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1. The cutting force and thrust force in an orthogonal cutting operation are 1470 N and
1589 N, respectively. The rake angle = 5o, 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.
2. 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 o 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.
3. In a turning operation on plain carbon steel whose Brinell hardness = 275 HB, the
cutting speed is set at 200 m/min and depth of cut = 6.0 mm. The lathe motor is rated
at 25 kW, and its mechanical efficiency = 90%. Using the appropriate specific energy
value from Table 21.2, determine the maximum feed that can be set for this operation.
Use of a spreadsheet calculator is recommended for the iterative calculations required
in this problem.
4. Orthogonal cutting is performed on a metal whose mass specific heat = 1.0 J/g-C,
density = 2.9 g/cm3, and thermal diffusivity = 0.8 cm 2/s. The cutting speed is 4.5 m/s,
uncut chip thickness is 0.25 mm, and width of cut is 2.2 mm. The cutting force is
measured at 1170 N. Using Cook’s equation, determine the cutting temperature if the
ambient temperature = 22oC.
5. A tapered surface is to be turned on an automatic lathe. The workpiece is 750 mm long
with minimum and maximum diameters of 100 mm and 200 mm at opposite ends. The
automatic controls on the lathe permit the surface speed to be maintained at a constant
value of 200 m/min by adjusting the rotational speed as a function of work piece
diameter. Feed = 0.25 mm/rev and depth of cut = 3.0 mm. The rough geometry of the
piece has already been formed, and this operation will be the final cut. Determine (a)
the time required to turn the taper and (b) the rotational speeds at the beginning and
end of the cut.
6. A cylindrical workpart 200 mm in diameter and 700 mm long is to be turned in an
engine lathe. Cutting speed =2.30 m/s, feed =0.32 mm/rev, and depth of cut = 1.80 mm.
Determine (a) cutting time, and (b) metal removal rate.
7. A drilling operation is to be performed with a 12.7 mm diameter twist drill in a steel
workpart. The hole is a blind hole at a depth of 60 mm and the point angle is 118 o. The
cutting speed is 25 m/min and the feed is 0.30 mm/rev. Determine (a) the cutting time
to complete the drilling operation, and (b) metal removal rate during the operation,
after the drill bit reaches full diameter.
8. A gun-drilling operation is used to drill a 3.6 mm diameter hole to a certain depth. It
takes 4.5 minutes to perform the drilling operation using high pressure fluid delivery of
coolant to the drill point. The current spindle speed ¼ 4000 rev/min, and feed = 0.04
mm/rev. In order to improve the surface finish in the hole, it has been decided to
increase the speed by 20% and decrease the feed by 25%. How long will it take to
perform the operation at the new cutting conditions?
9. 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. Determine
(a) the actual machining time to make one pass across the surface and (b) the maximum
material removal rate during the cut.
10. A face milling operation is used to machine 6.0mm 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.
11. A three-axis CNC machining center is tended by a worker who loads and unloads parts
between machining cycles. The machining cycle takes 5.75 min, and the worker takes
2.80 min using a hoist to unload the part just completed and load and fixture the next
part onto the machine worktable. A proposal has been made to install a two position
pallet shuttle at the machine so that the worker and the machine tool can perform their
respective tasks simultaneously rather than sequentially. The pallet shuttle would
transfer the parts between the machine work table and the load/unload station in 15
sec. Determine (a) the current cycle time for the operation and (b) the cycle time if the
proposal is implemented. What is the percentage increase in hourly production rate that
would result from using the pallet shuttle?
12. A shaper is used to reduce the thickness of a 50mm part to 45mm. The part is made of
cast iron and has a tensile strength of 270 MPa and a Brinell hardness of 165 HB. The
starting dimensions of the part are 750 mm x 450 mm x 50 mm. The cutting speed is
0.125 m/sec and the feed is 0.40 mm/pass. The shaper ram is hydraulically driven and
has a return stroke time that is 50% of the cutting stroke time. An extra 150 mm must be
added before and after the part for acceleration and deceleration to take place.
Assuming the ram moves parallel to the long dimension of the part, how long will it
take to machine?

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