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Tutorial - Mechanics - 4 Example in The Lecture

This document contains 4 questions related to mechanics concepts in metal cutting operations. Question 1 provides data from a turning operation and asks to calculate specific cutting energy, required power, undeformed chip thickness, width of cut, shear angle, mean friction angle, and machining time. Question 2 shows an equation relating shear strength, specific cutting energy, and cutting ratio. Question 3 asks to calculate average undeformed chip area from a milling operation. Question 4 asks to determine shear plane length based on data from a turning operation on a slotted pipe.

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Chen WANYING
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71 views

Tutorial - Mechanics - 4 Example in The Lecture

This document contains 4 questions related to mechanics concepts in metal cutting operations. Question 1 provides data from a turning operation and asks to calculate specific cutting energy, required power, undeformed chip thickness, width of cut, shear angle, mean friction angle, and machining time. Question 2 shows an equation relating shear strength, specific cutting energy, and cutting ratio. Question 3 asks to calculate average undeformed chip area from a milling operation. Question 4 asks to determine shear plane length based on data from a turning operation on a slotted pipe.

Uploaded by

Chen WANYING
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Tutorial – Mechanics (Examples in the lecture notes)

Q1.
In an experimental turning operation where low-carbon steel was being machined using a carbide
tool, the following data were taken:
Cutting force Fc = 1 kN
Thrust force Ft = 0.5 kN
Working normal rake γne = 20 degrees
Feed f = 0.141 mm
Working major cutting-edge angle κr = 45 degrees
Depth of cut (back engagement) ap = 5 mm
Cutting speed v = 2 m/s
Cutting ratio rc = 0.2
Workpiece diameter dw = 100 mm
Workpiece machined length lw = 300 mm
Estimate from the data given:
a. The specific cutting energy of the work material ps
b. The power required for machining Pm
c. The undeformed chip thickness ac
d. The width of cut aw
e. The shear angle φ
f. The mean angle of friction on the tool face β
g. The time taken to complete the machining operation

Q2.
Show that in metal cutting when the working normal rake is zero, the ratio of the shear strength of
the work material 𝜏𝑠 to the specific cutting energy 𝑝𝑠 is given by

𝜏𝑠 (1 − 𝜇𝑟𝑐 )𝑟𝑐
=
𝑝𝑠 1 + 𝑟𝑐2

where μ is the coefficient of chip-tool friction, and 𝑟𝑐 is the cutting ratio.

Q3.
A slab milling operation is being carried out with a 100-mm diameter milling cutter having 8 teeth at
30 m/min. The depth of cut is 4 mm and table feed rate is 150 mm/min. The width of the workpiece
is 120 mm. Find the average cross-sectional area of the undeformed chip.

Q4.
In turning of a slotted pipe of diamond 90 mm, the chip produced was 125-mm long. If 𝜙 = 90°, 𝛾 =
20°, 𝑎𝑛𝑑 𝑠 = 0.2 𝑚𝑚/𝑟𝑒𝑣, determine the length of the shear plane.

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