
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Definition
| consists of forcing a hard roll having the same contour as the part to be ground against the grinding wheel while it is revolving; a water based coolant is used to flood the dressing zone. The crushing action fractures and dislodges some of the abrasive grains. |
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Term
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Definition
| is a type of grinding machine used for producing external cylindrical surfaces. |
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Term
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Definition
| the hardest of all materials. |
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Term
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Definition
| cleaning and sharpening the wheel. I f you do not ______, the wheel will not cut as well and will tend to plow and rub more. |
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Term
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Definition
| a mixture of alumina and magnetite is another natural abrasive still in use today and is used on coated paper and cloth. |
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Term
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Definition
| refers to the fracture of the grits and is the opposite of toughness. |
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Term
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Definition
| (grinding ratio) the cubic inches of stock removed divided by the cubic inches of wheel lost (from lost of grains). It is a measure of grinding production and reflects the amount of work a wheel can do during its useful life. |
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Term
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Definition
| a diamond that is a natural, off-color stone that is not suitabe for gems |
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Term
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Definition
| the bond strength which controls the fracturing of the grits. __________ is a measure of how strongly the grains are held in the wheel. It depends on the strength of the bonding materials and the amount of the bonding agent connecting the grains. |
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Term
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Definition
| process where the abrasives are bonded together into a wheel. It is the most common abrasive machining process. The performance of __________ wheels is greatly affected by the bonding material and the spatial arrangement of the particles grits. |
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Term
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Definition
| similar to grinding but materials such as sulfur, resin or wax are added to the bonding agent to modify the cutting action. |
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Term
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Definition
| an abrasive surface-finishing process where fine abrasive particles are charged (or embedded) into a soft material (called a ___). The material can range from cloth to cat iron or copper. |
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Term
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Definition
| used primarily in coated abrasives and air blasting. It is a natural abrasive that has commercial importance |
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Term
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Definition
| also called phenolic resins and cover a variety of work conditions; has replaced shellac and rubber wheels |
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Term
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Definition
| used to produce wheels that can operate at high speeds but must have a considerable degree of flexibility so as to resist side thrust. A rubber bond is composed of rubber, sulfur, and other vulcanizing agents that are mixed with the abrasive grains. |
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Term
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Definition
| wheels can be made this way by mixing the abrasive grains with shellac in a heated mixture, pressing or rolling into the desired shapes, and baking for several hours. This type of bond is used primarily for strong, thin wheels having some elasticity. |
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Term
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Definition
| this bond is formed with silicate of soda (waterglass) as the bond material. Because they are more brittle and not so strong as vitrified wheels, the abrasive grains are released more readily. |
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Term
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Definition
| made by charging an electric furnace with silica sand, petroleum coke, salt, and sawdust. By passing large amounts of current through the charge, a temperature of over 4000 F is maintained for several hours, and a solid mass of silicon carbide crystals results. |
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Term
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Definition
| a type of rough manual grinding that is done to remove fins, gates, risers, and rough spots from castings or flash from forgings, preparatory to further machining. |
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Term
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Definition
| used primarily to grind flat surfaces, has a reciprocating table and horizontal spindle. |
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Term
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Definition
| as grinding wheels lose their geometry during use, truing restores the original shape. A single-point diamond tool can be used to true the wheel while fracturing abrasive grains to expose new grains and new cutting edges on worn, glazed grains. |
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Term
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Definition
| composed of clays and other ceramic substances. ____________ are proous, strong, rigid, and unaffected by oils, water, or temperature over the ranges usually encountered in metal cutting. |
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Term
| Band-filling Machine- 652 |
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Definition
| This machine provides continuous cutting action. Most band filing is done on contour bandsawing machines by means of a special band file that is substituted for the usual bandsaw blade. |
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Term
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Definition
| These blades are available in straight, raker, wave, or combination sets. Blade width is very important in bandsawing because it determines the minimum radius that can be cut. |
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Term
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Definition
| Used in production to finish holes, splines, and flat surfaces. Typical workpieces include small to medium sized castings, forgings, screw machine parts, and stampings. It is composed of a series of teeth, each tooth standing slightly higher then the last. |
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Term
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Definition
| It is widely used and particularly well suited for mass production. Broaching usually produces better accuracy and finish than can be obtained by drilling, boring, or reaming. |
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Term
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Definition
