DeGarmo's Materials and Processes in Manufacturing
12th Edition
ISBN: 9781118987674
Author: J. T. Black, Ronald A. Kohser
Publisher: WILEY
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Chapter 22, Problem 12RQ
Discuss the constraints in the selection of a cutting tool.
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In 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
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Draw the geometry of single point cutting tool (3 views) and explain the importance of each angle in metal cutting.
Question 1: Explain the following terms and situations in metal cutting. Give enough explanation with figures if it is necessary.
a) Up and down milling operations. What are the effects on the workpiece surface finish and machine tool? b) Orthogonal and oblique cutting. c) Cutting force diagram in orthogonal cutting. d) Theoretical prediction of shear angle in orthogonal cutting. e) Machinability. f) Force and chatter vibrations. How can you detect the vibration during the machining? How can you decide which type of the vibration you have? g) Mode shapes. Mode coupling. h) Process damping. Which parameters can affect the process damping? i) j) Regenerative chatter vibrations. k) Stability lobes.
Question 2: How will the cutting force be affected by the following situations during the machining operation? Why?
a) Large rake angle b) Small relief angle c) Large nose radius d) Sharp cutting edge e) Smooth rake face f) Hard workpiece material g) High cutting speed h) Large feed rate i)…
Chapter 22 Solutions
DeGarmo's Materials and Processes in Manufacturing
Ch. 22 - For metal-cutting tools, what is the most...Ch. 22 - What is hot hardness compared to hardness?Ch. 22 - Prob. 3RQCh. 22 - Why is impact strength an important property in...Ch. 22 - Cemented carbide tools are made by a powder...Ch. 22 - What are the primary considerations in tool...Ch. 22 - What is the general strategy behind coated tools?Ch. 22 - Prob. 8RQCh. 22 - How is a CBN tool manufactured?Ch. 22 - Prob. 10RQ
Ch. 22 - Prob. 11RQCh. 22 - Discuss the constraints in the selection of a...Ch. 22 - What does cemented mean in the manufacture of...Ch. 22 - What advantage do ground carbide inserts have over...Ch. 22 - What is a chip groove?Ch. 22 - What is the DCL?Ch. 22 - Suppose you made four beams out of carbide, HSS,...Ch. 22 - Multiple coats or layers are put on the carbide...Ch. 22 - What tool material would you recommend for...Ch. 22 - What makes the process that makes TiC coatings for...Ch. 22 - Why does a TiN-coated tool consume less power than...Ch. 22 - For what work material are CBN tools more commonly...Ch. 22 - Why is CBN better for machining steel than...Ch. 22 - What is the typical coefficient of variation for...Ch. 22 - What is meant by the statement Tool life is a...Ch. 22 - The typical value of a coefficient of variation in...Ch. 22 - Machinability is defined in many ways. Explain how...Ch. 22 - What are the chief functions of cutting fluids?Ch. 22 - Prob. 29RQCh. 22 - Why is the PVD process used to coat HSS tools?Ch. 22 - Why is there no universal cutting tool material?Ch. 22 - What is an 18-4-1 HSS composed of?Ch. 22 - Over the years, tool materials have been developed...Ch. 22 - Why is the rigidity of the machine tool an...Ch. 22 - Explain how it can be that the tool wears when it...Ch. 22 - What is a honed edge on a cutting tool and why is...Ch. 22 - Suppose you have a turning operation using a tool...Ch. 22 - A 2 in.-diameter bar of steel was turned at 284...Ch. 22 - Prob. 3PCh. 22 - The following data have been obtained for...Ch. 22 - In the insert is set with a 0 side cutting-edge...Ch. 22 - Prob. 6PCh. 22 - Here is a single point tool. Identify angles A...Ch. 22 - Figure 22.B gives data for cutting speed and tool...
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- Question 2. The two sources of heat are (a) shearing in the primary shear plane and (b) friction at the tool-chip interface. What type of the tool wear or tool failure could be caused as a result of developing these heat sources on machining process? Explain your answer in accordance with following representation of tool wear. Insert cutting edgearrow_forward3. Draw the forces and angles involved in the cutting process and calculate shear angle (Ø), friction coefficient and tangential force if ,cutting force = 80 kN , resultant of forces =100kN , friction force=75kN, rake angle =20° undeformed chip thickness = 0.65mm and deformed chip thickness = 0.72mm .arrow_forward3. Draw the forces and angles involved in the cutting process and calculate shear angle (0), friction coefficient and tangential force if .cutting force 80 kN, resultant of forces 100KN, friction force-75KN, rake angle =20° undeformed chip thickness %3D 0.65mm and deformed chip thickness 0.72mm. %3Darrow_forward
- Write down the important properties of cutting tool?Write short note on4different types of cutting fluids commonly used in detail.arrow_forwardChoose TWO (2) types of cutting processes that are suitable for cutting thick materials (>20mm thick plate).arrow_forward(a) Draw and label the basic orthogonal cutting process model. The diagram must include cutting direction, shear plane, chip formation and all relevant angles. (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, Fo = 5000 N, and Thrust force, Fi= 200 N. Calculate the percentage of the total energy that is dissipated in the shear plane of cutting process. *)arrow_forward
- In an orthogonal cutting test, the cutting force and thrust force were observed to be 1000N and 500 N respectively. If the rake angle of tool is zero, What is the coefficient of friction in chip-tool interface ?arrow_forwardQ2 Describe FOUR (4) major independent and dependent variables that influence cutting process. (a)arrow_forward3. What are the important characteristics of a cutting tool material?arrow_forward
- Question 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_forwardi need the answer quicklyarrow_forwardUsing the Taylors tool life equation with exponent n = 0.5, if the cutting speed is reduced %3D by 50% the ratio of new tool life to original tool life isarrow_forward
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