Degarmo's Materials And Processes In Manufacturing
Degarmo's Materials And Processes In Manufacturing
13th Edition
ISBN: 9781119492825
Author: Black, J. Temple, Kohser, Ronald A., Author.
Publisher: Wiley,
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Chapter 21, Problem 1RQ

Why has the metal-cutting process resisted theoretical solution for so many years?

Expert Solution & Answer
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To determine

The reason that the metal cutting process resisted theoretical solution for so many years.

Explanation of Solution

The zone where the chip is formed is not entirely bounded. For example, where the work piece is deformed in the die, in metal cutting, the work piece has free surfaces. In lathe turning, there are free surfaces at the work piece diameter and on the top of the forming chip. And, the boundaries that do exist (the tool-chip interface and the not well-defined deformation zone boundary in the work material) are challenging to characterize.

Further complications of the process are that the strains are enormous, and the strain rate is very high. Material properties at such conditions are not typically known. There are also a large number of process variables.

The theoretical solutions always need to be validated experimentally. It isn't very easy to obtain reliable, consistent experimental results that quantitatively describe the local deformation in the chip formation zone. The chip formation zone extends into the work piece below what will become the finished surface.

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(d) Shear force.(e) Cutting force and thrust force.(f) Friction angle.
A furniture company that makes upholstered chairs and sofas must cut large quantities of fabrics. Many of these fabrics are strong and wear-resistant, which properties make them difficult to cut. What nontraditional process(es) would you recommend to the company for this application? Justify your answer by indicating the characteristics of the process that make it attractive.
The figure below shows a symmetric plane-strain upsetting process. The process may also be thought of as a form of side extrusion. Observations show that the deformation is confined to two shear planes, each one being analogous to that seen in plane-strain cutting. You may assume that there is no friction between the work material and the tool/die walls; the uniaxial yield strength of the material is σy and is independent of strain rate and temperature, and the material behaves as a rigid plastic solid.  a) Calculate the pressure (p) required for the upsetting process in terms of σy.  b) If friction existed at the die walls and the frictional work (energy) dissipation was 30% of the energy required for shape change alone (part (a) above), then what would be the pressure (p)?

Chapter 21 Solutions

Degarmo's Materials And Processes In Manufacturing

Ch. 21 - For orthogonal machining, the cutting edge radius...Ch. 21 - How do the magnitude of the strain and strain rate...Ch. 21 - Why is titanium such a difficult metal to machine?...Ch. 21 - Explain why you get segmented or discontinuous...Ch. 21 - Why is metal cutting shear stress such an...Ch. 21 - Which of the three cutting forces in oblique...Ch. 21 - How is the energy in a machining process typically...Ch. 21 - Where does the energy consumed in metal cutting...Ch. 21 - What are two ways of estimating the primary...Ch. 21 - What are the three different ways to perform...Ch. 21 - Why does the cutting force Fc increase with...Ch. 21 - Why doesnt the cutting force Fc increase with...Ch. 21 - Prob. 23RQCh. 21 - How does the selection of the machining parameters...Ch. 21 - Suppose you had a machining operation (boring)...Ch. 21 - Make a sketch like that shown in Figure 21.1 with...Ch. 21 - Show how you would do near orthogonal machining in...Ch. 21 - Can you do orthogonal machining on a shaper or...Ch. 21 - What process and material combination would yield...Ch. 21 - What is meant by the statement that machining...Ch. 21 - Prob. 31RQCh. 21 - Figure 21.4 provides suggested cutting speeds and...Ch. 21 - For problem 1, suppose you selected a speed of 145...Ch. 21 - If the cutting forces is 1000 lb calculate the...Ch. 21 - Explain how you would estimate the cutting force...Ch. 21 - For a turning operation, you have selected a...Ch. 21 - For a slab milling operation using a...Ch. 21 - The power required to machine metal is related to...Ch. 21 - In order to drill a hole in the material described...Ch. 21 - Suppose you have the data in Table 21.A obtained...Ch. 21 - Calculate the horsepower that a process is going...Ch. 21 - Explain how you would estimate the cutting force...Ch. 21 - Derive equations for F and N using the circular...Ch. 21 - Prob. 14PCh. 21 - Prob. 15PCh. 21 - A manufacturing engineer needs an estimate of the...Ch. 21 - Using Figure 21.4 for input data, determine the...Ch. 21 - Estimate the horsepower needed to remove metal at...Ch. 21 - For a turning process, the horsepower required was...

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