| On some round broaches, ___________ are provided for finishing. These have no cutting edges but are rounded disks that are from 0.001 to 0.003 inches larger than the size of the hole. The resulting rubbing action smooths and sizes the hole. |
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Term
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Definition
| These saws necessarily differ somewhat from straight blade forms. Because they must be relatively larger in comparison with the work, only the sizes up to about 19 inches in diameter have teeth that are cut into the disk. |
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Term
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Definition
| This is another name for a circular saw that is used for cutting metal. These saws rapidly cut and produce chips like a milling cutter while producing surfaces that are comparable in smoothness and accuracy with surfaces made by slitting saws in a milling machine or by a cutoff tool in a lathe. |
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Term
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Definition
| Metal-removing action is the same as in sawing in that chips are removed by cutting teeth that are arranged in succession along same plane on the surface of a tool |
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Term
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Definition
| one of 3 basic configurations of saw blades, the blade is tough and thin. It is also disposable |
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Term
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Definition
| Among the oldest single-point machining processes, work is moved past one or more stationary single-point cutting tools and can be used to produced horizontal, vertical, or inclined flat surfaces on large workpieces (too large for shapers), as well as for producing long flat cuts like those in the way of machine tools |
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Term
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Definition
| the pull end of the broach is passed through the part and key mates to the slot |
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Term
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Definition
| Push broaching machines are similar to an arbor press with a guided ram; typical capacities are 5 to 50 tons. This must be strong enough so that it will not buckle. If the length-to-diameter ratio L/Dr is greater than 25, the broach must be considered a long column which can buckle if overloaded. |
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Term
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Definition
| One of the 3 classifications of metal-sawing maching. There are two types, a manual hacksaw and a power hacksaw. These machines consist of a bed, a workholding frame and a power or manual mechanism for reciprocating. |
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Term
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Definition
| the feed per tooth in broaching id the change in hieght of successive teeeth. This is called______________. The sum of this gives the depth of cut. It also determines the chip load and varies depending on the type of broaching |
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Term
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Definition
| is a basic machining proccess in which chips are produced by a succession of small cutting edges, or teeth, arranged in a narrow line on a "blade" |
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Term
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Definition
| has largely been replaced by milling and broching as a production process. In this the workpiece is fed at right angles to the cutting motion between successive strokes of the tool. |
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Term
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Definition
| in this, the the rise per tooth is typically .003in to .006in. Smaller ones are made of solid construction but larger ones are made of modular construction |
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Term
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Definition
| refers to the manner in which teeth are offset from the centerline in order to make the kerf wider than the gage(thickness of the back) of the blade |
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Term
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Definition
| hold and locate the work in the machine tool with respect to the cutting tool |
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Term
|
Definition
| holding or maintaining the part in that location during cutting operations (resisting cutting forces) |
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Term
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Definition
| determine the position or location of geometrc shapes with respect to each other |
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Term
|
Definition
| special workholding device that determines location dimensions that are produced by machining or fastening operations |
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Term
|
Definition
| workholding device that holds work during mahining or assembly operations and establishes size dimensions. IT IS DESIGNED AND CONSTRUCTED FOR A PARTICULAR PART OR SHAPE |
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Term
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Definition
| for a positive location, the fixture must position the workpiece in each of three perpendicular planes |
|
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Term
|
Definition
| derive their name from the cross-sectional shape of the main member. Can only be used with parts having fairly simple shape |
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Term
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Definition
| used only for drilling round parts. |
|
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Term
|
Definition
| derive their name from the hinged leaf or cover that can be swung open to permit the workpiece to be inserted and then closed to clamp the work in position |
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Term
|
Definition
| derive their name from their boxlike construction. Have fixed sides and a hinged cover or leaf which opens to permit loading the workpiece, and a cam that locks the workpiece in place |
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Term
|
Definition
| the workholding devices are designed so that they all appear the same to the tool but different to the parts. The jigs or fixtures are all different, but the plates identical. |
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Term
|
Definition
| comes in many forms, force can be applied by a hand knob, a cam, or a wrench turning down a nut |
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Term
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Definition
| accomodates only small thickness variation from part to part, yet proivides consistent clamping force |
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Term
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Definition
| of the open-frame type, provide for the introduction of several component parts and the use of some type of fastening equipment |
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Term
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Definition
| used for ferromagnetic materials, available in rectangular shapes |
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Term
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Definition
| the holes of the work plate are connected to a vacuum pump, and can be opened or closed by means of valve screws |
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Term
|
Definition
