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.

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.

Elements Of Electromagnetics

7th Edition

ISBN:9780190698614

Author:Sadiku, Matthew N. O.

Publisher:Sadiku, Matthew N. O.

ChapterMA: Math Assessment

Section: Chapter Questions

Problem 1.1MA

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A. Assuming you have been given the responsibility of procuring some cutting toolfor UCSI workshop. Based on your knowledge in manufacturing processes, oneof the major properties of interest in a cutting tool material is the hot hardness.Explain the relationship between the cost of a cutting tool and its hot hardness citing at least FOUR (4) examples of cutting tools. b. During a certain machining experiment at the UCSI workshop, it is observedthat temperature at the tool workpiece interface is 1200 oC at a cutting speed of 300 mm/min with a feed rate of 0.002 mm/rev.(i) Analyse how the temperature will be affected if the cutting speed isincreased by 100 %.(ii) Determine the cutting speed necessary to achieve a maximum cuttingtemperature of 900 oC.
The shear strength of a certain work material 110000 lb/in?. An orthogonal cutting operation is performed using a tool with a rake angle is equal -12° and chip thickness before the cut is 0.026 in, width of cut is 0.120 in, also the chip thickness after cut is 0.082 in. Determine: (a) the shear plane angle, (b) the shear force, (c) cutting force, (d) thrust force, and (e) friction force.
1. Most common instrument used in the mechanical gages is the dial indicator, which of the following applications cannot be measured by the dial indicator? (a) All of them (b) Perpendicularity (c) Runout (d) Circularity (e) Roughness 2. The main mechanism for the flank wear on the single point cutting tool is: (a) Oxidation wear (b) Adhesion wear (c) None of them (d) Diffusion wear (e) Plastic deformation 3. Higher cutting speeds and temperatures are the main mechanism of the following tool wear mechanism: (a) Diffusion wear (b) Abrasion wear (c) None of them (d) Adhesion wear (e) Plastic Deformation
A process engineer is trying to improve the life of a cutting tool. He has run a 23 experiment using (1) cutting speed, (2) metal hardness, (3) and cutting angle as the factors. The data from the 2 replicates are shown below. (a) Do any of the 3 factors affect tool life? (b)what combination of the factor levels produces the longest tool life? (c) Is there a combination of cutting speed and cutting angle that always gives good results regardless of metal hardness? Replicate Run I II (1) 221 311 a 325 435 b 354 348 ab 552 472 c 440 453 ac 406 377 bc 605 500 abc 392 419
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?
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
2. The following data was obtained from an orthogonal cutting test: Rake angle = 20° Cutting speed = 100 m/min Chip length before cutting = 29.4 mm Chip length after cutting = 12.9 mm Vertical cutting force 1050 N Horizontal cutting force = 630 N Using Merchant's analysis, calculate (a) resultant force (c) friction force and friction angle (b) shear plane angle (d) total work done
Define specific energy for plane strain machining (cutting). In plane-strain machỉning, the two main sources of energy dissipation are deformation along the shear plane (~70%) and friction at the tool-chip contact along the rake face (~30%). Consider machining of a rigid perfectly-plastic work material whose uniaxial yield stress is 700 MPa, and is independent of strain rate and temperature. A tool of zero-degree rake angle is employed. Measurements showed the (deformed) chip thickness to be twice that of the undeformed chip thickness. Based on the aforementioned distribution of energy, estimate the specific energy for this process.
Q2 Describe FOUR (4) major independent and dependent variables that influence cutting process. (a)
2 1.4 1 The Taylor tool-life equation is directly applicable to flank wear. Explain whether or not it can be used to model tool life if other forms of wear are dominant.
Q3(a) Assuming you have been given the responsibility of procuring some cutting tool for UCSI workshop. Based on your knowledge in manufacturing processes, one of the major properties of interest in a cutting tool material is the hot hardness. Explain the relationship between the cost of a cutting tool and its hot hardness citing at least FOUR (4) examples of cutting tools.
3. 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. %3D