Kafrelshiekh University Subject: Production engineering (1)

Faculty of Engineering Academic Year: 2022/2023

Mechanical Engineering Dept. Date:
Dr. Mahmoud Tawfik

Machining

1- Show the general classification of the machining processes.

2- Machining is important commercially and technologically. Why?
3- Describe a tool having 8 14 5 6 20 15 1 signature in ASA system.
4- A tool has an approach (setting) angle of 55°, a normal rake angle of 22°, and a cutting
edge that lies in a plane parallel to the base of the tool. Find the side and back rake angles
for this condition.
5- A cutting tool has a setting angle of 60°, back rake angle 12°, and side rake angle of 18°;
find the normal rake angle on the assumption that the cutting is orthogonal. If this tool is
set at 2.5 mm above center during turning of a bar 100 diameter, what change will be
caused to the normal rake angle?
6- For the case of λ = 0 and a setting angle of 90° if the normal rake angle is 10°, the normal
relief angle is 7°, cutting speed is 200 mm/min, the tool feed rate is 20 mm/min, and the
tool nose is set at 2 mm above the center; calculate the actual rake and clearance angles
if the workpiece diameter is 200 mm.
7- Describe the tool geometry using orthogonal and ASA systems.
8- Explain the effect of tool setting on the ASA tool angles.
9- Show the effect of feed motion on the actual tool angles.
10- State the main requirements for tool materials.
11- Show the general classification of cutting tool materials.
12- Compare by drawing only between orthogonal cutting and oblique cutting in
machining operations.
13- Explain what is meant by hot hardness. Show the hot–hardness diagram for the
different tool materials.3

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14- What are the main characteristics of the following tool materials: cast alloys;
ceramics?
15- What are the properties of cemented carbide tools?
16- What are the desirable characteristics of a cutting tool material?
17- Explain the advantages of coated carbides over uncoated carbides. Name any three
materials used for coatings.
18- Show with net sketches five operations related to turning.
19- Show with drawing only two methods of horizontal boring machines.
20- Name the various ways in which a workpart can be held on a lathe.
21- Show with net sketches five operations related to drilling.
22- It is required to face a disk of 450 mm outer diameter with a central hole of 150 mm.
A lathe machine is used for that job, the spindle speed is 50 rpm, feed rate is 0.3 mm/rev,
and the depth of cut is 2.5 mm. The specific cutting energy at these cutting conditions is
1550 N/mm2. Calculate the machining time.
23- It is required to turn a steel shaft having a diameter of 50 mm and a length of 400
mm on a center lathe that uses a gearbox providing the following rotational speeds: 63,
100, 160, 250, 500, 710, 1000, and 1600 rpm. The machining has been performed under
the following conditions:

Calculate
a. The machining time
b. The volumetric removal rate.

24- In a rough turning operation of mild steel bar of 80–72 mm using a feed rate of 1
mm/rev, cutting speed is 30 m/min, and specific cutting energy is 1800 N/mm2. This process
is followed by a finishing process to a diameter of 71 mm, feed rate 0.2 mm/rev, cutting
speed 300 m/min, and specific cutting energy 4000 N/mm2. For both cases, calculate the
total machining time for the part if the length is 500 mm
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 25- A lathe, equipped with six-speed gearbox (35, 70, 140, 280, 560, and 1120 rpm), is
used to machine a shaft made of extruded brass of 60 mm diameter and a length of 500
mm. Its diameter is to be reduced to 55 mm in two cuts using the following conditions:

You are required to

a. Select suitable spindle speeds for roughing and finishing cuts
b. Calculate the total machining time

26- In a drilling operation using a twist drill, the rotational frequency is 5 s−1, the feed
rate is 0.25 mm/rev, and the drill diameter is 12 mm. Assuming that ks = 2000 N/mm2.
Calculate
a. The volumetric removal rate
b. The machining time if the workpiece thickness is 25 mm

27- The component shown as follows, 35 mm diameter of brass 70/30 having a specific
cutting energy 2000 N/mm2, is to be machined on the center lathe using turning tools of
carbide k type and HSS twist drills. The following speeds and feeds are used:

Turning: cutting speed 10π m/min, feed rate

0.2 mm/rev
Drilling: cutting speed 5π m/min and a feed
rate 0.25 mm/rev
For turning operation, calculate
a. The cutting time when turning 30 mm
diameter to the length of 55 mm
For drilling, calculate the depth of cut for when drilling 10 mm diameter.

