ASSIGNMENT # 03

MACHINING
ME-851
Submitted By
Sqn Ldr Umar Pak/16325
Flt Lt Wasiq Pak/18501
 ASSIGNMENT NO 3

Problem 1
An orthogonal machining process is executed on a work-piece
specimen. The workpiece width is 0.05 cm, the undeformed chip
thickness is 0.1 mm, and the cutting speed is 31.4 m/s. The
cutting tool is made from a C-2 carbide with a 10 ° rake angle.
During the process, the following data was collected:
Cutting Force = 1200 N
Thrust Force = 850 N
Deformed Chip Thickness = .15 mm
a. Estimate the shear angle.
b. Determine the coefficient of friction on the tool rake face.

Solution:
Required
(a) ϕ=¿ ?
(b) μ=¿ ?
γ cos α
tan ϕ ¿ (i)
1−γ sin α
0.1
⇒ γ= ¿ 0.667 substitute in (i)
0.15 =tan−1 ( .7421 ) ¿ ϕ ¿=36.59∘ Ans ¿
0.667 cos ( 10 )
∘
tan ϕ ¿
1−0.667 sin ( 10∘ )
¿ ¿

(b) μ=¿ ?

we know that
μ=tan ( β ) (i)

Also,

β ¿ α + tan
−1
( )
Ft
F c =45.31 - (ii) ¿
¿ ¿
Substituting eq (ii) in eq (i)
μ=tan ( 45.31 )
μ=1.01 Ans

Problem 2
An orthogonal cutting process is carried out on 1018 steel
using a carbide cutting tool with a 10° rake angle. The
cutting speed is 100 m/min, the depth of cut is 0.25 mm, and
the width of the cut is 4mm. Measurements at the tool rake
face indicate that the length of the seizure zone is 1mm, the
thickness of the seizure zone is 0.075 mm, and the length of
the contact zone is 1.25 mm. Estimate the true shear strain
experienced by the workpiece in the secondary shear zone
as it exits the seizure zone at a distance of 0.075 mm from
the tool interface and a distance of 0.035 mm from the tool
interface.

Considering Triangle ABE

AE
tan α ¿
BE
AE ¿ B E x tan α
AE ¿ 0.075 tan 10
¿ ¿

Considering Triangle BED

 DE
sin 85.66 ¿
DB
0.9867
BD
BD
¿
sin 85.66 ¿=sin
¿ 0.989
(
−1 0.075
0.989 )
¿¿

DE
sin ϕ= ¿
BD

o
ϕ=4.347
Considering Triangle ADC
AC
sin ϕ=
AD
❑
AC= AB x sin ( 4.347 )
❑
AC=0.075796 mm

For AB
0.075
Cosα =
AD
So,
A B=0.075 mm
Now, for Shear strain at 0.075 mm
∆x
γ=
A
bc +cd
γ=
ac
BD
γ=
AC
0.989
γ=
0.075
γ 1=13.3

Now, for Shear strain at 0.035 mm from tool interface

∆x
γ=
A
0.989
γ=
0.035
 γ 2=28.27

From the value we have observed that strain rate is more

neared to tool surface.
Problem 3
Given:
Depth of cut, to = .005”
Width of cut, w = .25”
Cutting speed, V= 400 ft/min
Rake angle, α = 10º
Cutting force, Fc = 135 lbs.
Thrust force, Ft = 50 lbs.
Shear angle, ø = 25º
Calculate Power and specific energy. Make necessary
assumptions if required.

Required

(i) Power = ?
(ii) Specific Energy??
Solution (i)
Power=?

Power = ?
P=FC ∗V
ft lbs
¿ 135 × 400=54000 Ans
min
P=1220.24 W Ans

(ii) Specific Energy

 uT =us + v f
F V F V FVc
¿ c = s s+ −( A )
ω t 0 V ω t0 V ω t 0 V
FC 135
⇒ UT= =
ω t 0 25 ×⋅005
lbs
¿ 108000 2
¿
F s=F c cos ϕ−F t sin ϕ
¿ 135 cos 25−50 sin 25
F s=101.22 lbs
F=F c sin α + Ft sin α
∘
¿ 135 sin 10+50 sin 10
F=72.68 lbs
V V V
= s = c V s=? V c =?
cos ( ϕ−θ ) cos α sin ϕ
400 ×cos 10
=V S =407.81
cos 15
400 x sin 25
=V c=175.01
cos 15

F s V s F c ⋅V c
108000 ¿ +
ω t 0V ω t 0V lbs
41278 12719.7268 ≈ 107995 in 2 ¿
¿ ¿ +
0.5 0.5
¿ ¿

Hence, total energy is converted into shear energy and friction

energy.
Problem 4
Given:
Rake angle, α = 10º
Cutting Speed, V = 75 m/min
Width of cut, w = 2.0 mm
Undeformed Chip Thickness, t0 = 0.25 mm
Specific Cutting Power, UC = 1 W. s/[Link]
Rake Face Coefficient of friction = 1.5
Calculate Pc, VC, Fc, Ft.

Required
(i) Pc
(ii) VC
(iii) Fc
(iv) Ft
Pc =F c x V (A)
F c =¿ ?
Fc V
Uc ¿
ω t0 V
Fc
⇒1 ¿
ωt0

F c =2× 25 ×1

F c =0.5 micro N or 500 N

substitute in (A)
m
⇒ Pc ¿500 × 75
min
Nm
Pc ¿ 37500
min

(ii) Vc
 tan β =μ

β ¿56.31
Vc V
⇒ ¿
sin ϕ cos ( ϕ−α ) =21.85 ∘ ¿ V ¿= sin ϕ ⋅V = sin 21.85× 75 ¿ V ¿=28.51 ¿
c c
α β cos ( ϕ−α ) cos ( 21.85−10 )
ϕ ¿ 45+ −
2 2
¿ ¿

F t =? β=α + tan
−1
( )
Ft
Fc

56.31=10+ tan
−1
( FcFt )
⇒ 46.31=tan ( )
−1 Ft
Ft

( ( )
tan ( 46.31 )=tan tan
Ft
Ft
Ft
=10468
Fc
F t=1.0468 × F c
Ft =523.403 N