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Tutorials Week 2 My Solutions

The document discusses material removal processes and machining. It provides an overview of different machining categories and processes like turning, milling and drilling. It also discusses the orthogonal cutting model and how it is used to analyze metal cutting operations.

Uploaded by

Josephine Bakewa
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© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
7 views

Tutorials Week 2 My Solutions

The document discusses material removal processes and machining. It provides an overview of different machining categories and processes like turning, milling and drilling. It also discusses the orthogonal cutting model and how it is used to analyze metal cutting operations.

Uploaded by

Josephine Bakewa
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 6

TUTORIALS: Theory of Metal Machining (Week 2)

REVIEW QUESTIONS
1. What are the three basic categories of material removal processes?

Machining Processes:Machining involves the removal of material from a workpiece


to achieve the desired shape and size. Common machining processes include
turning, milling, drilling, grinding, and electrical discharge machining (EDM).

Abrasive Processes:Abrasive processes use abrasives (hard particles or grains) to


remove material from the workpiece surface. Examples of abrasive processes
include grinding, honing, lapping, and abrasive jet machining.

Nontraditional Machining Processes:Nontraditional or unconventional machining


processes utilize methods different from traditional machining. These include
processes like electrical discharge machining (EDM), electrochemical machining
(ECM), laser machining, ultrasonic machining, and water jet cutting. They are
often used for materials that are difficult to machine using conventional methods
or for precision applications.

2. What distinguishes machining from other manufacturing processes?


Machining involves the removal of material from a workpiece to achieve desired
shapes and dimensions. It usually involves a cutting tool that removes excess
material through various processes like turning, milling, drilling, etc.

3. Identify some of the reasons why machining is commercially and


technologically important.
Machining is crucial for producing precise and complex components with tight
tolerances. It is used in a wide range of industries, including automotive,
aerospace, electronics, and more.

4. Name the three most common machining processes.


Turning, milling, and drilling are three of the most common machining processes.

5. What is an orthogonal cutting operation?


An orthogonal cutting operation is a machining process where the cutting edge of
the tool is perpendicular to the direction of tool travel.

6. Why is the orthogonal cutting model useful in the analysis of metal machining?
MCD656 ADVANCED MANUFACTURING TECHNOLOGY Page 1 of 4
The orthogonal cutting model simplifies the analysis of metal machining by
assuming certain ideal conditions, making it easier to understand and apply in
practice.

7. Identify the four forces that act upon the chip in the orthogonal metal
cutting model but cannot be measured directly in an operation.
The four forces are the shear force (Fs), the normal force (Fn), the friction force
along the rake face (Ff), and the friction force along the shear plane (Fc).

8. Identify the two forces that can be measured in the orthogonal metal cutting
model.
The cutting force (Fc) and the thrust force (Ft) can be measured in the orthogonal
metal cutting model.

9. What is the relationship between the coefficient of friction and the friction
angle in the orthogonal cutting model?
The coefficient of friction (μ) is equal to the tangent of the friction angle (φ) in
the orthogonal cutting model.

10. Describe in words what the Merchant equation tells us.


2.
 The Merchant equation relates the shear angle, chip thickness, and
cutting edge inclination angle in metal cutting. It helps in
understanding the geometry of the cutting process.

MULTIPLE CHOICE QUIZ


1. Which of the following manufacturing processes are classified as material
removal processes (two correct answers):
(a) casting, (b) drawing,
(c) extrusion, (d) forging,
(e) grinding, (f) machining,
(g) molding, (h) pressworking, and
(i) spinning?

MCD656 ADVANCED MANUFACTURING TECHNOLOGY Page 2 of 4


The
manufacturing
processes
classified as
material
removal
processes
among the
given options
are:

(e) Grinding -
Grinding
involves the
removal of
material using
abrasive
particles.

(f) Machining -
Machining
processes, such
as milling,
turning, and
drilling, involve
the removal of
material using
cutting tools.

MCD656 ADVANCED MANUFACTURING TECHNOLOGY Page 3 of 4


2. A lathe is used to perform which one of the following
manufacturing operations:
(a) broaching, (b) drilling,
(c) lapping, (d) milling, or
(e) turning?

3. With which one of the following geometric forms is the drilling operation
most closely associated:
(a) external cylinder, (b) flat plane,
(c) round hole, (d) screw threads, or
(e) sphere?

4. Which of the following are characteristics of the orthogonal cutting model


(three best answers):
(a) a circular cutting edge is used,
(b) a multiple- cutting-edge tool is used,
(c) a single-point tool is used,
(d) only two dimensions play an active role in the analysis,
(e) the cutting edge is parallel to the direction of cutting speed,
(f) the cutting edge is perpendicular to the direction of cutting speed, and
(g) the two elements of tool geometry are rake and relief angle?

5. The chip thickness ratio is which one of the following:


(a) tc/to, (b) to/tc,
(c) f/d, or (d) to/w,
where tc = chip thickness after the cut, to = chip thickness before the
cut, f = feed, d = depth, and w = width of cut?

MCD656 ADVANCED MANUFACTURING TECHNOLOGY Page 4 of 4


6. According to the Merchant equation, an increase in rake angle would have
which of the following results, all other factors remaining the same (two best
answers):
(a) decrease in friction angle,
(b) decrease in power requirements,
(c) decrease in shear plane angle,
(d) increase in cutting temperature, and
(e) increase in shear plane angle?

7. In using the orthogonal cutting model to approximate a turning operation,


the chip thickness before the cut to corresponds to which one of the
following cutting conditions in turning:
(a) depth of cut d, (b) feed f, or (c) speed v?

PROBLEMS
1. In an orthogonal cutting operation, the tool has a rake angle = 15 O. The chip
thickness before the cut = 0.30 mm and the cut yields a deformed chip
thickness = 0.65 mm.
Calculate: (a) the shear plane angle and
(b) the shear strain for the operation.

2. In Problem 1, suppose the rake angle were changed to 0O. Assuming that
the friction angle remains the same,
Determine: (a) the shear plane angle,
(b) the chip thickness, and
(c) the shear strain for the operation.

MCD656 ADVANCED MANUFACTURING TECHNOLOGY Page 5 of 4


3. In a turning operation, spindle speed is set to provide a cutting speed of 1.8
m/s. The feed and depth of cut are 2.6 mm and 0.30 mm, respectively. The tool
rake angle is 8O. After the cut, the deformed chip thickness is measured to
be
0.49 mm.
Determine: (a) shear plane angle and
(b) shear strain
Use the orthogonal cutting model as an approximation of the turning process.

4. 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.

5. In an orthogonal cutting operation, the rake angle = -5O, 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,
(d) coefficient of friction, and
(e) shear strain.

6. 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 5O 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.
MCD656 ADVANCED MANUFACTURING TECHNOLOGY Page 6 of 4

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