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28- Explain with net sketches the two forms of peripheral milling operation.
29- Show with net sketches five operations related to milling.
30- Draw four types of shapes that can cut by shaping and planning.
31- Compare with fine sketches the basic motions of shaping and Planing machines.
32- Describe with sketches only five operations related to shaping and planning.
33- A peripheral milling operation is performed on the top surface of a rectangular
workpart which is 400 mm long x 60 mm wide. The milling cutter, which is 80 mm in
diameter and has five teeth, overhangs the width of the part on both sides. Cutting speed
= 70 m/min, chip load = 0.25 mm/ tooth, and depth of cut = 5.0 mm.
Calculate
a- the actual machining time to make one pass across the surface.
b- the maximum material removal rate during the cut.
34- A face milling operation is used to machine 6.0 mm from the top surface of a
rectangular piece of aluminum 300 mm long by 125 mm wide in a single pass. The cutter
follows a path that is centered over the workpiece. It has four teeth and is 150 mm in
diameter. Cutting speed = 2.8 m/s, and chip load = 0.27 mm/tooth. Determine (a) the actual
machining time to make the pass across the surface and (b) the maximum metal removal
rate during cutting.
35- Calculate the shaping time for a workpiece length 600 mm and width 150 mm using
a feed rate of 0.5 mm/stroke. The height of the part was 60 mm, which was reduced to 50
mm at a maximum depth of cut 2 mm, the cutting speed was 30 m/min, and V:Vr was 1:2.
36- Consider the horizontal milling of a mild steel workpiece calculate machining time
for one travel if the workpiece length = 360 mm under the following conditions:
Machining parameters
• V = 60 m/min
• f = 360 mm/min
• t = 3.2 mm
Cutter
• Zc = 16 teeth
d = 144 mm
• bw = 40 mm
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37- A component is to be machined on the horizontal milling machine with a slab-milling
cutter of 100 mm diameter. The cutter has 16 teeth, cutting speed is 100 m/min, and the
feed per tooth is 0.025 mm. Calculate the machining time for one travel if the part length
is 500 mm.
38- During a vertical milling operation for cast iron block of 600 mm length, using a
cutter, having 100 mm diameter and 6 teeth, depth of cut 6 mm, workpiece feed rate 200
mm/min, cutting speed 20 m/min, and a cutting width of 40 mm.
Calculate
a. The cutter rotational speed
c. The machining time for one travel

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 Forming
1- Show the general classification of metal forming.
2- Describe with sketches only the four basic bulk deformation processes.
3- Describe with sketches only the three basic sheet metalworking processes.
4- Indicate some of the advantages of cold working relative to warm and hot working.
5- Define isothermal forming.
6- State disadvantages of friction in most metal forming processes.
7- List the common considerations in choosing an appropriate metalworking lubricant.
8- In rolling of steel, what are the differences between a bloom, a slab, and a billet?
9- Indicate with drawing only five types of rolling mills.
10- Indicate with drawing only thread rolling with flat dies.
11- Indicate with drawing only roll piercing.
12- Indicate with drawing types of forging dies.
13- Explain with fine sketches the terminology for a conventional impression die in
forging.
14- Explain with fine sketches upsetting and heading by forging.
15- Explain with fine sketches swaging and Radial forging by forging.
16- Explain with fine sketches Hubbing by forging.
17- What are some of the possible defects in drawn sheet-metal parts?
18- Describe each of the two types of sheet-metal bending operations: V-bending and
edge bending.
19- In a wire drawing operation, why must the drawing stress never exceed the yield
strength of the work metal?
20- Compare by drawing only impact extrusion and hydrostatic extrusion.
21- Show by drawing only heading of a wire stock procedure.
22- Prior to drawing, the beginning stock must be properly prepared. Explain.
23- Explain with fine sketches Shearing, Blanking, and Punching.
24- Compare by drawing only between cutoff, slotting, perforating, and parting in
sheet-metal-cutting operations.
25- Explain with fine sketches V-bending and edge bending.
26- Explain with fine sketches the stages in deformation of the work in deep drawing.
27- In a wire drawing operation, why must the drawing stress never exceed the yield
strength of the work metal?
28- List the common defects common defects in drawn parts.

