Assignment

Q.N.1. In a turning operation, it was observed that the tool life was 150 minutes when the cutting speed was 20 meters per minute. As the speed was increased to 25 meters per minute, the tool life dropped to 25.2 minutes. If the time required to change the tool was 2 minutes and if the cost of regrinding the tool was ten times the cost of turning per minute, calculate: (i) The most economical cutting speed, (ii) Tool life for maximum production.

Q.N.2. A tool with 18o rake angle is making an orthogonal cut, 3 mm wide, at a speed of 31 m/min and feed of 0.25 mm. The chip thickness ratio is 0.55, cutting force is 1392 N and feed force is 363 N. Find: (1) Chip thickness, (3) Co-efficient of friction on tool face, (2) Shear plane angle, (4) Shear force on shear plane,

(5) Energy consumed in KW-min per cubic centimeter of metal removed.

Q.N.3. The following data refers to an orthogonal cutting test: (1) Depth of cut: 1.5 mm, (3) Rake angle: 15o (5) Chip thickness ratio: 0.4, (6) Shear strength at zero compressive stress i.e., So =150 N/mm2 (7) Material constant, K = 0.2 in the relation S= So + KSn Calculate: (1) Shear plane angle, (3) Chip flow speed (5) Power at tool. (2) Fraction angle, (4) Shear force on shear plane, (2) Width of cut: 5 mm (4) Cutting speed = 25 m/min

Q.N.4. The following observations are made while machining Mild steel with a tool of (0-10-66-75-1 mm ORS) shape. (1) Spindle speed = 400 rpm (3) Depth of cut = 2.5 mm, (5) Cut chip thickness = 0.40 mm. Determine: (1) Chip thickness ratio, (2) Shear plane angle, (3) Dynamic shear strain. (2) Work dia. = 60 mm, (4) Tool feed rate = 80 mm/min,

Q.N.5. During turning of a metallic workpiece with a single point having tool signature of 0-8-67-10-10-60-1 as per (ORS) system, the following observations were made Feed = 0.15 mm/rev, Cutting speed = 80 m/min, Calculate the following: (i) Chip reduction co-efficient, (iii) Shear strain. (ii) Shear angle, Depth of cut = 1 mm, Chip thickness = 0.35.

Q.N.6. During machining of C-45 steel with 0-10-6-6-8-90-1 mm (ORS) shape carbide cutting tool, the following observations made : Depth of cut = 1.5 mm, Feed = 0.15 mm/rev, Speed = 200 m/min, Tangential cutting force = 1500 N, Feed thrust force = 800 N Chip thickness = 0.45. Calculate shear force, normal force at shear plane, friction force, kinetic co-efficient of friction, specific cutting energy.

Q.N.7. In an orthogonal turning of M.S part using a depth of cut 1.5 mm and feed 0.2 mm/rev, a chip thickness of 0.45 is obtained. If the rake angle of tool is 0o. Calculate the following: (i) Chip thickness ratio (iii) Chip contraction co-efficient. (ii) Shear angle,

Q.N.8. In an orthogonal cutting operation the following data have been observed: Cutting speed, Rake angle, Cutting force Thrust force, Chip thickness, Uncut chip thickness, v = 2 m/s.

= 15o
Fc = 500 N, Ft = 225 N = 0.228 mm. = 0.129 mm.

Determine shear angle, friction angle, shear stress along the shear plane and power for the cutting operation and also find chip velocity, shear strain in chip and shear strain rate.

Q.N.9. In an orthogonal cutting operation, the following data have been observed: Cutting speed, Uncut chip thickness, Width of cut Chip thickness ratio Rake angle, Cutting force Thrust force, = 0.24 m/s. = 0.08 mm. = 4.13 mm = 0.61. = 20o = 363 N, = 128 N

Determine shear angle, frictional angle, chip velocity, shear strain in chip, shear strain rate, shear stress along shear plane, power for cutting operation.

Q.N.10. For facing operation with H.S.S. tool for M.S. bar, the following data was observed: Cutting speed, Uncut chip thickness, Depth of cut Feed Cutting force = 0.3 m/s. = 0.08 mm. = 3 mm = 0.5 mm/rev, = 200 N.

Find cutting power, motor power, specific cutting resistance and unit power (assume lathe efficiency 0.84).

Q.N.11. A 50 mm outside diameter tubing is turned on a lathe with cutting speed of 25 rpm, = 15o , feed = 0.15 mm/rev. It is found that cutting force = 2500 N and feed force = 1000 N. The length of continuous chip is 80 mm in one revolution. Calculate co-efficient of friction, shear angle, velocity of chip along tool face.

