SHEETS
SHEETS
SHEETS
SHEET No (1)
3. Derive the equation for the normal force acting at the chip/tool interface (10th
wk 2004)
4. Discuss the theory of Lee and Schaffer with a neat sketch. (P.42).
5. Derive an expression for the specific cutting energy p s in terms of the shear
angle φ and the mean shear strength of the work material τ s in orthogonal
cutting. Assume that the shear angle relationship of ernest and merchant
applies, i.e.,
2φ + β – γne = π /2
6. In an orthogonal turning operation the resultant cutting force, was 200 Kg. If the
cutting force is 120 Kg and the rake angle, γ=15°, the cutting ratio, r = 0.6,
calculate: the normal force F t , the shear angle and draw a circular force
diagram and derive the equation of friction force Ff. (2.b Jan 2005)
8. In an orthogonal cutting test on mild steel the following results were obtained:
ac = 0.25 mm Fc = 900 N
a0 = 0.75 mm Ft = 450 N
10. In an orthogonal cutting operation the following data were available: (10th wk
2004)
cutting speed: 20 m/min Material: medium carbon
thrust force: 60 Kg steel
chip thickness= 0.6 mm Main cutting force: 120 Kg
w.p. diameter: 80mm rake angle, γ=15°
depth of cut = 0.4 mm
:Calculate
a. friction force,
b. the length of the shear plane,
c. w.p. rotational speed,
d. the shear angle
e. shear force
f. the cutting ratio,
g. the resultant cutting force
h. Draw Merchant Circle of forces.
11. In an orthogonal turning operation the following data were calculated: [no 2
sheet M. Riad]
chip thickness= 0.45 mm Main cutting force: 1130 N
feed = 0.25 mm/rev rake angle, γ=10°
thrust force: 295 N cutting speed: 150 m/min
:Calculate
a. friction force,
b. velocity of the chip along tool face,
c. the shear angle
d. shear stress
e. the cutting ratio,
f. specific cutting energy
12. During machining of a medium carbon steel with a 10 deg rake angle cutting
tool, the following observations have been made: [no 3 sheet M. Riad]
chip thickness= 0.4 mm Main cutting force: 1600 N
feed = 0.25 mm/rev depth of cut = 2 mm
thrust force: 850 N cutting speed = 200 m/min
:Calculate
a. shear force
b. normal force on the shear plane,
c. friction force
d. normal force on the tool face
e. specific cutting energy
13. In an orthogonal turning operation of a tube the following data were given: [no
5 sheet M. Riad]
feed = 0.25 mm/rev main cutting force = 1850
thrust force = 1150 N N
tube outside diameter= 73 rake angle, γ=10°
mm rotational speed = 210 rpm
tube inside diameter = 67
mm
length of continuous chip for one revolution of workpiece= 88 mm
:Calculate
a. friction force,
b. the shear angle
c. shear stress
d. the cutting ratio,
e. specific cutting energy
15. A planer tool has a rake angle of 11° is set to operate with a depth of cut 1.2
mm and cutting speed of 15 m/min. The chip is 6 mm wide and thickness of
chip after cutting is 4.45 mm. If the material being cut is Killed steel having a
shear strength of 520 MN/m2, and the coefficient of friction is found to be 0.94.
Determine the amperes of the lead wires to the motor, knowing that the
efficiency of the motor is 85% and that of planer 70% and the voltage is 380 V.
[no 9 sheet M. Riad]
17. In orthogonal turning operation, the following data were given: tube outside
diameter=93 mm, inside diameter=87 mm, mean shear strength=700 MN/m2,
rake angle of 10°. Spindle speed= 150 rpm, mean chip thickness=0.5 mm,
volume of chip for one revolution of workpiece= 2.2 mm 3. Assume that the
shear angle relationship of Ernest & Merchant applies, Calculate [no 14 sheet
M. Riad]
a. Coefficient of friction,
b. Machining time of 200 mm length
c. shear strain
d. specific cutting energy
18. A lathe running idle consumes 325 W. When cutting an alloy steel at 24 m/min
the power input raises to 2580 W. Find the cutting force, the torque at the
spindle speed of 1200 rpm. Calculate the efficiency of the lathe at such
conditions. [no 16 sheet M. Riad]
19. The power required to turn medium carbon steel is around 3.8 J/mm 3. If the
maximum power at the machine spindle is 3.75 KW. Find the maximum rate of
metal removal, also find for the cutting speed of 40 m/min, and feed rate of
20. In facing a tubular workpiece of a steel material on a lathe the following data
were available: [no 19 sheet M. Riad]
outer diameter = rake angle, γ=15°
66mm feed rate = 0.25 mm/rev
inner diameter = 60mm cutting speed: 78 m/min
chip thickness= 0.75 mm
shear flow strength of
mean coefficient of
material=600 MN/m2 friction=0.8
:Calculate
a. Specific power consumption
b. The motor power if the friction at the machine
elements consumes 40% of the power input.