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Rolling
1- A 42.0-mm-thick plate made of low carbon steel is to be reduced to 34.0 mm in one pass in
a rolling operation. As the thickness is reduced, the plate widens by 4%. The yield strength
of the steel plate is 174 MPa and the tensile strength is 290 MPa. The entrance speed of
the plate is 15.0 m/min. The roll radius is 325 mm and the rotational speed is 49.0 rev/min.
Determine (a) the minimum required coefficient of friction that would make this rolling
operation possible, (b) exit velocity of the plate, and (c) forward slip.
2- A series of cold rolling operations are to be used to reduce the thickness of a plate from
50mmdown to 25 mm in a reversing two-high mill. Roll diameter = 700 mm and coefficient
of friction between rolls and work = 0.15. The specification is that the draft is to be equal
on each pass. Determine (a) minimum number of passes required, and (b) draft for each
pass?
3- A single-pass rolling operation reduces a 20 mm thick plate to 18 mm. The starting plate
is 200 mm wide. Roll radius = 250 mm and rotational speed = 12 rev/min. The work
material has a strength coefficient = 600 MPa and a strength coefficient = 0.22. Determine
(a) roll force, (b) roll torque, and (c) power required for this operation.
4- A 300-mm-wide strip 25-mm thick is fed through a rolling mill with two powered rolls each
of radius = 250 mm. The work thickness is to be reduced to 22 mm in one pass at a roll
speed of 50 rev/min. The work material has a flow curve defined by K = 275 MPa and n =
0.15, and the coefficient of friction between the rolls and the work is assumed to be 0.12.
Determine if the friction is sufficient to permit the rolling operation to be accomplished. If
so, calculate the roll force, torque, and horsepower.

Forging
1- A cylindrical part is warm upset forged in an open die. The initial diameter is 45 mm and
the initial height is 40 mm. The height after forging is 25 mm. The coefficient of friction at
the die–work interface is 0.20. The yield strength of the work material is 285 MPa, and its
flow curve is defined by a strength coefficient of 600 MPa and a strain-hardening exponent
of 0.12. Determine the force in the operation (a) just as the yield point is reached (yield at
strain = 0.002), (b) at a height of 35 mm, (c) at a height of 30 mm, and (d) at a height of
25 mm.
2- A cold heading operation is performed to produce the head on a steel nail. The strength
coefficient for this steel is 600 MPa, and the strain-hardening exponent is 0.22. Coefficient
of friction at the die–work interface is 0.14. The wire stock out of which the nail is made is
5.00 mm in diameter. The head is to have a diameter of 9.5 mm and a thickness of 1.6 mm.
The final length of the nail is 120 mm. (a) What length of stock must project out of the die
in order to provide sufficient volume of material for this upsetting operation? (b) Compute
the maximum force that the punch must apply to form the head in this open-die operation.
3- A cylindrical workpiece is subjected toa cold upset forging operation. The starting piece
is 75 mm in height and 50mmin diameter. It is reduced in the operation to a height of 36
mm. The work material has a flow curve defined by K = 350MPaand n = 0.17.Assume a

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 coefficient of friction of 0.1.Determine the force as the process begins, at intermediate
heights of 62mm, 49 mm, and at the final height of 36 mm.