| C2H2, used along with oxygen to produce monoxide and hydrogen (in the first stage) |
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Term
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Definition
| Excess fuel produces this. This type of flame is used when welding in Monel and high carbon steels |
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Term
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Definition
| added in the form of solid metal wire or rod to fill slight gaps |
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Term
|
Definition
| the use of controlled, localized upsetting as a means of straightening warped or buckled plates |
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Term
|
Definition
| used to clean the surfaces and remove contaminating oxide |
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Term
|
Definition
| Almost all oxyfuel gas welding is of this type. The metals to be joined are simply melted where a weld is desired |
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Term
|
Definition
|
|
Term
|
Definition
| an alternative fuel gass, methyl acetylene propadiene |
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Term
|
Definition
| ratio of 1:1 to 1.15:1, most welding is done with this type of flame because it has the LEAST chemical effect on the heated metal |
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Term
|
Definition
| ratio of 1.5:1, hotter than a neutral flame. Used when welding copper and copper alloys, but considered harmful when welding steel |
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Term
|
Definition
| AKA flame cutting, metal is melted by the flame of the oxygas fuel |
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Term
|
Definition
| a group of welding processes that use the flame produced by the combustion of a fuel gas and oxygen as their heat source |
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Term
|
Definition
| used if the workpiece is already hot from another process. No heating is required. A supply of oxygen thru a small pipe is used initiate and continue a cut |
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Term
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Definition
|
|
Term
|
Definition
| used to burn acetylene and oxygen |
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Term
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Definition
| between 2 electrodes, a concentrated heat source tht can approach high teperatures |
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Term
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Definition
| All ______________ processes employ the same basic circuit. Welding currents vary from 1 to 4000 amps (100-1000 is the most typical) |
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Definition
| modification of the submerged arc process, iron powder is deposited in the joint as a means of increasing deposition rate |
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Term
| consumable electrode process |
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Definition
| part of the the group of arc welding process where the electrode is consumed and thus supplies the metal needed to fill the joint |
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Term
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Definition
| when direct current is used and the elctrode is made negative, direct-current electrode-negative. characterized by fast melting of the electrode and a shallow molten pool on the workpiece |
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Definition
| if the workpiece is made negative and the electrode positive, direct-current electrode-positive |
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Definition
| terminal thru which electric current passes |
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Term
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Definition
| used to deoxidize and remove impurities from molten metal |
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Term
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Definition
| overcomes shielded metal arc limitations by moving powdered flux to the interior of a continuous tubular electrode |
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Term
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Definition
| If the shielding gas flowing through the torch becomes the primary protection for the arc and molten metal, the electrode becomes a continuous uncoated metal wire. |
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Term
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Definition
| a nonconsumable tungsten electrode provides the arc but not the filler metal. The pointed electrode is positioned, and inert gas flows to provide a protective shield around the electrode. |
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Term
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Definition
| If voltage and aperage are increased, the mode becomes __________. The electrode melts from the heat of the arc and the metal drops form with a diameter equal to the electrode wire |
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Term
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Definition
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Term
| nonconsumable electrode process |
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Definition
| employs a tungsten electrode which is not consumed by the arc, except by relatively slow variation. A separate metal wire is required to supply the filler metal |
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Term
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Definition
| gas that transfers it heat to the workpiece and melts the metal |
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Term
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Definition
| the depth of melting in the workpiece |
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Term
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Definition
| When an inert gas is forced through a constricted arc and heated ______ is formed |
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Term
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Definition
| the arc is maintained between either the welding gun or the workpiece |
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Term
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Definition
| available in DC or AC, employ the drooping voltage characteristics |
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Term
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Definition
| Produced from all thermal cutting processes where the cut surface is generalliy in tension |
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Term
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Definition
| leads from a direct current power source whereby the electrode is the positive pole and the work piece is the negative pole of the arc. |
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Term
| shielded metal arc welding |
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Definition
| AKA stick welding, most common arc welding process. Low cost, and very versatile. However, it pis discontinuous, and requires slag removal after each welding pass. |
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Term
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Definition
| The lowest currents and the use of CO2 shield gas promotes ________________. |
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Term
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Definition
| a protective coating used to accumulate impurities, prevent oxidation, and slow cooling of the weld |
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Term
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Definition
