a) Find the horsepower consumed in cutting, shearing and friction.

b) Find a maximum lathe horsepower, assuming the machine efficiency is 95% and i
t
requires 1/8 idle horsepower.
c) Based on the cutting horsepower, what material(s) might we be cutting?
3. What roles do rake and relief angles play in cutting tools?
ans. the rake angle will change the basic cutting parameters. A positive rake (s
harp tool) will give
lower cutting forces, but less edge strength. A negative or neutral rake will gi
ve higher cutting
forces, but more strength. The relief angle provide a gap behind the cutting edg
e so that the tool
does not rub the work.
4. Which of these statement is the most correct?
a) a continuous chip with built up edge may result when we try to cut too much m
etal.
b) a continuous chip will result when cutting very brittle work materials.
c) a discontinuous chip will result when we use fine feeds and speeds.
d) none of the above.
ans. a
5. One of the assumptions behind orthogonal cutting is,
a) that the rake angle is positive.
Medium velocity explosives, 5-15,000 ft/sec. (1524-4572 m/s),
Ammonium nitrate
Ammonium perchlorate
Amatol
Nitroguonidine
Dynamites
diluted PETN
3 bond types,
- straight, direct metal-to-metal - best type of bonding but difficult to obtain
when collision
velocity less than critical velocity.
- wavy - the interface is strong and the interface has waves.
- straight, but with a continuous layer - a weaker bond that results when the co
llision
velocity is too high and the alloy bonds are strong.
Advantages,
- can bond many dissimilar, normally unweldable metals
- the lack of heating preserves metal treatment
- the process is compact, portable, and easy to contain
- inexpensive
- welds can be done from in2 to hundreds of ft2
- no need for surface preparation
- the backer plate has no size limits
Disadvantages,
- the metals must have high enough impact resistance, and ductility.
- the geometries welded must be simple - flat, cylindrical, conical.
- the cladding plate cannot be too large.
- noise and blast can require worker protection, vacuum chambers, buried in sand
/water.
Typical applications,
- spot welding
page 232
- reinforcing aerospace materials with dissimilar metal ribs
- seam and lap welds.
- tubular transition joints
- flat plates
42.7.1 Practice Problems
-

1. TRUE / FALSE - Ductile metals can be welded with explosives.

2.What is the purpose of flux in welding?
3. List 20 parts you have seen that are welded. Indicate which welding process i
s the most appropriate
for each.
4. What types of processes would be best suited for joining the following items?
Indicate why.
a) two 12 dia. plastic pipes.
b) two 12 dia. steel pipes.
c) the sides of a plastic bag for potato chips.
d) two aluminum plates along one edge.
e) an aluminum and steel plate into a laminated plate.
f) steel muffler pipes.
5. What are the primary differences between welding soldering and gluing?