MECH 421 /6511

Assignment 3 due on Monday March 23, 2015

Question 1: Explain the effects of using fine vs. coarse powders in making P/M parts.
Question 2 ;
respectively.

Describe the relative advantages and limitations of cold and hot isostatic pressing,

Question 3: The cutting force increases with the depth of cut and decreasing rake angle. Explain why.
Question 4: Can cutting fluids have any adverse effects in machining? If so, what are they?
Problem 1
A gear is to be manufactured from iron powder. It is desired that it have a final density that is 90% of that
of cast iron, and it is known that the shrinkage in sintering will be approximately 5%. For a gear 2.5-in. in
diameter and with a 0.75-in. hub, what is the required press force?
Problem 2
The axisymmetric part shown in the accompanying figure is to be produced from fine copper powder and
is to have a tensile strength of 200 MPa. Determine the compacting pressure and the initial volume of
powder needed.

Problem 3
The part shown in the figure below is to be pressed of iron powders using a compaction pressure of 75,000
lb/in2. Dimensions are inches. Determine (a) the most appropriate pressing direction, (b) the required press
tonnage to perform this operation, and (c) the final weight of the part if the porosity is 10%. Assume
shrinkage during sintering can be neglected.

Problem 4
In a production turning operation, the workpart is 125 mm in diameter and 300 mm long. A feed of 0.225
mm/rev is used in the operation. If cutting speed = 3.0 m/s, the tool must be changed every 5 workparts; but
if cutting speed = 2.0 m/s, the tool can be used to produce 25 pieces between tool changes. Determine the
Taylor tool life equation for this job.
Problem 5
A face milling operation is performed on the top surface of a steel rectangular workpiece 12.0 in long by 2.5
in wide. The milling cutter follows a path that is centered over the workpiece. It has five teeth and a 3.0 in
diameter. Cutting speed = 250 ft/min, feed = 0.006 in/tooth, and depth of cut = 0.150 in. Determine (a) the
actual cutting time to make one pass across the surface and (b) the maximum metal removal rate during the
cut. (c) If an additional approach distance of 0.5 in is provided at the beginning of the pass (before cutting
begins), and an overtravel distance is provided at the end of the pass equal to the cutter radius plus 0.5 in,
what is the duration of the feed motion.
Problem 6
Low carbon steel having a tensile strength of 300 MPa and a shear strength of 220 MPa is cut in a turning
operation with a cutting speed of 3.0 m/s. The feed is 0.20 mm/rev and the depth of cut is 3.0 mm. The rake
angle of the tool is 5 in the direction of chip flow. The resulting chip ratio is 0.45. Using the orthogonal
model as an approximation of turning, determine (a) the shear plane angle, (b) shear force, (c) cutting force
and feed force.