TECHNICAL UNIVERSITY OF KENYA (TUK)

CAT I EMMU 7241: Machine Tool Vibrations and Cutting Dynamics

Attempt any THREE questions; all questions have equal marks

Q1 a) (i) What is the effect of cutting speed, feed and depth of cut on tool life?
(ii) Explain desirable properties of cutting tool materials?
(iii) What is machinability of metal? What factors affect the machinability?
sin
r=
b) i) Derive the following expression connected to machine tool cutting process: cos ( ) ; where r is the
cutting ratio, is the shear plane angle, and is the rake angle.
ii) An orthogonal cutting operation is carried out under the following conditions: t o = 0.1 mm, tc = 0.2 mm, width of cut
= 5 mm, v = 2 m/s, rake angle = 100 and coefficient of friction is 0.2, F c = 500 N, and Ft = 200 N. Calculate the
percentage of the total energy that is dissipated in the shear plane.
iii) Assume that, in orthogonal cutting, the rake angle is 25 and the coefficient of friction is 0.2. Use the cutting ratio
equation to determine the percentage increase in chip thickness when the friction is doubled.

Q2 (a) What do you understand by transmissibility in relation to vibrations?

(b) Establish an expression for the amplitude of forced damped vibrations, and use the expression to derive an equation
for the transmissibility ratio (TR).
(c) A machine tool of mass 70 kg mounted to ground through an isolation system of total stiffness 30 KN/m, with a
measured damping ratio of 0.2. During machining process the machine cutting tool produces a harmonic force of 450 N
at 125 rpm during steady-state operating conditions. Determine the:
i) amplitude of motion of the machine,
ii) phase shift of the motion (with respect to the exciting force),
iii) transmissibility ratio,
iv) maximum dynamic force transmitted to the floor, and
v) Maximum velocity of the machine.

Q3. (a) (i) Describe the effects of cutting fluids on chip formation. Explain why and how they influence the cutting
operation. Explain under what conditions you would discourage the use of cutting fluids.
(ii) In a dry cutting operation using a 5 0 rake angle, the measured forces were Fc = 1330 N and Ft = 740 N. When a
cutting fluid was used, these forces were Fc = 1200 N and Ft = 710 N. What is the change in the friction angle resulting
from the use of a cutting fluid?
(b) A stainless-steel bar 200mm diameter, is being turned on a lathe at 600 rpm and at a depth of cut, d = 0.254 cm. If
the power of the motor is 3750 W and has a mechanical efficiency of 80%, what is the maximum feed that you can
have at a spindle speed of 500 rpm before the motor stalls?

Q4. (a) Briefly explain three types of machine tool vibrations and their causes and effect. How can vibration be
controlled in a machine tool?
b) A number of tool life tests are conducted on two work materials under identical cutting conditions, varying only
speed in the test procedure. The first material, defined as the base material, yields a Taylor tool life equation VT 0.28 =
350, and the other material (test material) yields a Taylor equation VT 0.27 = 440, where speed is in m/min and tool life is
in minutes. Determine:
i) The machinability rating of the test material using the cutting speed that provides a 60-min tool life as the basis of
comparison.
ii) The percentage increase in tool life when the cutting speed for the test material is reduced by 50%.

Q5. a) With the aid of an appropriate diagram state and describe the role of each of the principal forces acting on the
work piece during an orthogonal machining operation. Which of the principal forces can be measured and how will
they be measured? Why is it important to have knowledge of the force components in machining operations?
b) In a machining operation that approximates orthogonal cutting, the cutting tool has a rake angle = 10 0. The chip
thickness before the cut to = 0.50 mm and the chip thickness after the cut tc = 1.125 mm. The measured cutting force
and thrust force are: Fc = 1559 N and Ft = 1271 N. The width of the orthogonal cutting operation w = 3.0 mm. For this
machining operation if the cutting speed v = 100 m/min, determine the:
i) shear plane angle,
ii) shear strain,
iii) friction angle,
iv) coefficient of friction,
1 v) shear strength of the work material,
vi) cutting power, and
vii) Specific energy.
 viii) Increase in temperature above ambient temperature of 20 0C if the volumetric specific heat for the work
material = 3.0 x10-3 J/mm3/C, and thermal diffusivity = 50x10-6 m2/s (or 50 mm2/s).