| an inert-gas tungsten arc gun joins the two pieces |
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Term
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Definition
| happens with higher currents and voltages, along with argon gas shielding and DCEP conditions. Small droplets emerge from a pointed electrode at a fast rate |
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Term
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Definition
| ads from a direct current power source whereby the work piece is the positive pole and the electrode is the negative pole of the arc. |
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Term
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Definition
| an arc welding process used to attach studs, screws, pins, or other fasteners to a metal surface |
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Term
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Definition
| No shielding gas is used. A thick later of granular flux is deposited ahead of the electrode. Only a few small flames are visible |
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Term
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Definition
| An arc established between the plasma torch and the workpiece. |
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Term
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Definition
| power supplies that alternate between DCEN and DCEP, but use regular waveforms to vary the fraction of time in each mode |
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Term
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Definition
| used to blow molten metal through the cut, cool the workpiece, and assist in the combustion of the material |
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Term
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Definition
| simple fusion welds without filler metal |
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Term
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Definition
| has its greatest use in the manufacture of pipes and tubes |
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Term
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Definition
| variation of forge welding that uses no heat but produces metallurgical bonds by a means of cold plastic deformation |
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Term
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Definition
| occurs when properly prepared surfaces are maintained in contact under sufficient pressure and time at an elevated temperature |
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Term
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Definition
| fusion welding process where heating results from the impingement of a beam of high-velocity electrons on the metal to be welded |
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Term
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Definition
| effective process for welding thick sections of steel plate. No arc. Heat is derived from the passage of electrical current through a liquid slag |
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Term
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Definition
| used to bond corrosion resistance sheets to heavier plates of base metal. An explosive material is placed on top of both metals and detonated in a progressive fashion |
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Term
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Definition
| resistance between the surfaces to be joined |
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Term
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Definition
| oxides and other surface impurities are dispaced into this, can be removed by subsequent machining |
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Term
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Definition
| 2 pieces of metal are first secured in current-carrying grips and lightly touched together. An intense flashing arc is created across the gap, abd the pieces are forced together under high pressure |
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Term
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Definition
| most ancient of the welding processes. Uses a charcoal forge and hammer |
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Term
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Definition
| heated strip of steel is formed into a cylinder, the edges are pressed together in either a lap, or butt configuration |
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Term
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Definition
| where the heat required to produce the joint is generated by friction heating at the interface. The components to be joined are prepared to have smooth, square-cut surfaces |
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Term
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Definition
| frictional heat is generated by a nonconsumable probe that is rotated at high speed between the abutting edges of rigidly clamped plates. A plasticized region is continually created |
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Term
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Definition
| used to obtain improved resistance to wear |
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Term
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Definition
| a gas is heated by an electric coil as it passes through a welding gun . Hot gas steam emerges and impinges on the joint area. Usually a slow process |
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Term
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Definition
| uses an external heat source. The parts are are held in fixtures and pressed against the opposite sides of an electrically heated tool. Simplest mass production technique to join plastics |
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Term
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Definition
| metal inserts are placed between the plastics to be joined and heated by means of induction. Thermoplastic material melts around the inserts and forms a joint |
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Term
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Definition
| a modification of friction welding where the moving piece is attached to a flywheel, the flywheel is brought to a speed and the kinetic energy is turned to friction, which joins the pieces |
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Term
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Definition
| process to weld thermoplastics |
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Term
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Definition
| groove or slit in the material caused by cutting |
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Term
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Definition
| A welded joint in which two overlapping metal parts are joined by means of a fillet, plug or slot weld. |
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Term
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Definition
| begins by drilling a hole through the material and then moving the beam in a programmed path. The heat from the beam is used to melt or evaporate the material being cut |
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Term
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Definition
| beam can be focused to a small diameter and high power. Used to melt material at the joint |
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Term
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Definition
| a noncontact process, no electrodes are involved. Performed with access to only one side of the joint |
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Term
