The coefficient of friction between the part and the tool in cold working tends to be: lower higher no different relative to its value in hot working

Question 1 An aluminium alloy component, is machined on a lathe. The lathe has a mechanical efficiency of 91%. The lathe performs a turning operation on the workpiece which has a diameter of 150 mm and a length of 400 mm. The shear strength of the aluminium alloy work piece is 230 MPa and the tensile strength is 420 MPa. To machine the component, the lathe operator uses a cemented carbide tipped tool, having a rake angle of 6°. Furthermore, the relevant processing parameters are selected from the relevant data provided in a handbook by the lathe tool supplier. Some of the data is reproduced in Tables 1 and 2. Table 1. Surface Cutting Speeds (m/min) Part Material Aluminium Brass Cast Iron Mild Steel Alloy High Speed 75 18 120 28 Steel Tool Material Cemented 180 100 220 170 Carbide Table 2. Typical recommended feeds for turning (mm/rev) Part Material Aluminium Brass Cast Iron Mild Steel Alloy High Speed 0.2 0.15 0.2 0.15 Тool Steel Material Cemented 0.3 0.25 0.4 0.25 Carbide The operator…

What are the major tests that are to be conducted on the machine tools? And briefly explain how to do thetests

Manufacturing

H.W! B A fully work-hardened Aluminium blank of 100mm diameter and 1.2 mm thickness has a constant flow Stress of 350 MPa. It is deep drawn in a constant thickness process to a cylindrical cup of somm mid-wall diameter. The blank-holder force is 30 KN and the friction coefficient is 0.1 a- what is the final height? b-what is the approximate value of the maximum Punch force ? Aus/a-37.5mm, b-57KN

Describe the work done is proportional to the force applied (F ) and the distance traveled (s).

2) 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 Friction

Please provide a sketch for each tool in each step! I want to get a full mark please read the instructions. Thank you!

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.

1) Orthogonal Cutting: In an orthogonal cutting test on mild steel, the following results are obtained: to = 0.3 mm tc = 0.7 mm w = 3 mm Fc = 1000 N FN = 500 N (Fp in your book) Tool rake y = 0 Calculate: a. Mean angle of friction ß on tool face b. Mean shear stress Ts