Example of coursework completed in a Manufacturing Processes class. Covered all the major types of additive and subtractive manufacturing.

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Homework Report #3: Abrasive Processes
MET 33800 Manufacturing Processes – Fall 2015
Department of Engineering Technology
Report By: Joseph Legan
Report Date: 10/22/15
Abrasive Process Abstract: Students will investigate in-depth the grinding category of
manufacturing processes. Investigation will include machine operation, types of
geometry generated, cutting tools and workholding devices.
Part 1: Answer the following questions:
1) Define and identify unique characteristics of the items below:
a. Abrasive Machining is the process of removing a small amount of material by
the interaction of abrasive grits and the workpiece at high speeds. It is a chip
removal process but the chips are very small. Depending upon type of
machine it can done to flat, round or profile shapes and almost any size.
b. Honing is uses fine bonded stones to remove a very small amount of
material. Honing can be done to the ID or OD of a cylinder. When used for a
part that must seal a specific lay pattern can be achieved by controlling the
spindle speed and the reciprocating of the stones along the workpiece.
c. Lapping is the process of allowing hard free abrasive particles to embed
themselves into a softer material that is then used to remove a very small
amount of material from a workpiece. Usually this is done with a lapping
machine and diamond free abrasive embedded into a cast iron lap. It is used
to create a very accurate and flat shape on the workpiece that has a high
surface finish, such as gauge blocks.
d. Surface Grinding is used to create flat and parallel surfaces on the workpiece.
Machines use a combination of horizontal and vertical spindles with rotary or
reciprocating tables. Each combination creates a different lay or pattern to the
finish. The grinding media is fed into the workpiece while the table either
reciprocates or rotates.
e. Centerless Grinding uses no workholding device, instead uses either support
rolls for ID grinding or a blade for OD grinding. The workpiece moves along
the grinding wheel by the regulating wheel. Creates a round profile for
internal or external operation.
f. Creep Feed Grinding is the process cutting a deep groove or profile in a
single pass with a very low feed rate. A soft wheel is used often with a
continuous dressing process.

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g. Abrasive Flow is primarily used to deburr material or workpieces. It is the
process of forcing a slurry or gel that contains abrasive over or through the
material. In doing this it removes a small material amount while increases the
surface finish and rounding edges. I have seen it used as extrude honing on
engine intakes to increase the flowrate.
2) Name four different shapes of grinding wheels.
 Straight
 Recessed one side
 Flaring cup
 Tapered
3) Define the characteristics of a grinding wheel with the marking A-36-L-5-V
A for regular aluminum oxide
36 grit
L for a medium grade wheel
5 for relatively dense structure
V for vitrified bond
Part 2: Complete the following table. On the following pages, Insert the correct term or
function for the machine component indicated.
Type Of Cutting
Tools Used
Type Of Work
Holding Devices
Typical Workpiece
Geometry Produced
Safety Hazards
Associated with the
Machine Tool
Surface
Grinder
Grinding wheels o
bonded stones
Table clamps,
magnetic chucks,
mechanical
fasteners.
Flat surfaces.
Sparks, airborne
chips in dust form.
Centerless
Grinder
Grinding Wheel
Blade or support
rolls
Round profiles
either ID or OD
Being pulled into the
machine as the
regulating wheel
and grinding wheel
rotate in opposite
directions.

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Abstract: Students will develop a manufacturing process plan for a simple component. Project
will include determination of appropriate manufacturing processes, workholding device,
manufacturing sequence and machining parameters. This process is not limited to the
equipment available in the Machine Tool Laboratory.
Part 3: Process Planning
Instructions:
1. Using the drawing shown below, develop a manufacturing process plan showing all
necessary machining operations.
2. Use the format shown on the following page: specify the machine type; work holding
method; cutting tool type and material; dimensional characteristics machined; and
inspection method for each operation.
3. Material is 1040 wrought medium carbon steel 225/275 BHN hardness. The material
does not require any heat-treating operation. Raw stock is 3.25-inch diameter bar

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Op#
Machine
Type
Process Description Workholding
Cutting
Tool
Inspection
Procedure
10 Stores Release 3.25” dia 1040 medium carbon
(225/275 BHN) bar stock to mfg
20 Cutoff Saw Rough finish length to 24.00” Vise HSS Blade Vernier Caliper
30 Engine Lathe Cut 1 Depth 0.375” along entire piece. New OD =
2.5”+0.000, -0.001
3 jaw chuck
with dead
center and tail
stock with live
center
Carbide
cutter
Vernier
Micrometer
40 Engine Lathe Cut 2 at 21.75” from left end, Depth 0.2495” to the right
end of piece.
3 jaw chuck
with dead
center and tail
stock with live
center
Carbide
cutter
Vernier
Micrometer
50 Engine Lathe Thread Cutting, from left end, set lathe to cut 2 threads
per inch and cut for 1.5”
3 jaw chuck
with dead
center and tail
stock with live
center
ACME
thread profile
carbide
cutter
ACME 3”-2
thread gauge
60 Engine Lathe Thread Cutting, from right end of 2.5” OD, set lathe to cut
2 threads per inch and cut for 11”
3 jaw chuck
with dead
center and tail
stock with live
center
ACME
thread profile
carbide
cutter
ACME 3”-2
thread gauge
70 Engine Lathe Right End Chamfer, chamfer the right end of workpiece
with tool rest at 45 degrees to centerline of workpiece
3 jaw chuck
with dead
center and tail
stock with live
center
1/16” wide
carbide
cutter
Compass and
steel ruler
80 Engine Lathe Left End Radius, radius left end of workpiece with tool
rest at 90 degrees to centerline of workpiece
3 jaw chuck
with dead
center and tail
stock with live
center
1/8” radius
carbide
cutter
Radius gauge
90 Horizontal mill Cut Keyway, locate along the centerline or workpiece and
1” in from left end plunge to a depth of ½” and transverse
table 10.75” in the X direction.
Vise ½” W x 1”
dia. woodruff
key seat
cutter
Vernier Caliper
100 Vertical Mill Drill # 1 for taper pin through workpiece, rotate workpiece
so keyway is horizontal and locate a point along
centerline and 1.28125” in from right edge.
Vise 25/64” drill
bit
Telescpoing
Gauge and
Vernier
micrometer
110 Vertical Mill Drill # 2 for taper pin to depth of 1.3334” Vise 27/64” drill
bit
Telescpoing
Gauge and
Vernier
micrometer
120 Vertical Mill Drill # 3 for taper pin to depth of 0.6667” Vise 29/64” drill
bit
Telescpoing
Gauge and
Vernier