Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 21, Problem 45QLP
To determine
Given your understanding of the basic metal-cutting process, what are the important physical and chemical properties of a cutting tool?
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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.
Identify the forces involved in a cutting operation. which of these forces contributes to the power required?
(a) Research the cutting tool alternatives which could be used for such operation. What are the
parameters that could be optimized in the geometry of the cutting tool (The seven elements of
tool geometry for a single point cutting tool)? What are some of the tool life criteria used in
production machining operations?
(b) In a turning operation on stainless steel with hardness = 200 HB, the cutting speed = 250
m/min, feed = 0.3 mm/rev, and depth of cut = 8 mm. How much power will the lathe draw in
performing this of 7 operation if it's mechanical efficiency = 95%. Use Table below to obtain the
annropriate specific enerey value
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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- (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_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_forwardQuestion 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)…arrow_forward
- 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.arrow_forward5. What are the adverse effects of tool wear in cutting processes? 6. What characteristics are required for cutting tool materials? V. Comprehensive questions. 1. Match each part with the most proper manufacturing process. (1) Aluminum beverage can Centrifugal casting (2) Copper wire Closed-die forging (3) Engine cylinder Die casting (4) Lathe body Drawing (5) Link rod of an engine Sand casting (6) Magnesium alloy camera frame Sheet-metal formingarrow_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_forward
- (b) During a certain machining experiment at the UCSI workshop, it is observed that temperature at the tool workpiece interface is 1200 °C at a cutting speed of 300 mm/min with a feed rate of 0.002 mm/rev. (1) Analyse how the temperature will be affected if the cutting speed is increased by 100 %. (ii) Detemine the cutting speed necessary to achieve a maximum cutting temperature of 900 °C.arrow_forward3. What are the important characteristics of a cutting tool material?arrow_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_forward
- 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 419arrow_forwardWhat are the three main deformation zones in metal cutting and how does the heat distributeover a metal during any cutting processarrow_forwardDuring orthogonal cutting operation of material has shear strength 95.5 Mpa. The cutting force is more than thrust force by 10%. The rake angle = 5°, the width of the cut = 5.0 mm, the chip thickness before the cut = 0.6, and the chip thickness ratio = 0.38. Determine (a) both cutting force and thrust force and (b) the coefficient of friction in the operation.arrow_forward
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