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ME 338 Manufacturing Processes II HW#1

This document outlines three homework problems for a manufacturing processes course. The first problem involves modeling the interaction between a tool and workpiece as a spring-damper system and analyzing the system's response to different forces. The second problem involves calculating grinding force, temperature rise, and stress in a silicon carbide grinding wheel grain. The third problem involves deriving optimal cutting velocity and tool life for maximum profit or lowest unit cost based on machining parameters and costs.

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Aditya Dave
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
87 views

ME 338 Manufacturing Processes II HW#1

This document outlines three homework problems for a manufacturing processes course. The first problem involves modeling the interaction between a tool and workpiece as a spring-damper system and analyzing the system's response to different forces. The second problem involves calculating grinding force, temperature rise, and stress in a silicon carbide grinding wheel grain. The third problem involves deriving optimal cutting velocity and tool life for maximum profit or lowest unit cost based on machining parameters and costs.

Uploaded by

Aditya Dave
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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ME 338

Manufacturing Processes II
HW#1
Instructor: Ramesh Singh
Assigned Date: Sept 6, 2009
Due Date: Sept 11, 2009



1. Assume the tool-workpiece contact to be a parallel spring damper system as shown in Fig. 1.



Fig. 1. Tool-workpiece spring damper system

+ + =
Viscous damping ratio, =


a) For free vibrations (F(t)=0), solve the differential equation and plot solutions for
critically damped(=1) and underdamped(<1)
b) Machine tools encounter unit impulse, unit step and periodic force functions which may
excite vibration in the machine.
Assuming F(t) to be unit impulse function and unit step function, plot their responses for
the spring-damper system for a critically damped condition (=1) and make
observations on the differences.


2. You are grinding a steel, which has a specific grinding energy (u) of 25 W-s/mm
3
. The
grinding wheel rotates at 3000 rpm, has a diameter (D) of 120 mm, thickness (b) of 20 mm,
and (c) 5 grains per mm
2
(c). The motor has a power of 2 kW. The work piece moves (v) at
1.5 m/min. The chip thickness ratio (r) is 10.

a) Determine the grinding force and force per grain.
b) Determine the temperature (K
2
is 0.2
o
K-m/N). Room temperature is 20
o
C.

Let the grain be a SiC grain modeled as a continuously varying circular beam as shown in
Fig. 2. Assume the force/grain is acting at the tip and the bonding is perfect. Use cantilever
beam theory to find maximum stress. Will these stresses be sufficient to fail the grain? Look
up all the properties of SiC.






3. Machining Economics
a) Derive the optimal cutting v
b) Find optimal cutting velocity and tool life for maximum profit
rate for the following conditions.
Given:
Taylor tool life equation
Machining (turning) parameters
Depth of cut, d = 1.00 mm
Feed, f = 0.2 mm/rev
Workpiece geometry
Workpiece diameter,
Workpiece length,
Time parameters
Setup time,
Tool replacement time,
Cost parameters
Machine utilization rate,
Machining overhead,
Tool cost,




Fig. 2. SiC grain geometry.
Derive the optimal cutting velocity and tool life for lowest unit cost.
elocity and tool life for maximum profit and maximum production
rate for the following conditions.
Taylor tool life equation VT
0.3
= 400, V (m/min)
Machining (turning) parameters
= 1.00 mm
= 0.2 mm/rev
Workpiece geometry
Workpiece diameter, D = 50 mm
Workpiece length, L = 200 mm

Setup time, t
p
= 0.80 min/pt
Tool replacement time, t
c
= 1.5 min/edge
Machine utilization rate, k
o
= 0.50 $/min
Machining overhead, k
m
= 0.05 $/min
Tool cost, k
t
= 2.50 $/edge

and maximum production

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