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Definition
| if a non transferred arc is used and only a mechanical bond is produced |
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Term
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Definition
| process to weld thermoplastics |
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Term
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Definition
| water-cooled means of confining molten metal to the gap |
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Term
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Definition
| coalesced metal formed between faying surfaces |
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Term
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Definition
| a rapid discharge of stored energy produces a brief period of arcing which is followed by the rapid application of force to expel the molten metal and produce the joint |
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Term
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Definition
| used if increased strength is required and multiple welds are needed. Where a dimple is embossed and flattened by the current |
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Term
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Definition
| where both heat and pressure are used to induce coalescence. Electrodes are placed in contact with the material and electrical resistance heating is used to raise the temp of the workpiece and the interface between them |
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Term
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Definition
| most widely used form of resistance welding. Fast, economic way to join overlapped materials that do not require disassembly |
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Term
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Definition
| used for light production work where cycles are not required. Lower electrode arm is stationary while the upper electrode (mounted on a pivot arm) is brought into contact by means of a foot pedal |
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Term
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Definition
| two or more sheets or plates of metal are passed through a rolling mill and joined together |
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Term
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Definition
| AKA overlaying, process of depositing a layer of weld material on the surface or edge of a base material of different composition. |
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Term
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Definition
| refers to a mechanical mixture of aluminum and iron oxide. When ignited, it reacts chemically |
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Term
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Definition
| superheated molten metal and slag are produced from an exothermic chemical reaction between a metal oxide and a metallic reducing agent. |
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Term
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Definition
| materials that can be welded because the material can be melted without degradation |
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Term
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Definition
| materials that do not soften with heat. They tend to only char or bur and must be joined with fasteners or adhesives |
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Term
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Definition
| small integral transformer gunts that offer reduced power losses and process efficiency |
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Term
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Definition
| a solid state process where coalescence is produced by the localized application od high-frequency vibrations to surfaces tht are held together under light, normal pressure |
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Term
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Definition
| similar to flash welding, but the heat is achieved through electrical resistance. The parts are clamped to the machine, pressure is applied, and current is passed through the joint |
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Term
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Definition
| relative movement between the two parts is used to generate heat in the direction parallel to the interface |
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Term
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Definition
| molten filler is deposited by gravity, capillary action is not requred to distribute the filler metal |
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Term
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Definition
| the permanent joining of similar or dissimilar metals or ceramics through the ue of heat and a filler metal whose melting temperature is below the melting point of the materials being joined |
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Term
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Definition
| does not requre additional thickness in the vicinity of the join. Most often used where strength requirements are not critical |
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Term
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Definition
| used to distribute the filler material between the closely fiitting surfaces of the joint |
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Term
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Definition
| assemblies are immersed in a bath of molten brazing metal. Bath provides both the heat and metal for the joint |
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Term
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Definition
| a measure of the flow characteristics of the molten braze metal and is a function of the metal, its remp, and clearance |
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Term
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Definition
| when flux and filler material are preloaded into the joints and simultaneously heated |
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Term
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Definition
| contributing factor to joint strength. If its too tight, may have unfilled voids. If its too lose, filler might escape |
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Term
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Definition
| provide bonding areas considerable larger than butt. Use when maximum strength is desired |
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Term
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Definition
| solder metal without lead (lead is banned from solder in the USA) |
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Term
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Definition
| alloys based on silver and copper with brazing temperatures significantly below pure copper |
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Term
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Definition
| a brazing type of operation where the filler metal has a melting temperature. Typically used for connecting thin metals |
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Term
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Definition
| common type of brazing where the gas flame torch is used. Most brazing is done in this manner |
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Term
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Definition
| a strong function of the surface tensions between the braze metal and the base alloy. Good when surfaces are clean |
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