Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 21, Problem 39QLP
To determine
Describe the effects that a dull tool can have on cutting operations
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Identify the forces involved in a cutting operation. which of these forces contributes to the power required?
A 150-mm-long, 12.5-mm-diameter 304 stainless-steel rod is being reduced in diameter
to 12.0 mm by turning on a lathe. The spindle rotates at N = 400 rpm, and the tool is
traveling at an axial speed of 200 mm/min. Calculate the cutting speed, material-
removal rate, cutting time, power dissipated, and cutting force.
%3D
(e) Briefly describe types of chips that occur in metal cutting.
(f) For orthogonal cutting, the tool rake angle =15°. The chip thickness before the cut is
0.30mm and the cut yields a deformed chip thickness =
0.65mm. Calculate the shear
plane angle and shear strain.
Chapter 21 Solutions
Manufacturing Engineering & Technology
Ch. 21 - Explain why continuous chips are not necessarily...Ch. 21 - Name the factors that contribute to the formation...Ch. 21 - What is the cutting ratio? Is it always less than...Ch. 21 - Explain the difference between positive and...Ch. 21 - Explain how a dull tool can lead to negative rake...Ch. 21 - Comment on the role and importance relief angle.Ch. 21 - Explain the difference between discontinuous chips...Ch. 21 - Why should we be interested in the magnitude of...Ch. 21 - What are the differences between orthogonal and...Ch. 21 - What is a BUE? Why does it form?
Ch. 21 - Is there any advantage to having a built-up edge...Ch. 21 - What is the function of chip breakers? How do they...Ch. 21 - Identify the forces involved in a cutting...Ch. 21 - Explain the characteristics of different types of...Ch. 21 - List the factors that contribute to poor surface...Ch. 21 - Explain what is meant by the term machinability...Ch. 21 - What is shaving in machining? When would it be...Ch. 21 - List reasons that machining operations may be...Ch. 21 - Are the locations of maximum temperature and...Ch. 21 - Is material ductility important for machinability?...Ch. 21 - Explain why studying the types of chips produced...Ch. 21 - Prob. 22QLPCh. 21 - Tool life can be almost infinite at low cutting...Ch. 21 - Explain the consequences of allowing temperatures...Ch. 21 - The cutting force increases with the depth of cut...Ch. 21 - Why is it not always advisable to increase the...Ch. 21 - What are the consequences if a cutting tool chips?Ch. 21 - What are the effects of performing a cutting...Ch. 21 - Prob. 29QLPCh. 21 - Prob. 30QLPCh. 21 - Prob. 31QLPCh. 21 - Prob. 32QLPCh. 21 - Comment on your observations regarding Figs. 21.1...Ch. 21 - Prob. 34QLPCh. 21 - Comment on your observations regarding the...Ch. 21 - Why does the temperature in cutting depend on the...Ch. 21 - You will note that the values of a and b in Eq....Ch. 21 - Prob. 38QLPCh. 21 - Prob. 39QLPCh. 21 - Explain whether it is desirable to have a high or...Ch. 21 - The Taylor tool-life equation is directly...Ch. 21 - Prob. 42QLPCh. 21 - Why are tool temperatures low at low cutting...Ch. 21 - Can high-speed machining be performed without the...Ch. 21 - Prob. 45QLPCh. 21 - Prob. 46QLPCh. 21 - State whether or not the following statements are...Ch. 21 - Let n = 0.5 and C = 400 in the Taylor equation for...Ch. 21 - Assume that, in orthogonal cutting, the rake angle...Ch. 21 - Prob. 50QTPCh. 21 - Prob. 51QTPCh. 21 - Using trigonometric relationships, derive an...Ch. 21 - An orthogonal cutting operation is being carried...Ch. 21 - Prob. 54QTPCh. 21 - Prob. 55QTPCh. 21 - Prob. 56QTPCh. 21 - Show that, for the same shear angle, there are two...Ch. 21 - With appropriate diagrams, show how the use of a...Ch. 21 - In a cutting operation using a 5 rake angle, the...Ch. 21 - For a turning operation using a ceramic cutting...Ch. 21 - In Example 21.3, if the cutting speed V is...Ch. 21 - Using Eq. (21.30), select an appropriate feed for...Ch. 21 - With a carbide tool, the temperature in a cutting...Ch. 21 - The following flank wear data were collected in a...Ch. 21 - The following data are available from orthogonal...Ch. 21 - Prob. 66QTPCh. 21 - Design an experimental setup whereby orthogonal...Ch. 21 - Describe your thoughts on whether chips produced...Ch. 21 - Recall that cutting tools can be designed so that...Ch. 21 - Recall that the chip-formation mechanism also can...Ch. 21 - Prob. 73SDPCh. 21 - Describe your thoughts regarding the recycling of...Ch. 21 - List products that can be directly produced from...Ch. 21 - Obtain a wood planer and some wood specimens. Show...Ch. 21 - It has been noted that the chips from certain...Ch. 21 - As we have seen, chips carry away the majority of...