Extrusion
4- A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by indirect
(backward) extrusion to a 20 mm diameter. The die angle is 90o. The Johnson equation has
a = 0.8 and b = 1.4, and the flow curve for the work metal has a strength coefficient of 800
MPa and strain-hardening exponent of 0.13. Determine (a) extrusion ratio, (b) true strain
(homogeneous deformation), (c) extrusion strain, (d) ram pressure, and (e) ram force.
5- A billet that is 75 mm long with diameter = 35 mm is direct extruded to a diameter of 20
mm. The extrusion die has a die angle = 75o. For the work metal, K = 600 MPa and n =
0.25. In the Johnson extrusion strain equation, a = 0.8 and b = 1.4. Determine (a) extrusion
ratio, (b) true strain (homogeneous deformation), (c) extrusion strain, and (d) ram pressure
and force at L ¼ 70, 60, 50, 40, 30, 20, and 10 mm.
6- A billet 75mmlong and 25mmin diameter is to be extruded in a direct extrusion operation
with extrusion ratio rx = 4.0. The extrudate has a round cross section. The die angle (half
angle) = 90o. The work metal has a strength coefficient = 415 MPa, and strain-hardening
exponent = 0.18. Use the Johnson formula with a = 0.8 and b = 1.5 to estimate extrusion
strain. Determine the pressure applied to the end of the billet as the ram moves forward.

Drawing
7- A spool of wire has a starting diameter of 2.5 mm. It is drawn through a die with an opening
that is to 2.1 mm. The entrance angle of the die is 18o. Coefficient of friction at the work–
die interface is 0.08. The work metal has a strength coefficient of 450 MPa and a strain-
hardening coefficient of 0.26. The drawing is performed at room temperature. Determine
(a) area reduction, (b) draw stress, and (c) draw force required for the operation.
8- Bar stock of initial diameter = 90mmis drawn with a draft = 15mm.The draw die has an
entrance angle = 18o, and the coefficient of friction at the work–die interface = 0.08. The
metal behaves as a perfectly plastic material with yield stress = 105 MPa. Determine (a)
area reduction, (b) draw stress, (c) draw force required for the operation, and (d) power
to perform the operation if exit velocity = 1.0 m/min.
9- Wire is drawn through a draw die with entrance angle = 15o. Starting diameter is
2.5mmand final diameter ¼ 2.0 mm. The coefficient of friction at the work–die interface =
0.07. The metal has a strength coefficient K = 205 MPa and a strain-hardening exponent
n = 0.20. Determine the draw stress and draw force in this operation.

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Cutting Operations
10- A blanking operation is to be performed on 2.0-mm thick cold-rolled steel (half
hard). The part is circular with diameter = 75.0 mm. Determine the appropriate punch and
die sizes for this operation.
11- A round disk of 150-mm diameter is to be blanked from a strip of 3.2-mm, half-hard
cold rolled steel whose shear strength = 310 MPa. Determine (a) the appropriate punch
and die diameters, and (b) blanking force.

Drawing Operations
12- A cup-drawing operation is performed in which the inside diameter = 80 mm and
the height = 50 mm. The stock thickness = 3.0 mm, and the starting blank diameter = 150
mm. Punch and die radii = 4 mm. Tensile strength ¼ 400 MPa and yield strength = 180
MPa for this sheet metal. Determine (a) drawing ratio, (b) reduction, (c) drawing force,
and (d) blank holder force.
13- A deep drawing operation is performed in which the inside of the cylindrical cup has
a diameter of 4.25 in and a height = 2.65 in. The stock thickness = 3/16 in, and the starting
blank diameter = 7.7 in. Punch and die radii = 5/32 in. The metal has a tensile strength =
65,000 lb/in2, a yield strength = 32,000 lb/in2, and a shear strength of 40,000 lb/in2.
Determine (a) drawing ratio, (b) reduction, (c) drawing force, and (d) blank holder force.
14- A drawing operation is used to form a cylindrical cup with inside diameter = 75 mm
and height = 50mm. The starting blank size = 138 mm and the stock thickness = 2.4 mm.
Based on these data, is the operation feasible?

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