Tutorial for chip formation study (Topic 2)

[1] In an orthogonal cutting operation, the tool has a rake angle = 15. The chip thickness before the cut
= 0.30 mm and the cut yields a deformed chip thickness = 0.65 mm. Calculate the shear angle for
this operation.
Solution: (a) r = to/tc = 0.30/0.65 = 0.4615
 = tan-1(0.4615 cos 15/(1 - 0.4615 sin 15)) = tan-1(0.5062) = 26.85

If the rake angle were changed to  = 0. Assuming that the friction angle remains the same,
determine (a) the shear plane angle and (b) the chip thickness for the operation
Solution: From Problem 21.1,  = 15 and  = 26.85. Using the Merchant Equation, Eq.
(21.16):
 = 45 + /2 - /2; rearranging,  = 2(45) +  - 2
 = 2(45) + α - 2() = 90 + 15 – 2(26.85) = 51.3
Now, with  = 0 and  remaining the same at 51.3,  = 45 + 0/2 – 51.3/2 = 19.35
(b) Chip thickness at  = 0: tc = to/tan  = 0.30/tan 19.35 = 0.854 mm

[2] In a turning operation, spindle speed is set to provide a cutting speed of 1.8 m/s. The feed and depth
of cut of cut are 0.30 mm and 2.6 mm, respectively. The tool rake angle is 8. After the cut, the
deformed chip thickness is measured to be 0.49 mm. Determine (a) shear plane angle, (b) shear
strain, and (c) material removal rate. Use the orthogonal cutting model as an approximation of the
turning process.
Solution: (a) r = to/tc = 0.30/0.49 = 0.612
 = tan-1(0.612 cos 8/(1 – 0.612 sin 8)) = tan-1(0.6628) = 33.6
(b)  = cot 33.6 + tan (33.6 - 8) = 1.509 + 0.478 = 1.987
(c) RMR = (1.8 m/s x 103 mm/m)(0.3)(2.6) = 1404 mm3/s

[3] The cutting force and thrust force in an orthogonal cutting operation are 1470 N and 1589 N,
respectively. The rake angle = 5, the width of the cut = 5.0 mm, the chip thickness before the cut =
0.6, and the chip thickness ratio = 0.38. Determine (a) the shear strength of the work material and
(b) the coefficient of friction in the operation.
Solution: (a)  = tan-1(0.38 cos 5/(1 - 0.38 sin 5)) = tan-1(0.3916) = 21.38
Fs = 1470 cos 21.38 – 1589 sin 21.38 = 789.3 N
As = (0.6)(5.0)/sin 21.38 = 3.0/.3646 = 8.23 mm2
S = 789.3/8.23 = 95.9 N/mm2 = 95.9 MPa
(b)  = 45 + /2 - /2; rearranging,  = 2(45) +  - 2
 = 2(45) + α - 2() = 90 + 5 – 2(21.38) = 52.24
 = tan 52.24 = 1.291
[4] An orthogonal cutting operation is performed using a rake angle of 15, chip thickness before the
cut = 0.012 in and width of cut = 0.100 in. The chip thickness ratio is measured after the cut to be
0.55. Determine (a) the chip thickness after the cut, (b) shear angle, (c) friction angle, and (d)
coefficient of friction.
Solution: (a) r = to/tc, tc = to/r = 0.012/0.55 = 0.022 in
(b)  = tan-1(0.55 cos 15/(1 - 0.55 sin 15)) = tan-1(0.6194) = 31.8
(c)  = 2(45) + α - 2() = 90 + 15 - 2(31.8) = 41.5
(d)  = tan 41.5 = 0.88

