Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 21, Problem 52QTP
Using trigonometric relationships, derive an expression for the ratio of shear energy to frictional energy in orthogonal cutting, in terms of angles α, β, and φ only.
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39 An orthogonal cutting operation is being carried out under the following conditions: t0=0,38 mm, tc=0,65 mm, width
of the cut= 2.5 mm, V= 3.5 m/s, rake angle=D 6 , Fc= 515 N, and Ft= 210 N. Calculate the percentage of the total energy
that is dissipated in the shear plane.
The power input in cutting= F.V
Power for shearing=F,V,
t
I'c
tan ø =
Iccos a
tc
1-re sin a
cin
-1-
Note: Read the question carefully and give me right solutions according to the question.
In orthogonal cutting of steel tube of 150 mm diameter and 2 mm thick, the cutting force was 130 kg and feed force was 35 kg for chip thickness of 0.3mm. The orthogonal cut was taken at 60 meter per minute with a feed of 0.14 mm/rev. If the back rack angle of the cutting tool was - 8 o (minus 8 degree), then calculate the shear strain and strain energy per unit volume.
An orthogonal cutting operation is being carried out under the following conditions:
depth of cut, to = 0.1 mm, rake angle, a = 10°, Cutting force, Fc =1500 N, and Thrust
force, Ft = 800 N. Calculate the shear force.
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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- An orthogonal cutting operation is being carried out under the following conditions: t0 = 0.1mm, tc = 0.2 mm, width of cut = 5 mm, V = 2 m/s, rake angle = 10, Fc = 500 N, and Ft =200 N. Calculate the percentage of the total energy that is dissipated in the shear planearrow_forward3) The following data are available from orthogonal cutting experiment, Depth of cut t, = 0.13 mm, width of cut w = 2.5 mm, rake angle a = -5°, cutting speed v = 2 m/s, Chip thickness, t= 0.23 mm, cutting force, F. = 430 N, thrust force, F = 280 N. Determine the following: Shear angle Friction Coefficient u (using F= µ N) Shear Stress t,S Shear strain y on the shear plane. Power required to perform the operation. Gross power required if the efficiency of the machine is 85%. Specific Energy, Utarrow_forward2 1.57 Show that, for the same shear angle, there are two rake angles that give the same cutting ratio.arrow_forward
- Problem 10.21 Estimate the time required for one complete cut on a workpiece of length 350 mm and diameter 70 mm by a cutting tool which operates at 35 m/min. Take feed to be 0.25 mm/rev.arrow_forwardcalculate the time taken to complete a 300 mm long cut on an aluminium plate using a 75 mm diameter slab mill with 6 teeth.arrow_forwardQuestion 4. The following data are available from orthogonal cutting experiments. The depth of cut (feed) to = 0.13 mm, width of cut b = 2.5 mm, rake angle a = - 5°, and cutting speed V = 2 m/s. Chip thickness, t. (mm) = 0.23 Cutting force, F. (N) = 430 Thrust force, F; (N) = 280 Determine the shear angle ð, friction coefficient u , shear stress t, shear strain y on the shear plane, chip velocity Ve, and shear velocity Vs, as well as energies uf ,Ug, and uarrow_forward
- Write down the steps required to proof the mathematical relation for SHEAR PLANE ANGLE in Orthogonal Cutting Model. i-e. Prove the following relation:arrow_forwardIt is required to reduce the thickness of cast iron workpiece with dimensions (L x w x t) of (230 mm x 120 mm x 25 mm) to 22 mm using shaper machine. Given that average cutting speed is 21 m/min, feed 1.2 mm/double stroke, and return/cutting time ratio is 3/4. The approach at each end is 72 mm. If the permissible depth of cut is 2 mm, determine the cutting time in the following cases: i) Using shaper with a mechanically driven ram. ii) Using shaper with a hydraulically driven ram. Solution: i) Mechanically ( ii) Hydraulicallyarrow_forwardA student is using a lathe with 80-hp and 80% efficiency to fabricate a copper alloy with Sy = 1200ksi If the width of cut is 0.30 inand the student set a rake angle of 0and a cutting speed of 200fl / min while she assumed a coefficient of friction to be 0.5. What is the maximum depth of cut the student can achieve?arrow_forward
- (b) An orthogonal cutting operation is being carried out under the following conditions: depth of cut, to = 0.1 mm, chip thickness, to = 0.2 mm, width of cut = 4 mm, cutting speed, v = 3 m/s, rake angle, a = 10°, Cutting force, Fc = 500 N, and Thrust force, F1= 200 N. Calculate the percentage of the total energy that is dissipated in the shear plane of cutting process.arrow_forward(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.arrow_forwardParvinbhaiarrow_forward
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