Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 21, Problem 61QTP
In Example 21.3, if the cutting speed V is doubled, will the answer be different? Explain.
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(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.
(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.
Determine ratio of friction energy to total energy
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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- 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_forwardNote: 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.arrow_forwardTaking carbide as an example and using EQ.(8.30) determine how much the feed should be changed in order to keep the mean temperature constant when the cutting speed is doubled.arrow_forward
- An orthogonal cutting operations is being carried out in which uncut thickness is 0.010 mm, cutting speed is 130 m/min, rake angle is 15° and width of cut is 6 mm. It is observed that the chip thickness is 0.015 mm, the cutting force is 60 N and the thrust force is 25 N. The ratio of friction energy to total energy is (correct to twoarrow_forwardDiscuss the effects of cutting speed, feed rate, and depth of cut on the tool wear rate during a turning operation. How does each parameter influence the surface finish of the workpiece? Provide a detailed explanation based on the principles of metal cutting mechanics.arrow_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
- A 1 mm thick cylindrical tube, 100 mm in diameter, is orthogonally turned such that the entire wall thickness of the tube is cut in a single pass. The axial feed of the tool is 1 m/minute and the specific cutting energy (u) of the tube material is 6 J/mm³. Neglect contribution of feed force towards power. The power required to carry out this operation isarrow_forwardEstimate the machining time required in rough turning a 2.0-m-long, annealed aluminum-alloy round bar that is 75 mm in diameter, using (a) a high-speed steel tool; and (b) a carbine tool. Use a feed of 2 mm/rev. Assume max cutting speed for high-speed tools is moving 4 m/s and for carbide tools is moving 7 m/s.arrow_forwardWhat are the functions served by cutting fluid? Give broad classification of cutting fluid and explain each in detail .arrow_forward
- A student is using a lathe with 80-hp and 80% efficiency to fabricate a copper alloy with Sy= 1200 ksi. If the width of cut is 0.30 in. and the student set a rake angle of 0° and a cutting speed of 200 ft/ min while she assumed a coefficient of friction to be 0.5. What is the maximum depth of cut the student can achieve?arrow_forward8 - Orthogonal cutting is performed on a metal whose mass specific heat = 1.0 J/g-C, density 2.9 g/cm3, and thermal diffusivity = 0.8 cm2/s. The cutting speed is 4.5 m/s, uncut chip thickness (feed) is 0.25 mm, and width of cut (depth) is 2.2 mm. The cutting force is measured at 1170 N. Using Cook's equation, determine the cutting temperature. a) 417.09 b) O 707.60 C) 528.03 d) O 316.82 Boş bırakarrow_forward. What are parameters of cutting process? mention it with units.arrow_forward
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