Q.N.12. While Machining C20 steel with a triple carbide tool of shape 0-8-6-7-10-70-1 mm (ORS), the following forces have been recorded on a two dimensional dynamometer. Fz = 1300 N, Fx = 800 N Feed = 0.18 mm/rev, Chip thickness = 0.4 mm. Calculate the following: (i) (ii) (iii) Radial component of force fy Frictional force P and normal force N Kinematic co-efficient of friction . Depth of cut = 2 mm,

Q.N.13. During turning of metallic workpiece with a single point orthogonal cutting tool, the following observations were made:

= 15o, v = 60 m/min, Fc = 200 N, Fv = 80 N.

Feed = 0.25 mm/rev, Depth of cut = 2 mm.

Chip thickness = 0.4 mm. Find out the following: (i) (ii) (iii) (iv) (v) Chip thickness ratio and chip reduction ratio Shear angle Shear force Shear stress and shear strain Work done in shear.

Q.N.14. During machining of SAE (1040 steel) with a double carbide cutting tool 0-8-6-7-10-701 mm (ORS) shape, the following observations were made: (i) Spindle speed = 400 rpm (ii) Tool feed rate = 80 mm/min (iii) Depth of cut = 2.5 mm (iv) Work diameter =60 mm (v) Chip thickness = 0.4 mm. Find following: Chip thickness ratio, shear plane angle, shear strain.

Q.N.15. In orthogonal turning if the feed is 1.25 mm/rev and chip thickness after cutting is 2 mm, =10o, shear strength = 600 MPa, b = 10 mm, v = 30 m/min, = 0.9. Determine the following: (i) (ii) (iii) (iv) (v) (vi) Chip thickness ratio Shear angle Shear force Frictional angle Cutting force Power at the cutting tool.

Q.N.16. A tool life of 80 minutes is obtained at a speed of 50 m/min and 8 minutes at 100 m/min during a cutting test on a single point cutting tool. Determine the following: (i) Tool life equation, (ii) Cutting speed for 10 minutes tool life.

Q.N.17. An automatic lathe is to be used to machine brass components 75 mm long X 50 mm diameter using a depth of cut of 1.25 mm. Select the speed that minimizes the machining cost and calculate the corresponding tool life. Also estimate the cutting speed for minimum time of production. Assume that: Labour + overhead rate Reconditioning cost of tool edge Loading-unloading time of the workpiece Tool change time Feed Tool life relation, VTn = 300. = = = = = Rs. 5 per hr. Rs. 0.25 per edge 15 sec 5 min 0.2 mm/rev

Q.N.18. A 200 mm long and 30 mm dia. bar is turned on a lathe with feed of 0.25 mm/rev. the operating cost is 5 paise per min. while the tool cost is Rs. 1. Reconditioning cost of tool edge is Rs. 1 per edge. Tool changing time is 1 min. The requirements are such that either of the two tool materials X or Y can be used. Compare the machining cost per component while operating under most economical conditions for the two materials.

Q.N.19. The tool life for a HSS tool is given by VT1/7 = C1 and for carbide tool is VT1/5 = C2, if at a cutting speed of 24 m/min, the tool life is 128 min. Compare the life of two tools at a speed of 30 m/min.

Q.N.20. A tool life of 80 mm is obtained at a speed of 300 m/min and 8 mm at 60 m/min. Determine the following: (a) Tool life equation, (b) Cutting speed for 4 mm tool life.

Q.N.21. Determine the percentage change in cutting speed required to give 60% reduction in tool life (i.e., to reduce tool life to 2/5 of its former value). The life relation of tool is VTn = C. Let, n = 0.2.

Q.N.22. A carbide tool while machining a MS workpiece was found to have a life of 1 hour and 40 minutes when the cutting at 50 m/min. Find tool life if tool is to operate t speed 30% higher than previous one. Also calculate cutting speed if tool is required to have a life of 2 hours and 45 minutes. Assume n = 0.28.

Q.N.23. Determine optimum cutting speed for an operation carried on a lathe machine using following operations: Tool changing time = 4 min. Tool regrind time = 3 min. Machine running cost = 20 paise per min. Depreciation tool regrind = Rs. 1. The tool life equation is given by, VTn = C. Let C = 60; n = 1/5

Q.N.24. Find optimum cutting speed and tool life for minimum cost for machining medium carbon steel under the following conditions: Cost of operating machine Total cost of tool change = = 20 paise per min. Rs. 8.

The cutting speed is 40 m/min when tool life is 50 min for the depth of cut and feed employed. Let n= 0.2 and VTn = C.