Sona College of Technology, Salem-5

Department of Mechanical Engineering

ME 1203 MANUFACTURING TECHNOLOGY -II

Faculty Name: V.Sivaraman

Year & Section: II nd Year & C

UNIT -1 THEORY OF METAL CUTTING

Part –A

1. What is orthogonal cutting?

2. What are the functions of cutting fluids?
3. What is the function of chip breakers?
4. Name the factors that contribute to poor surface finish in cutting.
5. Define the term ‘tool life’.
6. What are the conditions that favours the formation of continuous chips with a
‘Built up edge’?
7. Name any two conditions for continuous chip formation while machining.
8. What is tool signature?
9. Write the difference between orthogonal & oblique cutting
10. Write the classification of tool material.

Part –B

1. Explain the types of chip formed during machining process.

2. Using Merchant’s circle diagram derive the expression for estimating the
cutting force during machining. Mention the assumption made.
3. Describe the forms of wears on the cutting tool with neat sketches.
4. Describe an expression for the determination of shear angle in orthogonal
metal cutting.
5. What is a chip? What are the different types of chips? How they are formed.
6. What is the measure of metal removing process machinability? What are the
factors that affect it?
7. A tool life of 110 minutes is obtained at 25 mpm and 10 ninutes at 65 mpm.
What is the tool equation? Determine the cutting speed for tool life of 1
minute and 200 minutes.
8. The following cutting speed & cutting time observations have been noted in a
machining process. Calculate
a) ‘n’ and c.
b) Recommend the cutting speed for a desired tool life of 60 minutes.
Cutting speed, V 25m/min 35 m/min.
Cutting time, T 90 min 20 min.
9. Write a short note on the following tool materials:
a. High speed steel, b. cemented carbides and cubic boron nitride.
10. The following equation for tool life is given for a turning operation:
VT 0.15 f0.8 d0.4 = c
A 60 minute too life was obtained while cutting at v=30m/min, f=0.4 mm/
rev and d= 2.4 mm.
Determine the change in tool life if the cutting speed, feed and depth of
cut are increased by 15% individually and also taken together.
11. During machining c 20 steel with a carbide cutting tool having a tool
geometry given by 0-5-6-8-75-1 mm ORS, the following forces have been
recorded by a two dimensional dynamometer:
Cutting force =1300 N.
Feed force = 800 N.
Determine the following:
Radial component of force, frictional force and normal force and kinetic
coefficient of friction µ.
12. During machining C25 steel with 0-10-6-7-8-90-1 mm ORS shaped triple
carbide cutting tool, the following observations have been made:
feed = 0.18 m/rev. depth of cut =2 mm, cutting speed 150 m/min.

Fz = 1600 N, Fx = 800 N, chip thickness = 0.4 mm. Determine

i) Chip reduction coefficient.
ii) Shear force and normal force and shear plane.
iii) Kinetic coefficient of friction.

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