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1.1. While doing orthogonal machining with a cutting tool having a 10 0 rake angle, the chip thickness is measured to be 0.4 mm, the uncut thickness being 0.16mm. Find out the shear plane angle and also the magnitude of shear strain. Soln. From the given data, chip thickness ratio or cutting ratio
r= t1 0.16 = = 0 .4 t2 0.4
r.Cos 0.4 Cos 10 0 = = 0.4232 1 r.Sin 1 0.4 Sin 10 0
Since, tan =
Therefore, = tan-1(0.4232) = 22.9380 Again, shear strain is given by = Cot + tan( ) = Cot 22.9380 + tan (22.9380-100) = 2.36+0.23 = 2.59 1.2. During orthogonal machining of a mild steel part, an uncut chip thickness of 0.8mm is used at 55rpm. If the chip thickness is 1.6mm, determine the chip thickness ratio. Also calculate the length of the chip removed in one minute if the work diameter is 50mm. Assume a continuous type of chip. Soln. Given that, t1 = 0.8mm and t2 = 1.6 mm. t1 0.8 = 0.5 Thus, r = = t 2 1.6 Length of the chip before cutting, L1 = .D.N = 5055 = 8635 mm/min L2 L = 2 Now, r = L1 8635 or, L2 = 8635 r = 8635 0.5 = 4137.5mm/min 1.3. During orthogonal cutting process, a chip length of 75mm was obtained with an uncut chip length of 195mm and the rake angle used was 200 with uncut chip thickness 0.45mm. The tangential and thrust components of cutting force were 1950N and 190N respectively. Calculate the shear plane angle, chip thickness, friction angle and resultant cutting force. Soln. Since L1 and L2 are given, the cutting ratio can be obtained as L 75 r= 2 = = 0.3846 L1 195 r.Cos 0.3846 Cos 20 0 tan = = = 0.4161 1 r.Sin 1 0.3846 Sin 20 0 So, = 22.590 Again, since r = 0.3846 t1 t 0.45 =r t2 = 1 = = 1.17 or, t2 r 0.3846
tan = tan =
Fxy + Fz . tan Fz Fxy . tan 190 + 1950 tan 20 = 0.4783 1950 190 tan 20
Or,
= 25.560
R=
2 Fz2 + Fxy
For an orthogonal cutting process on mild steel, using the following data: t1 = 0.3 mm, = 00 t2 = 0.85 mm Fz = 900N b1 = 2.5 mm Fxy = 450N
Calculate (a) the coefficient of friction between the tool and the chip, (b) the ultimate shear stress s of the work material. Soln. Applying the equation, = tan =
=
Fxy + Fz . tan Fz Fxy . tan
450 + 900 tan 10 608 .69 = = 0.74 900 450 tan 10 820 .653
tan = r.Cos 1 r.Sin
tan =
= 20 .3 0
s =
1.5.
From the following data, calculate (i) shear angle (ii) chip thickness (iii) velocity of chip along the tool face and (iv) coefficient of friction. Steel rod diameter 45mm, tool rake angle 30 0, cutting speed 25mpm, main cutting force 225kg and thrust force 100kg, uncut chip thickness 0.15mm and length of chip in one revolution 75mm.
t1 L L2 = 2 = t2 L1 .D.N
75 45
r=
= 31.980 or,
t2 = t1 0.15 = = 0.283 mm r 0.53
Sin Cos ( )
Coefficient of friction,
= tan =
= Fxy + Fz . tan Fz Fxy . tan
100 + 225 tan 30 229 .9038 = = 1.374 225 100 tan 30 167 .265
1.6.
For an orthogonal cutting operation, the machining data is as follows: uncut chip thickness 1.3mm, chip thickness 2mm, shear strength 6500kg/cm2, width of cut is 12mm, cutting speed 35mpm, coefficient of friction 0.95, and the tool rake angle 120. Calculate chip thickness ratio, shear angle, shearing force, friction angle, main cutting force and horse power consumed at the cutting tool. Soln. Chip thickness ratio, t1 t 2 = 1.3 / 2 = 0.65 Shear angle,
= tan 1
r.Cos 1 r.Sin 0.65 Cos 12 0 = tan 1 1 0.65 Sin12 0 0.63579 1 = tan 1 = tan (0.735 ) 0.86486
= 36.320
s =
Fs .Sin A1
Fs =
Fs =
Cos ( ) Cos ( + ) = 1580 .3 Cos ( 43 .53 12 ) 0.852366 = 1580 .3 = 3572 .9 kg Cos (36 .32 + 43 .53 12 ) 0.377
HP = 27.789 1.7. During orthogonal cutting of mild steel at 210mpm with a tool of rake angle 12 0, the width of cut and the uncut thickness are 1.8mm and 0.2mm respectively. If the average value of the coefficient of friction between the tool and the chip is 0.55 and shear stress of the workpiece material is 390N/mm2, calculate (i) the shear angle (ii) the cutting and the trust component of the machining force. Soln. = 120 And = tan or, = tan-1 = tan-1 0.55 = 28.80 Using Merchants first solution, 2 + = 2 = 90 0
2 = 90 + = 90 28 .8 +12 = 73 .2
or
Fs =
390 1.8 0.2 = 235 .57 N Sin 36 .6 Since, Fs = R.Cos ( + ) Fs 235 .57 235 .57 R= = = = 395 .12 N Cos ( + ) Cos (36 .6 + 28 .8 12 ) 0.5962
Thus, Fz = R.Cos ( ) = 395 .12 Cos (28 .8 12 ) = 378 .256 N And, Fxy = R.Sin ( ) = 395 .12 Sin (28 .8 12 ) =114 .189 N.
2.2 Calculate the cutting components of the force, shear angle, shear strain and work done in deformation, using the following data: cutting speed 16mpm, rake angle 100, chip thickness ratio 0.3, coefficient of friction 0.65, friction force on the tool chip interface 50kgf. 2.3 From the following data recorded during orthogonal cutting of an aluminum alloy, calculate the cutting force, feed force and the power consumed. t1 = 0.15mm, L1 = 160mm, = 180 L2 = 40mm, b1 = 3.8mm, s = 25kg/mm
2