Addis Ababa University

Addis Ababa Institute of Technology

School of Mechanical & Industrial Engineering
MANUFACTURING ENGINEERING I (MEng 3191) Total Marks: 30 %
Intermediate exam, 2017 Exam Date: 19-DEc-2017
Course manager: Time Allowed: 2:00 hr.
No! Mobile is allowed
No! Piece of paper
No! Share of calculator

Direction: 1.Read the questions carefully & give the correct answers on the answer sheets provided.

1. a) State the desirable properties of cutting tool material. [1]

b) What is tool signature? Describe a tool with 8-8-5-5-6-6-1 inch in ASA system. [2]
c) What is rake angle? Explain with neat sketch different types of rake angles in single point
tools. Explain the effect of each. [2]
d) A certain machine shop uses four cemented carbide grades in its operations. The chemical
composition of these grades are as follows: Grade 1 contains 95% WCand5%Co; Grade 2
contains 82%WC,4%Co, and 14% TiC; Grade 3 contains 80%WC, 10% Co, and 10% TiC; and
Grade 4 contains 89% WC and 11%Co. (a)Which grade should be used for finish turning of
unhardened steel? (b) Which grade should be used for rough milling of aluminium? (c) Which
grade should be used for finish turning of brass? (d) Which of the grades listed would be
suitable for machining cast iron? For each case, explain your recommendation.[2]
e) Draw the neat sketch of twist drill show all the parts including all angles. [3]
2. a) Name and briefly describe the four types of chips that occur in metal cutting.[2]
b) What is chip thickness ratio? Derive tan φ = (r cos α) / (1 - r sin α) where φ is the shear
angle and r= chip thickness ratio and α= rake angle. [3]
c) The following are the details during turning of mild steel work piece. Tool geometry 0-10-6-7-8-9-0.1
inch, Feed 0.19 mm /rev. Chip thickness= 0.385 mm. Calculate (a) Chip thickness ratio (b) Shear angle.[2]
3. a) Draw Merchant’s Force diagram showing all details and state the assumptions made in the
development of a such a diagram.[2]
b) . Derive the condition 2 φ+ β – α = π /2 stating the assumptions made by Earnst and Merchant.
Where Φ = Shear angle, β = Friction angle and α = Rake angle [3]
c) The following data refers to an orthogonal cutting process. Chip thickness is 0.228 mm, uncut
chip thickness is 0.127 mm, width of cut is 6.35 mm and cutting velocity is 2m/s. The cutting force
0
is 567 N and thrust force is 227N, rake angle is 10 . Determine a) Shear angle b) Friction angle c)
Shear stress d) Power consumed during cutting e) Chip flow velocity. [5]
 Solutions
Q.No Answers Marks
1a Wear resistance, Hot hardness, High toughness, Low coefficient of 1
friction, adequate thermal properties, Low cost
1b i) The geometry of single point cutting tools is designated or specified 1
in a series of values of the salient angles and nose radius in a definite
sequence is called as tool signature.
ii) 8-8-5-5-6-6-1 inch in ASA system 1
Back rake angle-Side rake angle-Back clearance angle- side clearance angle-
End cutting edge angle-approach angle-Nose radius in inch
1c 1
Angle of inclination of rake surface from reference plane

Positive rake – helps reduce cutting force and thus cutting power
requirement.
• Negative rake – to increase edge-strength and life of the tool
• Zero rake – to simplify design and manufacture of the form tools.

1d (a) Finish turning of unhardened steel. Specify a steel-cutting grade suitable for finishing. 0.5x
This is a grade with TiC and low cobalt. Choose grade 2. 4=2
(b) Rough milling of aluminum. Specify a non-steel roughing grade. This is a grade with
no TiC and high cobalt. Choose grade 4.
(c) Finish turning of brass. Specify a non-steel finishing grade. This is a grade with no
TiC and low cobalt. Choose grade 1.
(d) Machining cast iron. Cast iron is included with the non-steel grades. Specify grade 1
for finishing and grade 4 for roughing.

1e