A student is performing a turning operation with a workpiece with an initial diameter of 40 mm to produce a 30 mm diameter rod that is 100 mm long. The lathe power is 20 kW and is operating on 85% mechanical efficiency. If the student set the cutting speed to 0.5 m/min and the cutting tool is set to have a rake angle of 5 degrees:  a.) What material can we choose for the rod is the coefficient of friction is 0.5? b.) If we select 4130 normalized heat-treated steel for the rod, and coefficient of friction is 0.5, what will the maximum depth of cut we can achieve?

calculate the time taken to complete a 300 mm long cut on an aluminium plate using a 75 mm diameter slab mill with 6 teeth.

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In a production turning operation, the workpart is 60 mm in diameter and 500 mm long. A feed of 0.75 mm/rev is used in the operation. If cutting speed=9 m/s, the tool must be changed every 4 workparts; But if cutting speed=5 m/s, the tool can be used to produce 50 pieces between tool changes. Determine the Taylor tool life equation for this job. (use the equations given below for solution)

In a turning operation on low carbon steel with hardness = 135 HB, the cutting speed = 180 m/min, feed = 0.35 mm/rev, and depth of cut = 6.5 mm. The original work piece has 26 mm Diameter and 120 mm Length. How much power will the lathe draw in performing this operation if its mechanical efficiency = 90% and operator's efficiency = 82%? The specific energy is 3.8 J/mm³

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The following data was obtained from an orthogonal cutting test. Rake angle = 20° Depth of cut = 6 mm Feed rate = 0.25 mm/rev Cutting speed = 0.6 m/s Chip length before cutting = 29.4 mm Vertical cutting force = 1050 N Horizontal cutting force = 630 N Chip length after cutting = 12.9 mm Using Merchant's analysis, calculate (a) Magnitude of resultant force, (b) shear plane angle, (c) friction force and friction angle, and (d) various energies consumed.

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In 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 done

A HSS tool is used to turn a steel workpart that is 300 mm long and 80 mm in diameter. The parameters in the Taylor equation are: n = 0.13 and C = 75 (m/min) for a feed of 0.4 mm/rev. The operator and machine tool rate = $30.00/hr, and the tooling cost per cutting edge = $4.00. It takes 2.0 min to load and unload the workpart and 3.50 min to change tools. Determine: Tutting speed for maximum production rate, Tool life in min of cutting, and Cycle time and cost per unit of product. determine cutting speed for minimum cost.