Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 21, Problem 65QTP
The following data are available from orthogonal cutting experiments. In both cases depth of cut (feed) to = 0.13 mm, width of cut b = 2.5 mm, rake angle α = –5°, and cutting speed V = 2 m/s.
Determine the shear angle ϕ, friction coefficient μ, shear stress τ, shear strain γ on the shear plane, chip velocity Vc, and shear velocity Vs, as well as energies uf, us, and ut.
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1 question. 2 parts
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=6°, Fc= 515 N, and Ft=210 N. Calculate the percentage of the total energy that is dissipated in the shear plane.
3) 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, Ut
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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- 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.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_forwardIn an orthogonal cutting test with a bar of 75 mm diameter is reduced to 73 mm by using a HSS tool with arake angle = 10o, following observations were made: length of the chip, lc = 69.44 mm, cutting ratio r =0.3, the horizontal component of the cutting force, FH = 1450 N, and the vertical component of the cuttingforce, FV = 850 N. The various parameters recorded in this cutting operation are: depth of cut, d = 2 mm;feed rate, f = 0.3 mm/rev, cutting speed, V = 60 m/min. Using Merchant’s theory calculate the following:1) Friction force along rake face2) Normal force acting on rake face3) Shear force along the shear plane4) Normal force acting on shear plane5) The percentage error in shear angle predicted by Merchant’s theory6) Shear velocity7) Chip velocity8) Total work done9) The shear work proportion out of the total work done10) The friction work proportion out of the total work donearrow_forward
- Q3:- In an orthogonal cutting operation, the tool has a rake angle = 15°. The chip thickness before the cut = 0.30 mm and the cut yields a deformed chip thickness 0.65 mm. Calculate (a) the shear plane angle and (b) the shear strain for the operation. Suppose the rake angle were changed to a= 0°. Assuming that the friction angle remains the same, determine (a) the shear plane angle, (b) the chip thickness, and (c) the shear strain for the operation.arrow_forward2) In an orthogonal cutting operation, the cutting tool has a rake angle = 20°. The chip thickness before the cut = 0.25 mm. If the cutting force and thrust force are measured during an orthogonal cutting operation with values, Fc = 1450 N and Ft = 1990 N. The width of the orthogonal cutting operation w = 2.5 mm. the friction angle B is = 79.91° Determine: The Shear Angle The Shear Strain The Shear Strength of the material The Force of Frictionarrow_forwardManufacturingarrow_forward
- In a turning operation, cutting speed =200 m/min; feed = 0.25mm mm/rev, and depth of cut = 4.00mm Thermal diffusivity of the work material = 20m mm^2/s and volumetric specific heat =3.5(10^ -3 )J/mm^ 3 -C If the temperature increase above ambient temperature (20degreesC) is the angle measured by a tool-chip thermocouple to be 700degreesC, determine the specific energy for the work material in this operation.arrow_forwardClean solutionarrow_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
- Determine the:1- Shear Strain2- Shear stress3- Friction Coefficientarrow_forward%9. lu. O V;YA Q1 What is the difference between direct shear and indirect cutting? Q2_What are the factors affecting fatigue Q3_What is the difference between hardness and micro-hardness Q4_What is the fatigue limit? Q5_What is strain hardness? Q6 What is the difference between true stress and engineering stress Q7_What is the difference between true strain and engineering strain? What is the relationship that binds them? Q8_ When do the "ears" appear in drawn cup, through cup drawing tests? Q9 Could we use results of tensile tests predict impact failure behavior, why? Q10_Could you estimate ductile-to-brittle transition temperatures for metals having hexagonal close-packed structure, why? Q11 Can creep of metals happen in room temperature, when? Solve a question 1_2_3_4_5_6_7_8_9_10_11 IIarrow_forward1) In an orthogonal cutting operation, the cutting tool has a rake angle = 15°. The chip thickness before the cut = 0.20 mm and the chip thickness after the cut tc = 0.8 mm. If the cutting force and thrust force are measured during an orthogonal cutting operation with values, Fc = 2000 N and Ft = 1890 N. The width of the orthogonal cutting operation w = 2.5 mm. Determine: The Shear Angle The Shear Strain The Shear Strength of the material The Force of Friction The friction anglearrow_forward
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