[5] The orthogonal cutting operation described in previous involves a work material whose shear
strength is 40,000 lb/in2. Based on your answers to the previous problem, compute (a) the shear
force, (b) cutting force, (c) thrust force, and (d) friction force.
Solution: (a) As = (0.012)(0.10)/sin 31.8 = 0.00228 in2.
Fs = AsS = 0.0028(40,000) = 91.2 lb
(b) Fc = 91.2 cos (41.5 - 15)/cos (31.8 + 41.5 -15) = 155 lb
(c) Ft = 91.2 sin (41.5 - 15)/cos (31.8 + 41.5 -15) = 77.2 lb
(d) F = 155 sin 15 - 77.2 cos 15 = 115 lb

[6] In an orthogonal cutting operation, the rake angle = -5, chip thickness before the cut = 0.2 mm and
width of cut = 4.0 mm. The chip ratio = 0.4. Determine (a) the chip thickness after the cut, (b) shear
angle, (c) friction angle, and (d) coefficient of friction.
Solution: (a) r = to/tc, tc = to/r = 0.2/.4 = 0.5 mm
(b)  = tan-1(0.4 cos(–5)/(1 - 0.4 sin(–5))) = tan-1(0.3851) = 21.1
(c)  = 2(45) + α - 2() = 90 + (-5) - 2(21.8) = 42.9
(d)  = tan 42.9 = 0.93

[7] Low carbon steel having a tensile strength of 300 MPa and a shear strength of 220 MPa is cut in a
turning operation with a cutting speed of 3.0 m/s. The feed is 0.20 mm/rev and the depth of cut is
3.0 mm. The rake angle of the tool is 5 in the direction of chip flow. The resulting chip ratio is
0.45. Using the orthogonal model as an approximation of turning, determine (a) the shear plane
angle, (b) shear force, (c) cutting force and feed force.
Solution: (a)  = tan-1(0.45 cos 5/(1 - 0.45 sin 5)) = tan-1(0.4666) = 25.0
(b) As = tow/sin  = (0.2)(3.0)/sin 25.0 = 1.42 mm2.
Fs = AsS = 1.42(220) = 312 N
(c)  = 2(45) + α - 2() = 90 + 5 - 2(25.0) = 45.0
Fc = Fscos (β – α)/cos ( + β – α)
Fc = 312 cos(45 - 5)/cos(25.0 + 45.0 - 5) = 566 N
Ft = Fssin(β – α)/cos( + β – α)
Ft = 312 sin(45 - 5)/cos(25.0 + 45.0 - 5) = 474 N
[8] A turning operation is made with a rake angle of 10, a feed of 0.010 in/rev and a depth of cut =
0.100 in. The shear strength of the work material is known to be 50,000 lb/in2, and the chip
thickness ratio is measured after the cut to be 0.40. Determine the cutting force and the feed force.
Use the orthogonal cutting model as an approximation of the turning process.
Solution:  = tan-1(0.4 cos 10/(1 - 0.4 sin 10)) = tan-1(0.4233) = 22.9
As = (0.010)(0.10)/sin 22.9 = 0.00257 in2
Fs = AsS = 0.00256(50,000) = 128 lb
 = 2(45) + α - 2() = 90 + 10 - 2(22.9) = 54.1
Fc = 128 cos (54.1 - 10)/cos (22.9 + 54.1 - 10) = 236 lb
Ft = 128 sin (54.1 - 10)/cos (22.9 + 54.1 - 10) = 229 lb
Power and Energy in Machining
[1] In a turning operation on stainless steel with hardness = 200 HB, the cutting speed = 200 m/min,
feed = 0.25 mm/rev, and depth of cut = 7.5 mm. How much power will the lathe draw in performing
this operation if its mechanical efficiency = 90%. Use Table 21.2 to obtain the appropriate specific
energy value.
Solution: From Table 21.2, U = 2.8 N-m/mm3 = 2.8 J/mm3
RMR = vfd = (200 m/min)(103 mm/m)(0.25 mm)(7.5 mm) = 375,000 mm3/min = 6250 mm3/s
Pc = (6250 mm3/s)(2.8 J/mm3) = 17,500 J/s = 17,500 W = 17.5 kW
Accounting for mechanical efficiency, Pg = 17.5/0.90 = 19.44 kW