c. the thrust force,
d. the cutting force
1. Draw typical temperature contours in a cutting tool and show the effect of
coolants on these contours. (P.105)
3. It was found from experiments where the chips produced during shaping of
mild steel that the cutting conditions were as follows:
cutting speed = 1 m/s.
undeformed chip thickness = 0.5 mm.
width of chip = 5 mm.
working normal rake = 450.
.cutting force = 6000 N
thrust force = 0.
chip thickness = 1.2 mm.
width of cut aw = 2.5 mm
length of contact between chip and tool lf = 0.75 mm
thermal conductivity = 43.6 J/s m °K
specific heat capacity = 502 J/Kg °K
density = 7200 Kg/m3 & w.p. room temperature = 22 °C
.width of sec deformation zone / chip thickness w0 = 0.2
Calculate the max temperature along the tool face
4. Show that, when cutting metal orthogonally with a tool of zero rake angle, the
rate of heat generation, ps, in the shear zone is given by:
ps = Fc v (1-μrc)
where
Fc = cutting force
v = cutting speed
μ = mean coefficient of friction on the tool face.
rc = cutting ratio
(a) For the same conditions, calculate the mean shear-zone
temperature rise θs when the metal has a specific cutting energy
of 2.8 GN/m2, μ = 1.0, rc = 0.2, and 10 percent of the shear zone
heat is conducted into the workpiece. Assume, for the work
material, that ρ = 7200 kg/m3 and c= 500 J/kgK
Tool life
1. Show with the aid of a neat sketch the effect of the clearance angle on tool
wear. (P.22)
2. In a repeated use of a twist drill for drilling brass alloy, the tool life, estimated in
time units, was found to be 30 min at cutting speed, V=20 m/min. What will be
the speed that attains a tool life of 45 min, the constant n = 0.2. (2. Jan 2006 )
3. A single point cutting tool has a rake angle equal to zero and a clearance angle
of 20. By what percentage would the life of the tool between regrinds be
increased if a clearance angle of 8 0 were provided? (Assume the tool is
reground after a specified amount of flank wear has taken place and the rate of
wear of the tool normal to the wear land is constant).
4. Given the following data for a cutting process: (2. Jan 2005 )
Compute the C and n values for Taylor tool life equation and calculate the
.tool life in minutes for a cutting speed of 580 m/min
Surface roughness
2. Mention the factors that contribute to the natural surface roughness. (P.203)
3. A turning tool with a sharp corner and a major cutting edge angle of 60 0 is to be
used at a feed of 0.05 mm, what minor edge angle should be provided to obtain
an arithmetical mean? Surface roughness under ideal conditions of 3 μm?
4. What corner radius should be ground on a tool with a rounded corner to give an
arithmetical mean surface roughness of 10 μm when turning under ideal
conditions with a feed of 0.25 mm?
4. For single-shift working in particular turning operation, the cost of the labor and
machine time in resetting a cutting edge is $0.20, the cost of each throw-away
insert having four cutting edges is $0.80, and the depreciation of the insert
holder per insert is $0.08. The initial cost of the lathe was $20000, which is
amortized for 5 years. Machine running costs including labor and overheads
but neglecting depreciation are estimated at $6.00 /hr. If the Taylor tool-life
index for the carbide inserts is 0.25, calculate, for minimum second (m/s), if the
machine is to be used on a:
Single-shift, 40 hr/wk basis
Double-shift, 80 hr/wk basis
Assume 50 working weeks per year, a cutting speed for 60 s tool life of 7.6 m/s,
and a nonproductive time for loading and unloading a component of 3 min