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Tutorial - 1

The document outlines a tutorial for a manufacturing tooling and automated inspection course, focusing on various calculations related to machining processes. It includes problems on cutting forces, shear angles, and tool life in orthogonal machining of steel and aluminum alloys. The tutorial emphasizes the application of graphical methods and specific energy calculations in metal cutting operations.

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anshsahu996
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21 views1 page

Tutorial - 1

The document outlines a tutorial for a manufacturing tooling and automated inspection course, focusing on various calculations related to machining processes. It includes problems on cutting forces, shear angles, and tool life in orthogonal machining of steel and aluminum alloys. The tutorial emphasizes the application of graphical methods and specific energy calculations in metal cutting operations.

Uploaded by

anshsahu996
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Department of Production Engineering

PRPC21 - Manufacturing Tooling and Automated Inspection


Session July 2024
Tutorial – 1
Date: 08/08/2024

1. In a steel shaft (Ø60 mm) machining process (orthogonal machining), the cutting force
and the thrust force are measured by a tool dynamometer as 1350 N and 1300 N,
respectively. Back rake angle of the tool is 6°. Feed is 0.8 mm/rev and length of cut
chip is 9000 mm (continuous chip) at a rotational speed of 150 rpm. Width of cut is 5
mm. The cutting speed is 150 m/min. Evaluate the following by graphical method (i)
friction force, (ii) normal force to friction force, (iii) shear angle, (iv) shear force, (v)
coefficient of friction, (vi) normal force to shear force, (vii) shear stress required during
metal cutting, (viii) shear velocity, and (ix) chip flow velocity. Also calculate the shear
strain and power consumed in metal cutting.

2. In an orthogonal turning, a mild steel shaft at 220 m/min having diameter of 60 mm


with rake angle of 8°, the cut chip thickness and feed are 1.2 and 0.6 mm/rev,
respectively. The width of cut is 5 mm. Calculate cutting force and thrust force
components of the machining force if the average coefficient of friction between the
tool and the chip is 0.25. The shear strength of the work material is 410 MPa. In
addition, the tool failure occurred in 25 min when the mild steel shaft was turned at 400
rpm. When the speed was changed to 300 rpm, the tool failed in 45 min of cutting time.
Assuming straight line relationship, evaluate the cutting speed to achieve 50 min tool
life?

3. In turning of an aluminium alloy workpiece diameter of 50 mm on a 25 kW lathe


(mechanical efficiency 80%) at a width of cut of 5 mm, a rake angle of 8°, and a cutting
speed of 160 m/min, the coefficient of friction is of 0.3. The length of cut chip is 6000
mm. Assume the specific energy of aluminium alloy to be 0.92 Ws/mm3. Evaluate shear
strength of the material.

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