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- In machining a mild steel work piece with carbide tool, the life of the tool was found to be 1 hour and 40 minutes, at a spindle speed of 30 m/min. Calculate the tool life if it has to be operated at a speed of 40% higher than the initial cutting speed. Also calculate the cutting speed if the tool is required to have a life of 2 hours and 45 minutes. Assume Taylor's exponent valuen is 0.28.arrow_forwardA steel rod 250 mm long and 200 mm in diameter is being reduced to 190 mm in diameter all over its length in one travel. The machine spindle rotates at 500 rpm, whereas the tool is moving at an axial feed of 0.5 mm/rev; calculate the following: Material removal rate (mm3/min) Consumed gross power in Nm/s if cutting force is 477.5N and mechanical efficiency is 90% Cutting time plzz complete in 30 minutesarrow_forwardQuestion 3. a. A cast iron component for motorcycle is to be turned with machine settings of feed = 0.22 mm/rev, and speed = 100 m/min. The cutting tool is a carbide tip with a nose radius of 1.2 mm and the rai for the material at a cutting speed of 100 m/min is 1.3. Calculate the surface roughness for this cut. [6 marks]arrow_forward
- Example 3.18 A low carbon steel bar of 147 mm diameter with length of 630 mm is being turned with uncoated carbide insert. The observed tool life are 24 and 12 for cutting velocities of 90 m/min and 120 m/min respectively. The feed and depth of cut are 0.2 mm./rev and 2 mm respectively. Use the unmachined to calculate the cutting velocity (i) When tool life is 20 min. the cutting velocity in m/min is (a) 87 (b) 97 (c) 107 (d) 114 (ii) Neglect over travel or approach of the tool. When tool life is 20 min, the machining time in remain for a single pass is (a) 5 (b) 10 (c) 15 (d) 20arrow_forward. What are parameters of cutting process? mention it with units.arrow_forwardIn a cutting test with 0.3 mm flank wear as tool failure criterion, a tool life of 10 min was obtained at a cutting velocity of 20 m/min. Taking tool life exponent as 0.25, the tool life in minutes at 40 m/min of cutting velocity will bearrow_forward
- I need the answer at 20 minutearrow_forward3. On an upright drilling machine, a 20 mm diameter hole is to be produced in a plate of SAEE112 steel of 30 mm thickness. The cutting speed selected is 10 m/min, and the cutting torque measured is 20 N.m. Calculate the spindle speed, the depth of cut, the main cutting force, and the cutting power.arrow_forwardParvinbhaiarrow_forward
- (a) Explain the differences between High-speed steels, cubic boron nitride and polycrystalline diamonds cutting tools.arrow_forward2 2 .19 Make a list of the alloying elements used in high-speed steels. Explain w hat their functions are and why they are so effective in cutting tools.arrow_forwardExplain the following terms and situations in metal cutting. Give enough explanation with figures if it is necessary. A)Force and chatter vibrations. How can you detect the vibration during the machining? How can you decide which type of the vibration you have? B) Mode shapes. C)Mode coupling. D)Process damping. Which parameters can affect the process damping? i)Mode coupling. j) Regenerative chatter vibrations. k) Stability lobes.arrow_forward
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